De-inking Plastic Films
Transcript of De-inking Plastic Films
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De-inking Plastic Films
Elizabeth BeaudoinKristin FraserBeverly Pate
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Problem Statement
Develop de-inking process considering
Type of plastic filmCollection strategiesCost of production
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What is De-Inking?
De-inking - removes ink, dyes, and other contaminates from a given material
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Why De-Ink?
Growth of demand in plastics leads to an increase in plastic waste
Poor physical and mechanical properties due to residual ink
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Why De-Ink?
Removing ink increases quality
De-inked plastic has a higher selling value
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Problems with Recycled Plastic
Strength and elongation at break are decreased
Gases formed in extruded polymer
Color from residual ink
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Project Milestones
1. Understand mechanism2. Separation techniques3. Recovery issues4. Marketability5. Plant location optimization6. Profitability
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To Understand Ink Attachment
1. Composition
2. Surface tension
3. pH
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What is Ink Composed of?
1. Pigments2. Binders3. Carriers4. Additives
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Surface Tension
Caused by cohesion forces
Broken when cohesive forces are overcome by a stronger force
Surfactants create this atmosphere
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Corona Discharge
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pH
Causes the binder to agglomerate or extend
Isoelectric point - pH at which the number of anions and cations are equal
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Ink Detachment
1. Deprotonation
2. Surface adsorption
3. Ink detachment
4. Solubilization and stabilization
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Deprotonization
HDPE
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Surface adsorption
HDPE
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Raw Materials
PlasticWhy pick Wal-Mart bags?
Water-based inkMade of HDPEWal-Mart donates used bags
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Raw Materials
BaseIsoelectric point - pH of a solution at which the net charge of a molecule is zero
3.1 for carboxylic acid
A pH of 12 is used
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Raw Materials
Deionized waterEliminates ions that could react with the deprotonated carboxylic acid groups
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Raw Materials
Surfactant - linear molecule that modifies surface tension
Four types of surfactant:1. Cationic 2. Anionic 3. Amphoteric4. Nonionic
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Raw Materials
Surfactant continuedTo increase de-inking efficiency1. Longer alkyl chain length 2. Higher surfactant concentration
Hexadecyltrimethylammoniumbromide
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Raw Materials
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Solution Cleaning
o Hydrocyclone
•Density separator
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Modified Hydrocyclone
The heavy stream exit flow can get clogged
Accumulation chamber resolves this problem
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Considered Agitation Techniques
1. Multiple CSTs with net separation
2. Batch industrial washing machine
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Separating Techniques
1. Froth Floatation
2. Anionic Exchange Chromatography
3. Centrifuge
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Marketability
HDPE usage increases annuallyThere is a larger demand for recycled plastic than can be met Nonrenewable natural resources used to make plastic are being depleted
The economic feasibility of de-inking HDPE will likely increase in the future
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Market Size
Amount of plastic possibly recovered in 2006 is 96 thousand tons
45% of plastic is film70% of plastic film is HDPEAssume 15% recovery
Bags recovered ~ 5,000 tons/year
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Plastic Recovered vs. Year
y = 91.951x - 182555R2 = 0.9758
0
200
400
600
800
1000
1200
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1990 1992 1994 1996 1998 2000 2002
Year
Plas
tic R
ecov
ered
(tho
usan
ds o
f ton
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Plant Location
Location Model created in GAMSOptimize profit by minimizing transportation costsDetermine optimal locationInfeasible solution
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Plant Location
Plant location determined using excel simulations1. Calculated distances2. Calculated bags available 3. Compared revenue and transportation
costs– Transportation cost = distance * cost of
traveling
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Plant Location
4. Determined profitability
5. Calculated total transportation cost
6. Compared NPW of possible plant locations
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Plant Location
3 possible plant locationsNew Rochelle, NYGreenwich, CTEnglewood, NJ
Optimal Plant location:
Englewood, NJ
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Equipment Costs
$1,102,758Total
$100,0001$100,000Trucks
$1,7501$1,750Pump
$13,0001$13,257Storage Tank
$4,3001$4,305Slicer
$4,9601$4,958Recycle Tank
$93,0001$92,917Pelletizer
$489,0001$488,909Extruder
$139,0001$138,886Hydrocyclone
$22,0004$5,439Soaker
$236,0001$236,021Washer/Dryer
TotalQuantityPriceEquipment
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$8,435,400Total Capital Investment
$1,265,310Working Capital
$7,170,060Fixed Capital Investment
$6,193,917Total Product Cost
Profitability
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Profitability
$1,750,826Net Present Worth
16.03%Return on Investment, ROI
4.2985Pay-Out Time, POT
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Recommendations
Consider expansions and multiple plant locationsExtend project lifeConsider de-inking other forms of HDPE
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Questions?
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Main Polymers Used in Plastic Film
The branches prevent the nonlinear molecules from packing as closely as the
linear, reducing their density
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LDPE vs. HDPE
HDPE is made by Ziegler-Natta vinyl polymerization
Uses a transition metal to initiate polymerization
LDPE is made by free-radical polymerization
Uses an initiator molecule that breaks into free radicals. The unpaired electrons attack ethylene’s C=C forming new radicals