TOHOKU UNIVERSITY

Yoshioka Lab., Graduate School of Environmental Studies, Tohoku University

6th Regional 3R Forum in Asia and the Pacific

The use of waste plastics as

chemicals and fuel

Tohoku University, Japan

Prof. Toshiaki Yoshioka

Mechanical recycling of PET bottles

1：solution of bags 2：compression

3：separation by hand 4：crushing

Mechanical recycling of PET bottles

5．washing 6．Wind sorting

Recycled PET flakes

Recycle Products from waste PET bottle

PEPP PS

PVC PET

Plastics

Additives

The kinds of Resins and Additives in Plastic

Materials (2013)Resins

Thermoplastics resin 85

Thermosetting resin 37

natural macromolecule, others 35

Total 153

Additives

Plasticizer 46

Stabilizer 39

Oxidation inhibitor 30

Ultraviolet absorbing agent 42

Antistatic 18

Flame retardant 24

Organic blowing agent 5

Lubricant 7

Antifungal 17

Crystalline nucleus agent 2

Total 230

Feedstock Recycling Facilities ( -2013)

Kobe Steel (Kakogawa)

Blast furnace: 10,000t

Nihon Steel (Yahata)

Coke Oven: 20,000t

Nihon Steel (Oita)

Cokes Oven: 25,000t

Teijin Fiber (Tokuyama)

Monomer B to B: 62,000t

Nihon Steel (Nagoya)

Coke Oven: 50,000t

JFE Steel (Chiba)

Gasification: 20,000t

Nippon Steel (Kimitsu)

Coke Oven: 20,000t

Sapporo Plastic Recycling

Liquefaction: 12,000t

Nihon Steel (Muroran)

Coke Oven: 20,000t

Rekisei Oils (Niigata)

Liquefaction: 6,000t

JFE Steel (Fukuyama)

Blast furnace/Coke Oven : 40,000t

Ube（Ube)

Gasification: 30,000t

PET Refine Technology (Kawasaki)

Monomer B to B: 22,000t

Showa Denko（Kawasaki)

Gasification: 60,000t

JFE Steel (Kawasaki)

40,000t/30,000t

Blast furnace/Coke Oven

（complied with C&P recycling law, 2005)

11 Facilities:

Monomer 1

Blast furnace 3

Coke oven 5

Gasification 3

Liquefaction 0

(Total 357 Kt/y)

Amount of contract for each recycling method in 2013

CategoriesAmount

(tons)

Share for total

(%)

Share for FR

(%)

Feedstock

Coke oven 192,503 29 61

Blast furnace 38,232 6 12

Gasification 85,463 13 27

Liquefaction 0 0 0

Total 316,198 47 100

Mechanical 356,626 53

Total of CP-P 672,824 100

Outline of Steel Making Process

Sintering machine

Molten iron

Slag

Coking coal

Iron Ore

Steam coal

(pulverized coal < 200mesh, 80%)

Pig iron making process Steel making process

converter

continuous

caster

Rolling process

Steel products

Slabs/Billet

Converter gas

Blast furnace gas

Coke oven gasTar

Coke oven

Coke

Coal

Sintered ore

--1000 C

--1200 C

Blast furnace

--2000 C

--1500 C

Usage of waste plastics in blast furnace

Sintering machine

Molten iron

Slag

Coking coal

Iron Ore

Pig iron making process Steel making process

converter

continuous

caster

Rolling process

Steel products

Slabs/Billet

Converter gas

Blast furnace gas

Coke oven gasTar

Coke oven

Coke

Coal

Sintered ore

--1000 C

--1200 C

Blast furnace

--2000 C

--1500 CWaste Plastics

Steam coal

(pulverized coal < 200mesh, 80%)

Usage of waste plastics in cake oven

Sintering machine

Molten iron

Slag

Coking coal

Iron Ore

Steam coal

(pulverized coal < 200mesh, 80%)

Pig iron making process Steel making process

converter

continuous

caster

Rolling process

Steel products

Slabs/Billet

Converter gas

Blast furnace gas

Coke oven gasTar

Coke oven

Coke

Coal

Sintered ore

--1000 C

--1200 C

Blast furnace

--2000 C

--1500 C

Waste Plastics

Gasification (KPR process)

O2 +

Steam

Law-temperature

gasification furnace(fluidized-bed type)

600℃

High-temperature

gasification furnace(swirling type)

1400℃

Scrubber

CO shift

De-sulfur

H2

CO2

Caustic soda

raw material

Silo

O2 +

Steam

Quench Sodium sulfite

raw material

RPF

Outline of Gasification (KPR process)

Waste

Plastics

Pre-treatment

plantGasification Scrubber CO shift De-sulfur

H2CO2NaClSlag

Metal

recoveryDry ice

Liquefied CO2

Metal

Building

materials

Slag

treatment

Caustic

Soda

Compressor

195T/D

175T/D

Sodium sulfite

(NaHSO3)

NaOH

Law-temperature

High-temperature

NH3H2 business

S

*future*future

Outline of liquefaction process flow

Ｍ

Ａ

Ａ

Ｍ

ＭＭ

Ｍ

Ｍ

残渣

残渣冷却コンベア

溶融槽

熱分解装置

脱塩装置

脱塩装置ホッパー

造粒物サイロ

乾燥機

造粒機

磁選

風選

破砕機廃プラスチック（ベール状に減容 されたもので搬入）

油化工程

前処理工程 脱塩化水素・分解工程

乾燥機サイクロン脱塩ガス 燃焼炉

塩化水素吸収塔

塩酸タンク

分解油ドラム 重質油タンク

軽質油タンク

生成油回収塔

排ガス燃焼装置

生成油回収工程

塩酸処理工程 排ガス処理工程

中質油タンク

Ａ

Ａ

Ｍ

Ｍ

Cost estimation in the liquefaction of packaging waste plastics

Sales of Waste Plastics Amount of

treatment

Unit price JPY Total/1000

JPY

ratio/%

Amount of treatment 14000 t 68,000/t 952,000 94.8%

Product oil Total sales 51,800 5.2%

light oil (sale) 1106 KL 20/L 22,120 2.2%

middle oil (sale) 420 KL 50/L 21,000 2.1%

heavy oil (sale) 434 KL 20/L 8,680 0.9%

Total sales 1,003,800 100.0%

Running cost Amount of

treatment

Transport unit

price/JPY

Total/1000

JPY

ratio/%

light-oil (shipment) 1106 KL 16.3/L 18,028 1.8%

middle-oil (shipment) 420 KL 2/L 840 0.1%

heavy-oil (shipment) 434 KL 2/L 868 0.1%

Expenses 896,375 86.7%

Total running cost 916,111 91.3%

Gasins 87,689 8.7%

Comparison of the composition of residues with ilmenite

0 20 40 60 80 100

800

900

1000

1100

Ilmenite ore 50.0

62.0

59.7

56.8

61.8

31.0

31.0

30.2

29.8

43.5 6.5

9.9

11.0

7.2

6.7

0.2

2.4

carbon

Content (%)

Tem

pera

ture

(oC

)OthersFe2O3TiO2

↓residues

↓

Energy capacity of fuel, materials, and resources

LP

G

Kero

sen

e

City

gas

Heavy o

il

coal

woo

d

coke

PV

C

PS

PP

PE

PET

In

cin

eratio

nw

aste

Natu

ral g

as

fiber

pap

er

gla

ss

garb

ag

e

0

2,000

4,000

6,000

8,000

10,000

12,000

Kcal/kg

Reduction of CO2 emissions in key industries

by waste plastic use

Coal

consumption (t）CO2

emission（t）

CO2

reduction（t）Reduction

ratio(%)

5,54 million

6.32 million

3.0

4.256.92

→42.85 million

149.35

→143.03 million

Power

generation

Steel

industry

Cement

industry

80.04

→ 64.39 million

184.72

→179.18 million

3.46 million 15.39.50 million

→0

21.92

→18.56 million

Paper/pulp

industry 1.27 million 16.45.11million

→012.73

→10.64 million

Circles of 50km and 100km radius around the

each basic industry plants in Japan

Steel industry

Power plant

Petroleum industry

Cement industry

Paper & Pulp industry

50km radius

100km radius

Transfer Technology (TransTech)

Present society suffering from some issues

Ideal future society

Selection of Tech.

TransTech

TransTech

TransTech

New Tech.

Selection of Tech.

Selection of Tech.

New Tech.

New Tech.

Thank you for your attention!

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