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Best available and emerging technologies for PVC production, processing and disposal

Best available and emerging technologies for PVC production, processing and disposal. A Sevenster Fourth Andean Conference on PVC Sustainability Bogota, Colombia, September 28, 2010. Contents of the presentation. Best available and emerging technologies for PVC Production and processing

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Best available and emerging technologies for PVC production, processing and disposal

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  1. Best available and emerging technologies for PVC production, processing and disposal A Sevenster Fourth Andean Conference on PVC Sustainability Bogota, Colombia, September 28, 2010

  2. Contents of the presentation • Best available and emerging technologies for PVC • Production and processing • End of life • Additives • Status of core additives • Developments • New PVC carbon footprinting & sustainability tool • (Optional background slides) Eco-profiles, LCA and EPD

  3. BAT in PVC manufacturing and processing Responsible manufacturing Health Environment Safety THREE PILLARS • Voluntary commitments • Good Practices

  4. Some voluntary commitments • Australia • Industry Product Stewardship commitment launched in October 2002 • Some of the commitments • Residual VCM in finished resin < 1 ppm:ACHIEVED • VCM emissions not greater than 50g/tonne PVC:ACHIEVED • Phase out of cadmium stabilisers by 2003: ACHIEVED • Phase out of lead stabilisers by 2010: ON TRACK • Europe (next slide) • South America • Brazilian pipes and fittings producers committed to replace lead stabilisers by calcium/zinc • USA • Industry initiatives to phase out lead

  5. Voluntary commitments in Europe • ECVM industry Charters • Voluntary commitments to reduce environmental impact of manufacturing activities • Target setting for emission limits, essentially EDC and VCM • Apply Best Available Techniques (associated BAT documents) • Reviews by an independent third party • VCM and S-PVC (1994), E-PVC (1998) • 3rd verification of VCM/S-PVC Charter and 2nd verification of E-PVC Charter currently in progress • More information on www.pvc.org • Vinyl 2010 • Refer to presentation by Helmuth Leitner, but as reminder: • Phase out of cadmium • Progressive phase out of lead, complete by 2015 • Phase out of Bisphenol A in polymerisation • Risk assessments on all phthalates • Development of recycling

  6. Good Practices • ECVM Annual Health, Safety and Environment Conference • 30 - 40 participants, typically production managerial staff. All companies represented • One and a half day • Review of accidents, incidents and near misses (“True confessions”) • Exchange of information on HSE issues related to manufacturing • US companies also meet regularly to discuss safety in manufacturing

  7. Emerging technologies for PVC production • Incremental improvements of the established processes • For example recovery of process water • Environmental impact of current acetylene process worse than ethylene process • Could it become sustainable? • Raw materials can be obtained from renewable resources • Ethylene from bio-based ethanol (Brazil) or from methanol synthesized from waste (“Methanol to Olefin” processes) • Chlorine obtained from sea salt with electricity from renewable sources

  8. BAT for end of life treatment of PVC • Landfilling to be avoided wherever possible • Unsustainable “solution”, waste of space and resources • Recycling to be favoured, because it’s best for saving resources and energy but • Collection of sufficiently homogeneous waste streams is an (essentially economic) issue • It can be hampered by standards, regulations (e.g. REACH) and public acceptance • Energy recovery is an option, but PVC has disadvantages compared to e.g. polyolefins • Constraints on incinerator design/operations to keep corrosion manageable; it is feasible up to a chlorine content of 5-6% • Generation of neutriaisation residues • Cooperation of the value chain is essential for success

  9. Global Warming potential reduction through recycling • Recent study by PE International • The figure depicts the results in terms of Global Warming Potential • The diagram clearly demonstrates that incineration carries much higher burdens (3-4kg CO2-eq.) than mechanical recycling • “System expansion” refers to the inclusion of new production of PVC with additives (which are different for cable and rigid PVC)

  10. Emerging technologies for end-of-life PVC • Mechanical recycling • Vinyloop/Texyloop (See Vinyl 2010 presentation) • Progress in sorting and separation technologies, allowing to recycle more “difficult PVC waste”: For example Autovinyle in France http://www.autovinyle.com/en_index.html • Feedstock recycling • Lots of laboratory studies on gasification and pyrolysis, but very few commercially demonstrated processes • High investments • Energy recovery from waste on PVC production sites • Energy and sometimes HCl recovery • Recovery of incineration residues • Neutrec (developed by Solvay) • Halosep (developed by Watech/RGS90/Stena withthe support of Vinyl 2010)

  11. Autovinyle processfor dismantled parts Manufacturing products from PVC recyclate (Autovinyle) Densification and micronisation  Pévéchouc ® Calendering or injection Collection of PVC parts ELV

  12. The Neutrec ® process (Solvay) • The Flue Gas Cleaning Residues collected in the bag filter are mixed with hydraulic binders, then placed in an aqueous solution with certain additives • The suspension is filtered • The insoluble part contains in particular most of the heavy metals. They are solidified into inert matter • The brine is further purified and reused in the manufacture of sodium carbonate • Seewww.neutrec.com

  13. The Halosep ® process • Recovers 98-99 % of the chlorine from incineration flue gas waste residues in the form of salts • Applicable to Semi-Dry and Wet incineration processes • Reduces by 50–75 % the amount of neutralisation waste to be disposed to landfills and improves its leaching properties • The treated waste complies with the leaching limit criteria for heavy metals for non-hazardous waste • The main product is a salt brine free from dioxins, furans and heavy metals • Cadmium, zinc and lead can be extracted in various amounts

  14. Additives • Status of core additives • Plasticisers • Stabilisers • Developments in plasticisers

  15. Plasticisers – three main groups: Products Other plasticisers LOW molecular weight phthalates SVHC * HIGH molecular weight phthalates non-SVHC • DEHP • BBP • DBP • DIBP • DINP • DIDP • DPHP • DIUP • DTDP • Adipates • Benzoates • Citrates • DINCH • Others There are ~ 100 plasticisers on the market but Phthalates represent ~ 90% of the WE plasticiser market 15

  16. Plasticisers are mostly used in Flexible PVC products LOW molecular weight phthalates HIGH molecular weight phthalates Other plasticisers • Medical (DEHP) • General purpose PVC applications (DEHP) • Adhesives (DIBP) • Cosmetics (DBP/DIBP) • PVC Wire & cable • PVC Flooring & wall covering • PVC Film & sheet • PVC Synthetic leather • PVC Coated fabrics • Automotive • Toys • Food contact • Sealants • Medical • Niche applications 16

  17. Worldwide Plasticiser Consumption Other Other Other DINP/DIDP DINP/DIDP DEHP DEHP DEHP represents 50% of the phthalates used Worldwide… …but only 17% of the phthalates used in Europe • Notes : • Other Plasticisers include Adipates, Trimelliatates, Benzoates, DINCH & Citrates • 2) Other Phthalates include Linears, DPHP, DIUP, DTDP, DOTP, DIBP, DBP Source: 2007 Chemical Economics Handbook – SRI Consulting 17

  18. Evolution of Plasticiser Consumption in Europe DINP/DIDP/DPHP Ongoing substitution of classified LMW by non-classified HMW plasticisers Source: ECPI 2010 18 Source: ECPI, 2008

  19. Stabilisers • Cadmium • Not used on EU market anymore (Vinyl 2010) • 100 ppm limit likely to become mandatory for ALL applications • Recycling issue: Hope for a 1000 ppm limit for cadmium originating from recycling, in rigid building applications excluding drinking water pipes • Tin • Regulatory restrictions for di-butyltin in EU as from 2012 • Industry has anticipated • Lead • Phase out ahead of Vinyl 2010 schedule • Will be also an issue in recycling • Lead replaced by calcium/zinc – calcium/organic stabilisers

  20. Alternatives to phthalates • Some commercial non-phthalate options for general purpose use in PVC • Epoxidised Oils (e.g. epoxidised soybean oil): Long term compatibility problems and processability issues • Citrates: Currently limited availability and higher costs. Performance lacking in permanence • Polyesters: Poor processability, higher costs • Terephthalates • Cyclohexanoatediesters: DINCH® • Polyol esters: Danisco’sGrindsted® Soft-N-Safe • Comparison with phthalates (presentation by D. Naert(ExxonMobil Chemical) on behalf of ECPI at the“PVC Formulation 2009” conference on 16 – 18 March 2009 • Phthalates like DEHP,DINP,DIDP have proventrack records of meeting GP plasticiser performance • Main difference between phthalates: level of permanencyand processability • Base set for a “General Purpose phthalate” witha maximum index of 10 for each of the 5 key parameters

  21. Terephthalates

  22. Cyclohexanoate diesters (DINCH®)

  23. Polyol esters: Danisco Grindsted®Soft-N-Safe

  24. PVC sustainability tool • Developed by Adisa Azapagic, Haruna Gujba, Anthony Morgan and Heinz Stichnothe • School of Chemical Engineering and Analytical Science, The University of Manchester • Enables calculations of carbon footprint of different PVC products and processes on a life cycle basis • Cradle to gate • Cradle to grave • Calculates other environmental impacts • Calculates value added along supply chains • Includes case studies and a range of databases

  25. New tool to assess PVC sustainability • Questions explored within the PVC sustainability tool • What is the carbon intensity of a PVC supply chain/process/product? • Where are the ‘hot spots’? • What are the low-carbon options for reducing the carbon intensity? • What would be the cost? And value added? • How would other environmental impacts change? • Main features of the tool • Tailored for the PVC industry/supply chains • Free of charge • Simple to use • Integrated case studies • Includes data bases • Materials • Energy • Transport • Packaging • Waste management • Enables ‘what if’ scenario analysis

  26. Built-in case studies and examples

  27. Top-level view of the tool Data shown for illustration only

  28. Identifying carbon ‘hot spots’ Data shown for illustration only

  29. Other environmental impacts • Acidification • Eutrophication • Ozone depletion • Photochemical smog • Human toxicity Data shown for illustration only

  30. Background slides (optional) • LCAs remain the basis for scientific assessments of environmental impacts • High quality data available for plastic resins in general, and PVC in particular

  31. Eco-profiles • Cradle-to-gate Life Cycle Inventories • Benefits • Essential basis for LCA studies of products • Possibility of environmental benchmarking • Encouraging environmental improvements in manufacturing • PlasticsEurope eco-profiles • Average representing the majority of European production • Publicly available at http://lca.plasticseurope.org • Included in the International Reference Life Cycle Data System (ILCD) • Eco-profiles of PVC resin • 92 % coverage of Western European industry • Collected and calculated in 2005 by IFEU • Eco-profiles of PVC conversion processes published in 2010 • Pipes and profiles extrusion, sheet calendering and coating, injection molding

  32. Results of eco-profiles of PVC resin

  33. EPD of PVC resin • Environmental Product Declarations are so-called ‘Type III environmental declarations’ • Quantified environmental data for a product using predetermined parameters, based on ISO 14040 series • The environmental data may be supplemented by other quantitative and qualitative environmental information • The PVC EPD were the first to be published under a new EPD programme launched by PlasticsEurope • Defined “Product Category Rules”, i.e. “Set of specific rules, requirements, and guidelines for developing Type III environmental declarations for one or more product categories” • Essentially based on the eco-profiles http://lca.plasticseurope.org

  34. EPD results for 1 kg of PVC

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