INDUSTRIAL TECHNOLOGY DEVELOPMENT INSTITUTE (ITDI) DEPARTMENT OF SCIENCE AND TECHNOLOGY (DOST) DOST Compound, Bicutan Taguig City 1631T l h (+632) 8372071 l l 2182 2215 T l f (+632) 8373167Telephone no. (+632) 8372071 local 2182, 2215. Telefax: (+632) 8373167Website: http//mis.dost.gov.ph/itdi

Presented by: ARACELI MAGSINO MONSADA, Dr-Engg. Materials Science DivisionMaterials Science Division ITDI-DOST, Bicutan , Taguig City, MMTelephone: +632-837-2071 loc. 2201;2233

e-mail: celimonsada@yahoo.come a ce o sada@ya oo co

Presented during the :Presented during the : UNEP-AIST Workshop on Waste Plastics Management, March 01-04, 2011, AIST Tsukuba Center, Tsukuba City, Japan

ITDI is the largest R &D Insitute of the Department of S i d T h l (DOST)Science and Technology (DOST)

MANDATEMANDATEMANDATEMANDATE

Research & Development

Technology Transfer

Generation of new scientific and

Diffusion of R&D f

technological breakthroughs and

R&D results

Technical

ginnovation

Services

ITDI is a multi-disciplinary R&D institute catering to the technologyical needs of various industry sectorsto the technologyical needs of various industry sectors.

VISIONVISIONVISIONVISION

Excellence in propelling development asExcellence in propelling development as provider of technologies and services for industry.industry.

MISSIONMISSIONMISSIONMISSION

To make local industry globally competitive.

Life of today has greatly modernized. It’s a fact of life, that we Welcome and enjoy the comforts and convenience brought by the Modernization of life New plastic packaging materials Modernization of life…. New plastic packaging materials.

• New packaging materials and technology are being developed (one time use; disposables)

• Lifestyles are changing, for example: fast food ( Jollibee, D ld i f d ( dl )Mc Donalds, etc. ; instant food (noodles, etc.)

• We experience increasing pressure and influence to buy more; Th l i i i i• The population is increasing.

ECOLOGICAL SOLID WASTE MANAGEMENT ACT of 2000• NO TO OPEN DUMPSITES

• SEGREGATION AT SOURCE• SEGREGATION AT SOURCE

• MATERIALS RECOVERY FACILITY (MRF)

• RECYCLING – PACKAGING MATERIALS ARE RECYCLABLE

SANITARY LANDFILL• SANITARY LANDFILL

RA 9003 Approval : January 26, 2001pp y ,IRR Effectivity: January 06, 2002

MIXED WASTES IN DISPOSAL FACILITY :

MIXED WASTES IN TRANSFER STATION: MIXED WASTES IN TRANSFER STATION:

CanalsStreets

Bays PLASTICS especially plastic bags are very p g yvisible in garbage; blamed for flashfloods, ,clogged canals due to irresponsible disposal. p p

SOURCES OF RESIDUALS

Sources of Residuals

Institution1%

Market3%

Commercial8%

Residential88%88%

RESIDUALS : THESE ARE WASTE PLASTICS MIXED IN THE GARBAGE, SOILED AND ,DIRTY…. DESCRIBED AS NON-RECYCLABLES.

SOURCE : WACS CONDUCTED ON MARCH 2009, PAYATAS, QC.

COMPOSITION OF RESIDUALS AT THE CONTROLLED DISPOSAL FACILITYCONTROLLED DISPOSAL FACILITY

Composition of Residuals

Styrofoam3% Others

29%

L i Laminates6%

Sando Bags62%62%

WEIGHT OF RESIDUALSWEIGHT OF RESIDUALS

Weight, kgg , gResidual Residential Institution Market Commercial Total

Styrofoam 6,011 123 181 649 6,964 SandoBags 139 482 152 280 9870 149 784 Sando Bags 139,482 152 280 9,870 149,784

Laminates 12,880 1,050 4,541 1,189 19,659 Others 64,685 103 259 6,405 71,452 Total 223,057 1,427 5,261 18,113 247,858

NOTE: DAILY GENERATION : ABOUT 248 TONS/DAY ( ONLY 1 MAJOR CITY IN METRO MANILA)

ITDI HAS AN INTEGRATED APPROACH TO SOLID WASTE MANAGEMENT WHICH TO SOLID WASTE MANAGEMENT WHICH INCLUDES DEVELOPMENT OF TECHNOLOGIES ON:TECHNOLOGIES ON:

Special wastes Clay Lined

Non

yLandfill 4%

Biodegradables

Non-biodegradables

Recycling

Bioreactor

Technologies

• plastics

56%40%

o eacto

Biogas digester Ecoshops/Buying Centers

Biomassp y g

IN VESSEL COMPOSTING SYSTEM: IN-VESSEL COMPOSTING SYSTEM: DOST-ITDI BIOREACTOR TECHNOLOGY

chargingcharging

Control panelp

Front view

charging

discharging

BACK view

discharging

17

Technology Challenge: Recyling/conversion of post y g pconsumer waste plastics into useful productsp

• Processing/Recycling of Scrap Packaging Laminates Laminates

• Plastic Composite Boards R li f PET B l• Recycling of PET Bottles

• Recycling/Processing of Styropor/Styrofoam and Plastic Sando Bags using the ITDI Densifier

• Waste Plastics in Asphalt Concrete • Waste Plastics in Asphalt Concrete • Thermal Processing of Plastic Packaging Laminates

ALTERNATIVE PLASTICS RECYCLING

The Technology on processing waste styropor using the“Styro Oven” or now the Densifier was developed inSty o O e o o t e e s e as de e opedcooperation with the Packaging Council of thePhilippines (PPCP) in 2004.

In 2006, the PPIA adopted the same technology(improved) for processing waste plastic bags (PE PP)(improved) for processing waste plastic bags (PE, PP).

“Recycling/Processing of Waste St /S d b i thStyro/Sandobags using the

Styro/Plastic Densifier ”Styro/Plastic Densifier

Description of the TechnologyDescription of the Technology

The technology mainly involves densification of The technology mainly involves densification of “waste Styro” or “plastic bags” by melting them i t bl ki il t t ll d h ti in a vegetable cooking oil at a controlled heating temperature; converting the waste styro/plastic bags into rigid functional products.

Simple, affordable, environment-friendly and able to generate livelihood;and able to generate livelihood; decentralizing plastics recycling (community level).

POST CONSUMER WASTE STYROPOR

EXPANDED POLYSTYRENE (EPS)POLYSTYRENE (EPS)

E d d F d P lExtruded Foamed Polystyrene(FPS)

POST CONSUMER WASTE PLASTIC BAGS

Plastic Carry/Shopping bags ( supermarkets, malls, stores, food shops, restaurants, etc.) - Polyethylene (PE)

Poly/Sando Bags ( wet markets, retailers, dry goods shops, etc.) - Polyethylene (PE)

Flexible Plastic Packaging - consumer productsFlexible Plastic Packaging - consumer products (Polypropylene (PP), PE)

RECYCLING PROCESS

Waste Styro/Plastic Bags

Size Reduction(Shredding/Grinding)

Melting/Densification

D ifi d P d t Densified Products (functional, novelty)

THE STYRO OVEN/ PLASTIC DENSIFIER

FEATURES :

S l l i h d bl j k d b d i h Steel casserole with cover, double jacketed body with a melting capacity of 50 kgs per batch

A motorized blunger for homogeneous mixing.g g g

A cylindrical steel downspout - to facilitate the discharge of melted plastic during casting into

the metal moldsthe metal molds.

The exhaust/chimney is installed with a charcoal stack to absorb smoke emission during melting.

The temperature recorder measures the melting temperature

LPG fired with three-line burner.

Portable unit, mobile.

THE PRODUCT The resulting molten waste plastic is easily molded by CASTING INTO THE METAL MOULDS whichby CASTING INTO THE METAL MOULDS which displayed potential uses for tabletops, planters, blocks for pathways, floorings, and other valuable f ifunctional products.

Molding by CastingMolding by Casting

Table Tops

COLORED GARDEN POTS

TILES/PAVING BLOCKS STACKED ON SHELVESSTACKED ON SHELVES

TILES/PAVING BLOCKSTILES/PAVING BLOCKS

ECONOMIC PROSPECTS OF DENSIFYING S O S CSSTYRO AND PLASTICS

1 COMMERCIALIZATION SUSTAINABILITY1. COMMERCIALIZATION SUSTAINABILITY MAY BE UNCERTAIN DUE TO LIMITED PRODUCT MARKETSPRODUCT MARKETS

2. NOVELTY PRODUCTS OF DENSIFICATION NOT COMPETITIVE WITH CONVENTIONAL ALTERNATIVES

ADVANTAGES AND DISADVANTAGES OF DENSIFYING STYRO AND PLASTICSDENSIFYING STYRO AND PLASTICS

1. ADVANTAGES

CAN PRODUCE NOVELTY/USABLE PRODUCTSSMALL SCALE OPERATIONSCAN HANDLE UNCLEANED RAW MATERIALS

2. DISADVANTAGES

PRODUCTS PRODUCED HAVE LIMITED MARKETSGAS EMISSIONS MAY CAUSE HEALTH RISK

PROBLEMSRELATIVELY HIGH OPERATING COST

TECHNOLOGY UPDATE /ENDEAVOR

CONDUCT MONITORING AND IMPACT CONDUCT MONITORING AND IMPACT ASSESSMENT ON THE APPLICABILITY OF ITDI STYROPLASTIC DENSIFIER IN LGU’S SWM PROGRAM( to start April 2011) ( p )Industry Cooperator: PPCPI th D i f th D ifi Improve the Design of the Densifier -feeding/loading of shredded plastics ; mixing efficiency, exhaust system, etc. ( in progress)

ALTERNATIVE PLASTIC RECYCLING

WASTE PLASTIC BAGSWASTE PLASTIC BAGS IN ASPHALT CONCRETE

Consists of aggregates and asphalt with waste gg g pplastic bags

Constructing new road pavementsg pResurfacing of road pavements (repair of potholes)

INDUSTRY COOPERATOR: PPIA

p )

AsphaltShredded waste plastic bags

Blending/Mixing

Shredded waste plastic bags

Asphalt with waste plastic bags

Mixing

Asphalt with waste plastic bags Aggregates

Mixing

Asphalt concrete with waste plastic bags

Processing of asphalt with t l ti bwaste plastic bags

Processing of Asphalt concrete with waste plastic bags

Pot Hole Scraping & leveling

Filling/Patching Asphalt –plastic mix road Concrete after compaction

Pot Hole after patching with A h l lPot Hole before repair Asphalt-plastic-aggregate mix

ADVANTAGES AND DISADVANTAGES OF S CS SPLASTICS IN ASPHALT MIX

1. ADVANTAGES :HUGE MARKET FOR WASTE PLASTICSBETTER ASPHALT APPLICATION PERFORMANCE

QUALITYALREADY A PROVEN TECHNOLOGY ABROAD

2. DISADVANTAGES LONGER PROCESSING OF ASPHALT MIX

ITDI WASTE PLASTIC TO FUEL R & D UNDERTAKINGR & D UNDERTAKING …..

Project Title : THERMAL PROCESSING OF INDUSTRIAL

Impl m ntin R &D Di i i n

THERMAL PROCESSING OF INDUSTRIAL WASTES BY PYROLYSIS

Implementing R &D Divisions:Chemicals and Energy Division (CED)Materials Science Division(MSD)- Industrial T TTechnology Development Institute (ITDI)

Industry Cooperator: Unilever Philippines

Objective:To design and test a thermal processing equipment that g p g q p

will utilize industrial wastes such as plastic laminates for heat and oil recovery by pyrolysis.

SCHEMATIC DIAGRAM OF THE PYROLYSIS SYSTEM

Cooling TowerGas Emission

PYROLYSIS SYSTEM

WasteWaterWW

Cold Water

Hot waterScrubber

Gas

Hot water

PyrolyzerNon-condensable Gas

Condenser

AfterburnerAsh Oil Condensate

LPG

Design of Prototype Pyrolyzer

Dimension of rotating drum: 45 cm diameter *

g yp y y

g60 cm length

Volume of rotating drum: 0.175 m3

B lk d it f l i t 49 74 k / 3Bulk density of laminates: 49.74 kg/m3

Amount of laminates at 75% capacity: 6.53 kg/batchkg/batch

Capacity of prototype : 20 kg/hr @ 3 batches/hrFurnace temperature: 450°C

COMPONENTS USED FOR THE FABRICATION OF A PROTOTYPE PYROLYZER

Reactor (rotating drum) Furnace Scrubber and condenserand condenser

PROTOTYPE THERMAL PROCESSINGPROTOTYPE THERMAL PROCESSING

PROXIMATE ANALYSIS OF PACKAGING LAMINATES

Parameter Average Value, % Test Method used

% Volatile Combustible 91.01 ASTM D3175-07Matter

% Moisture Content 3.60 ASTM D3173-03

% Fixed Carbon 3.04 ASTM D5681-98a

% Ash 2 35 ASTM D3174-04% Ash 2.35 ASTM D3174 04

CONVERSION OF WASTE PLASTICS TO ENERGY : INDUSTRIAL SCALE

WASTE PLASTICS AS ALTERNATIVE FUEL RESOURCE (AFR) IN CEMENT KILNS

Dioxin monitoring set‐upAFR Facility at Holcim Lugait Plant, Misamis Oriental

WASTE PLASTICS TO ENERGY : INDUSTRIAL SCALE

CONVERSION OF WASTE PLASTICS TO

SCALE

CLEAN DIESEL FUEL

Poly-Green Technology and Resources IncResources, Inc.

Contact:Anna N. Poannapo1116@yahoo.comannapo1116@yahoo.comTel: +632 3641702Fax: +632 3640936

WASTE PLASTICS TO ENERGY : INDUSTRIAL SCALE

IMPORTANT FEATURES OF THE TECHNOLOGY: SCALE

Philippines’ first technology innovation to process waste plastics ( “ non-recyclables”) to liquid fuel

Technology is modular in concept, operating at 5, 10 and 20 tons/day capacities; operation can be

i d t i ll l t d i bcarried out in smaller plants and processing may be situated wherever deemed necessary;

Th t h l d li id h d b i The technology produces liquid hydrocarbon in December 2007. The liquid fuel produced was proven to exhibit all the properties of a regular diesel

Poly Green Technology and

proven to exhibit all the properties of a regular diesel fuel but with lowered sulfur contents.

Poly-Green Technology and Resources, Inc.

PROCESS FLOW:

Poly Green Technology andPoly-Green Technology and Resources, Inc.

PROCESS FLOW :PROCESS FLOW :

WASTE PLASTICS TO ENERGY : INDUSTRIAL SCALE

IMPORTANT FEATURES OF THE PROCESS: SCALE

The process is done inside a vacuum, hence no resultant chemicals are released in the atmosphere.

The conversion efficiency rate is 75-80% depending on feedstock components;p ;

Target market : Diesel for industrial uses.

The construction of its 5-ton daily production capacity is still underway and maybe completed this year.

Poly-Green Technology andPoly-Green Technology and Resources, Inc.

OTHER PLASTICS RECYCLING ENDEAVORS :ENDEAVORS :

Size: Small and Micro EntrepreneurshipSize: Small and Micro Entrepreneurship Key Players : Non-governmental organizations,

cooperatives, foundations, local government units (municipal down to barangay units), etc.( p g y ),

I i ibl Si f i h l i Invisible Sisters – transforming trash plastic bags into treasures. g

Kilus Foundation – bags out of waste stand up (aluminum –plastic)pouches

OTHER PLASTICS RECYCLING ENDEAVORS : KILUS FOUNDATIONENDEAVORS : KILUS FOUNDATION

INVISIBLE SISTERS Founded in 2008 by artist Ann Wizer, The Invisible sisters uses the old technique of crocheting, turning what are often seen as trash into works of art and fashion pieces.

The work of the Invisible Sisters advocates Environmental conservation with the use of recyclable plastic bags, compact discs, video/audio cassette reels, computer Wir in th ir pr d ti nWires in their production.

Essentials of Successful Waste PlasticsEssentials of Successful Waste PlasticsEssentials of Successful Waste Plastics Essentials of Successful Waste Plastics Recycling Project Recycling Project

••

LET US AIM A “ ZERO PLASTIC” INLET US AIM A ZERO PLASTIC IN LANDFILLS /DISPOSAL FACILITY AND LET T US PROVE THAT PLASTICS ARELET T US PROVE THAT PLASTICS ARE

ECOLOGY FRIENDLY MATERIALS