Volume III: Guidelines

Volume III: Guidelines

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1. Recycling Guidelines for WASTE GENERATORS

11..11 IInnttrroodduuccttiioonnThe Recycling Guidelines for Waste Generators are prepared for the individuals and entities thatgenerate waste in their everyday life or business activities. Such individuals and business entitiesinclude:

1. Households 2. Business entities(offices, commercial,industry, and service

establishments)

3. Institutions

The waste generators play significant roles in the recycling activities as their effort to segregaterecyclable materials from waste stream, and pre-treat the recyclables will greatly affect the efficiencyof recycling processors, i.e. dealers and end-users of recyclable materials.

Thus, this Guideline will focus on what can be recycled, why we need recycling, and how thoseresources can be recycled from household, business entities and institutions. The contents of theGuideline are:

1. Target recyclable materials

2. Key roles of waste generators

3. Proper handling of each recyclable materials

The guidelines are prepared as the result of joint works between JICA Study Team and the TechnicalWorking Groups that are organized under the Study in the Philippines by the representatives fromthe government, industry as well as other key organizations in promoting recycling activities.

We really hope that the guidelines will help and assist the household, business entities, andinstitutions, and enhance their recycling activities and contribute to the realization of a material-recycle society in this country.


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11..22 TTaarrggeett rreeccyyccllaabbllee mmaatteerriiaallss

Target materials included in this Guideline are, papers, metals (tin and aluminum), glass containers,plastics, and electric/electronic home appliances (cell phone batteries, PC and its parts, TV andrefrigerator).

Pictures below illustrate some of the typical forms of those recyclable materials.

Papers

Newspaper

Magazines Copy/printing paper

Mixed paper Cardboard Other papers

Used brown Kraft paper,and Old corrugating cartons

Metals

Tin cans Aluminum cans

Glasscontainers

Amber (Brown) Flint (Clear) Emerald green (Green)


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PET PE/PP Rigids PE/PP Films & Bags

Plastics*

Foam PS EPS PVC

Electronic/homeappliance

PC and its parts TV Refrigerator

Cell Phone Battery

Plastic types have been grouped according to the following:

PET – Polyethylene Terephthalate which are used for many bottles application becausethey are inexpensive, lightweight and shatter-resistant. (ex. Mineral/Drinking WaterBottles)

PVC- Polyvinyl Chloride products which are used for pipes and fittings. It is noted thatover 80% of PVC used in applications have service lives of more than 10 years, thus,there is usually minimal PVC in municipal wastes.


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PE/PP Rigids – Polyethylene and Polypropylene products which are used in rigidapplications such as bottles, pallets, crates, drums and other hard plastics.

PE/PP Films and Bags – Polyethylene and Polypropylene products which are used inflexible applications such as bags, liners, and other single or mono-component softplastics.

Foam PS – Polystyrene products which are used in food service packaging.

EPS – Polystyrene products which are used as cushioning materials for fresh produce,electronic or appliance industries, among other products.

11..33 KKeeyy rroolleess ooff wwaassttee ggeenneerraattoorrssRecycling activities can only succeed when all relevant parties play theirrespective roles. In this sense, waste generators, i.e. households, businessentities, and institutions, are expected to follow the following roles andresponsibilities:

(1) Households

Segregation and handling of recyclable materials at sources in accordance with theRecycling Guideline (if applicable).

Actively participate and give support to the recycling activities and programs organized

Sharing of households information in relation to wastes and recycling

Educating households particularly the children on recycling practices

Practicing recycling at premises away from home such as working places and publicpremises

(2) Business Entities and Institutions

Segregation and handling of recyclable materials at sources in accordance with theRecycling Guideline (if applicable).

Actively participate and give support to recycling activities and organized programs

Awareness raising among recycling industry workers

Sharing information and raising awareness on recycling through networks such asbusiness associations


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Inclusion of recycling guidelines and practices in the educational curricula

Promoting the use of the plastics coding system to facilitate identification, segregationand recycling.

(3) Industries and Retailers

Participating and supporting recycling activities and programs organized

Designing and manufacturing eco-friendly products with recyclable materials

Promoting in-house segregation and implementing in-house recycling activities andestablishing a network of recycling stakeholders

Strengthening and publicizing the existing network of waste traders

Sharing industrial information related to waste and recycling to relevant associationsand/or the Government

Awareness raising among recycling industry workers

Carrying out daily operation while following the Recycling Guidelines (if applicable)

11..44 PPrrooppeerr hhaannddlliinngg ooff eeaacchh rreeccyyccllaabbllee mmaatteerriiaallThe waste generated from households, business entities, and institutions can be segregated intocompostable waste and non-compostable waste (recyclable materials).

Organic (compostable): Kitchen wastes, Garden wastes,

Non-Organic (Recyclables): Paper, Aluminum cans, Plastic, Glass bottles, etc.

Recyclable materials can be further classified and pre-treated according to characteristics of thematerials and local requirements. The following are examples of typical handling methods foreach type of target recyclable materials in this Guideline.


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11..55 PPaappeerrss

Segregate and bale by types of papers.

Newspapers/add leaflets Corrugating cartons Magazines

Following table shows methods of segregation and impurities to be avoided for each paper types.

Types of Paper Segregationmethod Impurities to be avoided

Recyclable papers

Newspaper/add leaflet Bale Organic matters

Magazines Bale Organic matters, Aroma paper,

Books Bale Organic matters,

Cardboard (tissue paper box, milkcartons, etc.)

Bale Organic matters, No plastic, tapes

Copy/printing paper Bale Organic matters, Dark printings

Used brown Kraft paper, and Oldcorrugating cartons

Bale Organic matters, Dark printings

Other

Brochures and catalogues Bale Organic matters

Calendars Bale Organic matters, spiral

Envelops Bale Organic matters, Plastic sheet,

Paper bags (grocery bags) Bale Organic matters,

Paper binders

Paper containers (cigarette box, eggcase)

Bale Organic matters, Plastic sheet

Phone books Bale Organic matters

Posters Bale Organic matters

Core (roll) of paper towels, toiletpapers

Organic matters

Hard to recycle papers (should not be mixed with scrap paper for proper recycling)


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Types of Paper Segregationmethod Impurities to be avoided

Thermal paper

Carbon paper

Coated papers / cardboard (metal,film)

Paper printed with dark colors (black,red, blue, green)

Used tissue papers

Photos

Plastic coated papers

Aluminum coated papers

l Do not mix paper with other materials, such as staples.

l Do not use packing tapes.

l Dirty paper should be discarded as municipal waste.

l Small pieces of paper that might easily scatter should be placed in a bag orenvelope.

11..66 MMeettaallss

Metals can be segregated into tin cans and aluminum cans. Rinse with water to remove organicmatters, and for aluminum cans, crash to reduce volume.

Tin cans Aluminum cans

Example of tin can and aluminum can segregation and impurities to be avoided is shown below:


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Types Example Segregation method Impurities to beavoided

Steel can Food container,cookie can, etc.

Wash and dry Plastic/paper labels,organic matter

Beverage can Wash, dry, and crashAluminumcan

Organic matter

The following table lists the steel/aluminum cans that need special attention, and are not dealt in thisGuideline.

Hard to recycle steel/aluminum cans

ImpurityTypes Example Segregation

method to be avoided accepted

Steel can Spray can Use up allcontent thendiscard

Plastic nozzle

Paint can

- -

No need toclean residue

Oil can

- -

No need toclean residue

Other steel products

Cooking pot /pans

- -

Silverwares - -


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Knifes

- -

Others

11..77 GGllaassss ccoonnttaaiinneerrssGlass bottles can be categorized as ‘one-way bottle’, and ‘returnable bottle’. Both of them should berinsed off with water and segregated by color, i.e. amber (brown), flint (clear), and emerald green(green). Broken glass bottles and other containers may be accepted for glass culet, depending uponthe local dealers. Broken bottles and other containers should also be segregated by colors, i.e. amber(brown), flint (clear), and emerald green (green).

Types Example Segregationmethod

Impurity to beavoided

Glass bottles

(one-way bottle)

Jam jar, beer bottle, andwine bottle.

By color,

Wash and dry

Plastic/paper/aluminum coatedlabels, cap, organicmatter, ceramics

Jam jar, beer bottle, andwine bottle.

By color,

Wash and dry

Organic matter, cap,other

Glass bottles

(returnablebottle, can beused about 30times)

Others -acceptedif content is lime

-culets areaccepted

-no glass pellets

Broken bottle, glass

(accepted at San MiguelPackaging for glassculets. Colored bottlesare accepted but shouldbe segregated)

(Placed in bag) Plastic/paper/aluminum coatedlabels, cap, organicmatter, ceramics,other foreignmaterials


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Cosmetic / vitamindrink bottles

By color,

Wash and dry

Flint (clear) oramber (brown)

Plastic/paper/aluminum coatedlabels, cap, organicmatter, ceramics

Tempered glass

Organic matter,foreign materials

l Rinse off with water and remove food residue. Be careful not to brake it.

l Remove cap and labels.

Some local dealers will not accept broken glass and other special types of glass as shown in thefollowing table.

Glass that needs special attention

Flat glass

(ex. windowglass such asjalousy)

- -

fluorescent bulb - -

11..88 PPllaassttiiccssPlastics are used in forms of bottles, food trays, food packaging, various films, caps, cushioning, andother applications.

Among them, PET (Polyethylene Terephthalate) bottle is one of the most frequently used plasticbeverage and other liquid containers in everyday life. For proper recycling, takeoff cap and label from the bottle, then rinse off the content with water. Then,crush it to reduce volume. Finally, give it to Eco-aides/ MRF/ recycling facilitiesaccording to local conditions.


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Take off capand label

Rinse and dry Crush Recycling

Recycling PET is done as follows:

Segregate Compress/ crush Grind

As for the other types of plastics, the recycling practice involves:

CLEANING COMPRESSING/

CRUSHING

GRINDING PELLETIZING &

COMPOUNDING

Export or Bottle-to BottleRecycling

Place in Sacks


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Following are examples of forms of other types of plastics and segregation methods.

Plastic type Example Segregation Impurity to be avoided

PET Wash and dry Cap, label, residue

PE/PP Rigids Wash and dry Foreign contaminants

PE/PP Films andBags

Wash and dry Foreign contaminants

Foam PS Wash and dry Food residue and foreigncontaminants

EPS Wash and dry Food residue and foreigncontaminants

PVC Wash and dry Foreign contaminants


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l Plastic containers that store hazardous materials should be treated according to localrequirements.

l All plastic recyclables have to be cleaned

l Whenever possible, PET recyclables must be separated by color

l Plastic bags should be torn on the sides

11..99 EElleeccttrriicc//eelleeccttrroonniicc hhoommee aapppplliiaanncceess

Electric/electronic home appliances that can be recycled include PC and its peripherals, televisionset, refrigerator, and cell phone battery.

Types Example Segregationmethod

Impurity to beavoided

PC andperipherals

TV set

Refrigerator

Cell PhoneBattery

Not to mix withmunicipal waste

Dirt or other foreignmaterials

l Proper storage: Electric/Electronic appliances should be kept indoor whereverpossible as dirt or rust caused by rain will reduce the quality, thus, buy back price ofthe materials.

l Cell phone/ mobile phone batteries should be handled with care to avoid breakageand as much as possible cover the ends/ electrical contacts with insulating tape. Cellphone batteries should also not be mixed with municipal waste.


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2. Recycling Guidelines for Dealers of Recyclable

Materials

22..11 IInnttrroodduuccttiioonnThe Recycling Guidelines for Dealers of Recyclable Materials are prepared for the individuals andentities that deal with recyclable materials as their business or non-business activities. Suchindividuals and business entities include:

?á Traders of recyclable materials

?á Junkshops and junk dealers

?á Material recovery facility (MRF)

?á Other individuals and entities dealing with recyclables as valuable and tradable materials

The dealers of recyclable materials play significant roles in keeping the current recyclingperformance in the Philippines through active collection and trading of valuable waste materials.They also provide job opportunities to the socio-economically weak people through creating jobs inrelation to collection, sorting and primary processing of recyclable materials.

On the other hand, due to no existence of technical guidance on proper collection, handling andprimary processing of recyclable materials, they are sometimes not well prepared to meet thequantity or quality requirement of end-users or exporters. Also, in terms of working safety andhygiene as well as environment management, there are some junkshops and junk dealers thatimproperly handle and process the collected recyclables.

To address these issues, the Guidelines consist of the following:

1. Quality Standard for Acceptance of Recyclable Materials by Dealers, which specifies, by eachrecyclable item, the quality standard to meet requirement of end-users or exporters;

2. Facility standard for storage or warehouse of recyclable materials;

3. Data management of trading activities at the level of individual dealers such as inventory controland bookkeeping.

The guidelines were prepared as the result of joint works between JICA Study Team and theTechnical Working Groups that are organized under the Study in the Philippines by therepresentatives from the government, industry as well as other key organizations in promotingrecycling activities.

We really hope that the guidelines will help and assist the dealers to develop and enhance theirrecycling activities and contribute to the realization of a material-recycle society in this country.


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22..22 QQuuaalliittyy SSttaannddaarrdd ffoorr AAcccceeppttaannccee ooff RReeccyyccllaabbllee MMaatteerriiaallss

22..22..11 SSccrraapp PPaappeerrss

(1) Scope of the Quality Standard to be Applied

The quality standard for scrap paper to be provided below will be applied to old newspaper,cardboard, old magazine, office paper, used brown kraft and old corrugating carton, andmiscellaneous papers, of which the definitions are given below.

Table 2.2.1 Definitions of Scrap Papers

Category DescriptionNewspaper Newspapers discarded from households, offices, government institutions and

others including advertisement leaflets folded in the newspaper. Six months oldnewspaper must be segregated and classified as lower grade quality.

Cardboard Cardboards discarded from cardboard and paper container manufacturers as wellas from households, offices, government institutions and others. This is classifiedas white cardboards and grayback or chipboard.

Magazine Magazines and books discarded from households, offices, government institutionsand others such as those returned from bookstores and dead stock.

Office paper Paper and paper products discarded from offices, mainly unbound printing paperincluding used copy paper. More specifically, it includes used copy paper,leaflet/pamphlet, name card, envelope, package paper, paper containers, etc.

Miscellaneouspaper

Paper, cardboard, or other paper products not categorized above. Carbonless paperand Thermo sensitive paper, papers laminated with plastic film and aluminum foilcan also be recycled. However, recovery is only about 50% or lower

Used BrownKraft paper andOld corrugatingcarton

Consists of old corrugated containers having liners of either test liner, jute orKraft, and old brown Kraft bags free of objectionable liners or contents, and brownKraft cuttings from supermarkets, households, offices and government institutions

Regarding office paper and miscellaneous paper, some of the paper and paper products must not bemixed with recyclable scrap paper as shown in the table below.

Table 2.2.2 Non-Recyclable Scrap Paper

?á Waterproof paper (paper cup, paper plate, paper container for cup noodles, yogurt or otherfood products, grease paper, etc.

?á Carbon paper?á Pressure-bonded postcard?á Sensitive paper (photographic, photo-sensitive)?á Papers laminated by plastic film, aluminum foil, etc.?á Iron-on printed papers?á Papers stamped with metal foil.?á Papers having odorant (paper container/box for soap, detergent, etc.)?á Braille papers (papers used for braille typewriting)?á Synthetic paper?á Wet papers or the dirty papers contaminated by oil, food leftover, etc. (used tissue paper,

paper towel, toilet paper, etc.)?á Other papers not suitable as raw material for paper production

(2) Unwanted Materials Not to Be Mixed with Scrap Papers

Unwanted materials that are prohibited to be mixed with scrap papers are divided into two


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categories, Category A and B as shown below.

1) Category A: Heterogeneous/foreign items that bring disruption to recycling

?á Stone, glass, metallic material, earth and sand, woodchip.?á Plastic materials?á Resin-impregnated paper, parchment paper, fabrics?á Tarpaulin paper, paraffin paper, paper-made building materials such as gypsum board?á Iron-on printing paper, Braille paper, Synthetic paper, bonded material?á Papers having contact with infectious waste?á Other papers that disturb recycled process or products

2) Category B: Unwanted items not to be mixed with scrap paper for proper recycling

?á Carbon paper?á Carbonless Copy Paper (CCP)?á Resin-coated paper and laminated paper?á Adhesive tape (except for recycling of cardboards)?á Thermo-sensitive paper, aromatic/perfumed paper and papers having odorant?á Other papers that are not suitable as raw materials for paper manufacturing

(3) Quality Standard for Acceptance of Scrap Papers by types

The quality standard for acceptance of scrap paper can be determined as follows:

1) Office Paper

Item Quality Standard1. Mixture of unwanted items

(1) Category A Not allowed(2) Category B Not allowed in principle. Even though it is unavoidable, it should

not exceed 0.5% of mix rate by colors.2. Water content Not exceed 12%

2) Magazine



not exceed 0.5% of mix rate.2. Mixture of non magazine Not exceed 5% of mix rate.3. Water content Not exceed 12%

3) Brown Kraft Paper


(1) Category A Not allowed(2) Category B Not allowed

2. Mixture of non brown Kraftpaper

Not exceed 0.5% of mix rate

3. Water content -


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4) Cardboard



not exceed 0.3% of mix rate.2. Mixture of non cardboard Not exceed 3% of mix rate.3. Water content Not exceed 12%

5) Newspaper



not exceed 0.3% of mix rate.2. Mixture of non newspaper Not exceed 1% of mix rate. (exc. Leaflets folded in the newspaper)3. Water content Not exceed 12%

6) Miscellaneous Paper


(1) Category A Not allowed(2) Category B Not allowed in principle. Even though it is unavoidable, it will not

exceed 0.5% of mix rate.2. Water content Not exceed 12%

(4) Style of Packing

The style of packing scrap paper is provided as follows:

?á In principle, scrap papers are required to be in the form of pressed bale package.

?á Unwanted items are not allowed to be utilized for tare. (The use of string and metal wire forbaling is allowed.)

(5) Sub-Standard Articles

The following scrap papers are defined and dealt with as sub-standard articles.

?á Degraded/deteriorated scrap papers

?á Sunburned scrap papers

?á Scrap papers contaminated by soil/dirt, rust, etc.

?á Other Scrap papers that are not in compliance with the quality standard defined above.

22..22..22 TTiinn CCaann


Tin can that is subject to the Guidelines is generally defined as an air-tight sealed container for thedistribution or storage of goods, composed of tin metal, and requires cutting or tearing of the metal


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as the means of opening. Cans hold diverse contents, but the overwhelming majority preserve foodby canning. No cans presently in wide use are composed primarily or wholly of tin; that term ratherreflects the near-exclusive use in cans of tinplate steel, which combined with the physical strengthand relatively low price of steel with the resistance to corrosion of tin. The pictures below show theexamples of tin cans, of which, all are subject to collection for recycling.

(2) Quality Standard for Acceptance of Tin Cans by Dealers

General quality standard for acceptance of tin cans by dealers will be described as shown in the tablebelow.

Table 2.2.3 General Quality Standard for Acceptance of Tin Cans by Dealers

Item Quality Standard1. Removal of contents ?á Contents must be rinsed out by water. (except for spray can)2. Mixture of non-tin cans ?á Not allowed.3. Labels ?á To be removed to the utmost extent.4. Spray cans ?á Contents must be finished up

?á Pressurized gas must be released by piercing a hole in cans orremoving the caps, spray buttons, etc.

5. Aluminum top ?á Not necessary to be removed.6. Volume reduction ?á To be compressed if possible.7. Lithograph can

(printed can)?á Maybe cut off the top and bottom part for easy compaction

8. Motor oil can ?á No washing needed (residue oil maybe collected for reuse)9. Cooking oil can ?á No washing needed (residue oil maybe collected for reuse)10. Paint can ?á (Residue maybe collected for resale)

The above general quality standard may be subject to change in accordance with the requirement offinal receivers of tin cans, the end-users or exporters. Therefore, it is essential to have common


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understanding on the acceptable quality of tin cans between dealers and end-users or exporters.

22..22..33 AAlluummiinnuumm CCaann


Aluminum can discussed here is the aluminum containers that are widely utilized to hold a singleserving of a beverage including carbonated beverages.

(2) Quality Standard for Acceptance of Aluminum Can by Dealers

General quality standard for acceptance of aluminum cans by dealers will be described as shown inthe table below.

Table 2.2.4 General Quality Standard for Acceptance of Aluminum Cans

Item Quality Standard1. Removal of contents ?á Contents must be rinsed out by water.2. Mix with non-aluminum

cans?á Not allowed, but depending upon the separate collection system

applied at the relevant localities3. Labels ?á To be removed to the utmost extent.4. Pull tab or pull top ?á Not necessary to be removed or separated from the cans5. Volume reduction ?á To be compressed if possible6. Unwanted aluminum

containers?á Aerosol can?á Tooth paste containers (Difficult to remove all the contents)

The above general quality standard may be subject to change in accordance with the requirement offinal receivers of aluminum cans, the end-users or exporters. Therefore, it is essential to havecommon understanding on the acceptable quality of aluminum cans between dealers and end-usersor exporters.

22..22..44 GGllaassss BBoottttlleess


The quality standard for glass bottles to be provided below is applied to the glass bottles used as thecontainers for food drinks or any other inhalable thing. The following glass or glass bottles are notsubject to the guidelines and not collected as recyclable materials.


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Table 2.2.5 Non-Recyclable Glass and Glass Bottles

Types of glass and glass bottles Reasons for non-collectionScrap glass (non-bottle) ?á Due to the different chemical composition, it cannot be

utilized as raw material for producing glass bottlesRefractory glass ?á It will not be completely melted in the manufacturing

process of glass bottles.Ceramics ?á It will degrade the quality of glass bottles if mixed.Glass bottles contaminated bysand, stone or dirt

?á It will degrade the quality of glass bottles if mixed.

Lactescent bottle ?á Due to the different chemical composition, it cannot beutilized as raw material for producing glass bottles.

Glass bottles used for pesticidesor harsh drugs

?á Risk of remaining hazardous substances.

(2) Quality Standard for Acceptance of Glass Bottles by Dealers

The quality standard for acceptance of glass bottles can be determined as shown in the table below.

Table 2.2.6 Quality Standard for Acceptance of Glass Bottles

Category of ForeignMaterials

Maximum Acceptable Amountof Foreign Materials Mixed

per 1 ton of Glass Bottles

Reference of Acceptable Amount

Aluminum 0g About 20 aluminum caps of 28mmdiameter

Steel 0g About 10 steel caps of 50mmdiameter

Other metals 0g -

Bottle cap

Plastic 0g About 130 plastic caps of 28mmdiameter

Ceramics 0g A large piece of a broken tea cupStone, concrete, sand,soil

0g Same as above

Colored bottles in flintbottles

0g One bottle of 720ml

Colored or flint (clear)bottles in differentcolored ones bottles

depends -

Remaining contentsand contamination

0g Bottles should be rinsed.

Glass with differentcomposition from glassbottles

0g Kitchenware, tableware, crystalglass, light bulbs, and lensesshould not be mixed.

Plastics, PET bottles,cans, and papers

0g No foreign material should bemixed.

22..22..55 SSccrraapp PPllaassttiiccss


The types of scrap plastics subject to the guidelines are PET bottles and other plastic containers andpackages. The pictures and figures in the next table show their examples.


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Table 2.2.7 Types of Scrap Plastics covered in the Guidelines

PET/ PC (Polycarbonate) PE/PP Rigids PE/PP Films and Bags

Foam PS EPS PVC


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Plastic types have been grouped according to the following:

PET – Polyethylene Terephthalate which are used for many bottles application becausethey are inexpensive, lightweight and shatter-resistant. (ex. Mineral/Drinking WaterBottles)

PVC- Polyvinyl Chloride products which are used for pipes and fittings. It is noted thatover 80% of PVC used in applications have service lives of more than 10 years, thus,there is usually minimal PVC in municipal wastes

PE/PP Rigids – Polyethylene and Polypropylene products which are used in rigidapplications such as bottles, pallets, crates, drums and other hard plastics.

PE/PP Films and Bags – Polyethylene and Polypropylene products which are used inflexible applications such as bags, liners, and other single or mono-component softplastics.

Foam PS – Polystyrene products which are used in food service packaging.

EPS – Polystyrene products which are used as cushioning materials for fresh produce,electronic or appliance industries, among other products.

(2) Quality Standard for Acceptance of Scrap Plastics

1) PET Bottles

Whenever possible, PET bottles must be compressed and baled by dealers before transferring to end-users. In addition, bottles must be separated into clear and colored.

(a) Required Properties of Baled PET Bottles

Item Required PropertiesStability No collapse during transfer or transport of balesEasy handling Easy to be unbundled

(b) Required Properties of PET Bottles transported in caged or enclosed trucks (not baled)

Item Required PropertiesStability Collected PET bottles should have canvass covers


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(c) Size, Weight and Bundling Material

Considering load efficiency by truck and standard size of cargo pallets, the following three types ofbales are highly recommended.

Size Weight Bundling Materials600*400*300 mm 15 – 20 kg Polypropylene or PET band600*400*600 mm 30 – 40 kg Ditto

1,000*1,000*1,000 mm 180 – 230 kg WireOr as specified by Recycling Companies

Remark:?á The size above indicates that of a press mold; therefore, the size of baled PET bottles may be slightly larger

than the numbers indicated in the table above.?á To avoid contamination by rust, galvanized steel wire is recommended when using wire for baling.

(d) Quality Standard for Baled PET Bottles

To obtain higher quality of recyclable materials at the lowest cost, the following quality standardsare recommended as the target for baled PET bottles.

Item Target Quality StandardMixing rate of bottles with caps Less than 10%Mixing rate of bottles including vinyl chloride Less than 0.5%Mixing rate of PE or PP bottles Less than 0.5%Mixing rate of glass bottles NoneMixing rate of aluminum or steel cans NoneMixing rate of paper containers NoneMixing rate of other foreign materials None

2) Other Plastic Containers and Packages

Non-PET plastic containers and packages are also required to be compressed and baled by dealersbefore transferring to the final users.

a Required Properties of Baled Plastic Containers and Packages

Item Required PropertiesStability No collapse during transfer or transport of balesSanitation No odor is generated from bales.

Organic materials capable of rotting/ decaying should not be attached orremain.

Easy handling Easy to be unbundled (Bulk specific gravity of 0.25t/m3 is highlyrecommended for the baled and bundled plastics.

b Required Properties of Plastic Containers and Packages transported in caged orenclosed trucks (not baled)

Item Required PropertiesSegregation Plastic Container and Packages should be properly segregated or

compartmentalized according to the classification stated in Item 2.5.1Sanitation No foul odor is generated.

Organic matter producing foul odor should not remain or should not be


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attached.

3) Size, Weight and Bundling Material

Considering load efficiency by truck and standard size of cargo pallets, the following three types ofbales are highly recommended.

Size Weight Bundling Materials600*400*300 mm 18 – 20 kg Polypropylene or PET band600*400*600 mm 36 – 50 kg ditto

1,000*1,000*1,000 mm 250 – 350 kg WireRemark:?á The Size above indicates that of a press mold; therefore, the size of baled PET bottles may be slightly larger

than the numbers indicated in the table above.?á To avoid contamination by rust, galvanized steel wire is recommended when using wire for baling.

4) Quality Standard for Baled non-PET Plastic Containers and Packages

To obtain higher quality of recyclable materials at the lowest cost, the following quality standard isrecommended as the target for baled non-PET plastic containers and packages.

Item Target QualityStandard

Remark

Minimum percentage of non-PETplastic containers and packages in thebale

More than 90%

Mixing rate of PET bottles Not allowedMixing rate of non-plastic containersand packages

Not allowed Mixing of metal, glass, or papercontainers and packages is strictlyavoided.

Mixing rate of other plastic types Not allowed A particular type of plastic must besegregated from all other plastics

Other foreign materials not listedabove

Not allowed Other foreign materials such asknives, glass and metal scraps othercontainers and packages, cloth,ceramics, sand and stone, foodleftovers, woodchips, paper, leather,rubber, etc. are all forbidden to bemixed in the bale.

Water content No drip of waterfrom the bale

(3) White Food Trays/Packages (Modify with PPCP)

Food trays and packages are required to be properly stacked (by size) in a transparent bag.

a Required Properties of Baled Food Trays

Item Required PropertiesSanitation The bag containing white food trays should be tightly sealed,

transparent, and free from contamination by foul odor-generatingsubstances especially food leftover as well as sand and soil.


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2) Size, Weight and Bundling Material

The following two sizes of bags are recommended considering load efficiency and workability.

Size Weight1500*1200 mm (25 µêthickness) 2.3 – 3.0 kg1200*1000 mm (25 µ†thickness) 1.7 – 2.0 kg

3) Quality Standard for PSP (Styrofoam) Food Trays/Clamshells/Packages

To obtain higher quality of recyclable materials at the lowest cost, the following quality standard isrecommended as the target for baled white food trays and packages.

Item Target (weight %) RemarkMinimum percentage ofwhite food trays/packages

More than 90% -

Foreign materials Not allowed -Non-white food traysmade from expandedstyrene

Colored trays, trays with patterns

Trays other than above Not allowed PE, PP, PET, etc.Plastic containers otherthan trays

Cups for instant noodles, etc.

Organic materials such asfood leftovers

Food waste, woodchips, paper, leather,rubber and those containing any of theseorganic materials

Other Knife, glass, metal, ceramicsWater No drip of water

from the baled bags-

22..22..66 UUsseedd//SSuurrpplluuss EElleeccttrriiccaall aanndd EElleeccttrroonniicc HHoommee AApppplliiaanncceess

(1) Cell phone batteries

1) Required Physical Properties

Item Required CriteriaProper Separation ?á Cell phone batteries should be sorted by material (Nickel-

Cadmium (Ni-Cd), Lithium-Ion, Lithium-Polymer, andNickel-Metal Hydride)

Recycling mark of batteries by types of metals used in JapanDismantling from the cellphones

?á Cell phone batteries must be dismantled from cell phones atthe time of their disposal. Once removed, batteries should bemanaged with care to avoid breakage. While they are notfragile, they may break in rough handling.

Mix with other types of ?á It is not allowed to mix cell phone batteries with other types


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batteries of batteries such as primary dry cells (alkaline batteries,manganese batteries, zinc carbon batteries), car batteries, etc.

Avoidance of accidentalheat generation or ignition

?á Batteries should be treated as if they still contain electricalcharge. Their electrical contacts/ ends should be covered withinsulating tapes in order to avoid heat generation, shortcircuits and ignition which may cause fire.

2) Quality Standard for Acceptance of Cell Phone Batteries

So far, there is no formal collection and recycling mechanism for cell phone batteries available in thePhilippines. Therefore, the quality standard will be determined when formal collection and recyclingmechanism for cell phone batteries in the Philippines based on the quality requirement of the finalreceivers to be designated.

(2) Other Used/Surplus Electric and Electronic Home Appliances (PersonalComputers, Refrigerators, and TV sets)

For other used/surplus electric and electronic home appliances mentioned above, the quality standardfor acceptance by final users should be determined in accordance with the quality requirement by thefinal receivers in the Philippines. However, the Dealers must at least comply with the followingbasic requirement.

Item RequirementLabor safety ?á It is prohibited to apply unsafe methods for dismantling the

appliances as well as for extracting valuable materials such as useof hazardous chemical substances, burning of non-valuable partswithout any license or permission by the relevant authorities.

Pollution Control ?á Dealers must comply with the relevant laws and regulation inrelation to environment protection if they generate residualmaterials of any forms (gaseous, liquid, or solid) by processing andtreating the appliances within their premises.

22..33 SSttoorraaggee SSttaannddaarrddss ffoorr RReeccyyccllaabbllee MMaatteerriiaallss

22..33..11 PPuurrppoossee ooff SSttoorraaggee SSttaannddaarrddss

The purpose of storage standard are:

?á To guide dealer’s proper storage of recyclable materials to prevent depreciation of recyclablematerials and

?á To guide dealer’s efforts to protect environment and workers health and safety on the dealer’spremises.


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22..33..22 SSttoorraaggee SSttaannddaarrddss

(1) General Standard for Storage Facility

General standard for storage or warehouse of recyclable materials are provided as shown in the tablebelow.

Item General StandardLocation of thestorage/warehouse

?á The storage facility should be located at sufficient distance from sresidential areas and food preparation/consumption facilities.

Structure ofstorage/warehouse

?á The storage facility should have a fence or wall (when recyclablematerials directly contact the fence or wall, the fence or wall shouldhave enough structural strength and stability to withstand).

?á The storage facility should have a roof and walls to avoid recyclablematerials being wet by rain and deteriorated by sunlight.

?á The storage facility should have a proper ventilation system.?á When rinsing of recyclable materials are conducted at the premises, the

premises should have drainage and a wastewater treatment facility toprevent water pollution and a floor covered with impermeable materialssuch as concrete.

(2) Proper Operation of Storage/Warehouse of Recyclable Materials

The storage/warehouse of recyclable materials must make sure that

?á The storage facility should be secured against access by rats, mosquitoes, and other vermin.

?á When recyclable materials are not stored within containers, a pile of recyclable materials shouldbe kept below the following height.

?á

22..44 DDaattaa MMaannaaggeemmeenntt

22..44..11 PPuurrppoossee ooff DDaattaa MMaannaaggeemmeenntt

The purpose of data management by the dealer is to plan for efficient collection and sales ofrecyclable materials and minimize loss of and storage spaces for recyclable materials collected.

22..44..22 SSttaannddaarrdd PPrraaccttiiccee

(1) Management of Data

1) Micro Data Collection

Data on the following items should be collected to identify the flow of inbound and outbound

FenceFence

50% Slope

Ground

50% Slope

Wall

Ground


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recyclable materials through the transaction.

?á Type of recyclable materials?á Date of purchase/sale?á Volume/quantity and buying/selling price of recyclable materials?á Name and contact address of sellers and buyers?á Quality of recyclable materials (levels of sorting, rinsing, compressing, etc. by sellers and

required by buyers)

2) Compilation and processing of Data

Micro data collected above at the level of individual dealers can be managed in a table format bymaterial as shown below.

Material Name:Transaction

No.Date Volume/

Quantity(A)

Price(B)

UnitPrice(B/A)

Name of seller(or buyer)

Address/telephoneof seller (or buyer)

QualityRequired(sorting

level, etc.)

Collected data can be used for identifying the trend of supply/demand, the trend of unit price(buying/selling), large sellers/buyers, quality required by buyers, and stock of recyclable materialsand available storage capacity as follows.

• Trend of supply/demand: if the volume/quantity is aggregated by month or year, it mayshow a seasonal or historical trend of supply/demand volume/quantity.

• Trend of unit price (buying/selling): if the unit price (price divided by volume/quantity) isaveraged by month or year, it may show seasonal or historical trend and a range offluctuation of the unit price.

• Large sellers/buyers: if the volume/quantity of recyclable materials is sorted by seller/buyer,it may provide information about who are large sellers/buyers.

• Quality sellers: if the quality of recyclable materials is evaluated based on certain criteria, itmay provide information about who are quality sellers (those who can provide recyclablematerials properly sorted, rinsed, compressed, baled, etc.).

• Quality required by buyers: if the conditions of recyclable materials required by each buyeris consolidated and prioritized based on the frequency of buyers needs, the information mayconstitute the future acceptance criteria.

• Stock of recyclable materials and available storage capacity: the stock can be identified byinventory taking and calculation based on inbound and outbound flow of materials.Available storage capacity can be calculated based on the total capacity and stock


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volume/quantity.

3. Technical Guidelines for Recycling Industries

33..11 NNeecceessssaarryy RReeqquuiirreemmeennttss ffoorr RReeccyycclliinngg FFaacciilliittyyFacilities that are going to treat and recycle wastes materials should be compliance with the nationalsafety and health regulations/codes in addition to the environmental requirements. The facilities arealso required to periodically inspect by the government authority and/or their representatives.

The following closes describe essential technologies and necessary information for the recyclingindustries.

33..11..11 FFaacciilliittyy ffoorr wwaassttee ppaappeerr rreeccyycclliinngg

(1) Typical recycling process

The recycling of the waste paper is almost similar process as manufacturing of virgin papers exceptraw materials, which are either waste papers or woods (pulps). The following are typical wasterecycling process integrated with a paper production.


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Waste papercollection

Segregation &Temp Storage

Generalpaper (White)

PrintedpaperMagazines Cardboard

paperLaminated

paper

Segregation & Shredding

Removeimpurities &

irons

RemovingLaminate

1st pulperstage

1st De-inking

Pre-treatm

ent

Preparation


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PULPING

COARSE SCREENING

HI DENSITY CLEANING

PRE SCREENING

PRE FLOTATION

HEAVY REJECT CLEANING

FINE SCREENING

LIGHT WEIGHT REJECT CLEANING

THICKENING 1

DISPERSING

HD STORAGE

POST FLOTATION

THICKENING 2

WASHING

PAPER MILL

FINISHED PAPER

WHITEWATERSYSTEM

WHITE WATERFLOTATION

WHITE WATERSYSTEM

WASTE PAPER


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(2) Required facility and main equipment

• Waste paper receiving area

• Wight scale and record station

• Temporary storage area

• Segregation area

• Roofed stock yard (or storage room)

• Pulping tank

• De-inking & bleaching system

• Paper manufacturing system

• Wastewater treatment system

• Sludge treatment system

• Process water recycling system

(3) The environment protection

The operation of facility is essentially required to fully comply with the environmental law andregulations.

The paper manufacturing process basically requires with consuming a large amount of process water,and as a result, the production generates enormous amounts of the wastewater. The effluent of thewastewater is heavily polluted through de-inking, bleaching, pulping, diluting and paper millingprocesses. Consequently the wastewater cannot directly discharge without treatments into theenvironment. In order to prevent the environment from these wastewater effluents, the recyclingfacility is strictly required with installing appropriate wastewater treatment process (system). Inaddition, sledges that are discharged from the wastewater treatment facility are also contaminatedwith hazardous impurities, as chemicals and odors. The sludge therefore is needed to properly treatwithout re-generating new contaminations.

(4) Safety and health measures

1) Safety measures:

As a nature of paper, it is easily flamed and also becomes smolders under a lack of air (oxygen).Some cases, the wastepaper are spontaneously ignited while in storing under particular conditionssuch as mixing of organic matters with adequate amount of moistures. In order to protect suchaccidental firing, it is required with providing fire extinguishers as well as firefighting equipment inthe waste paper storage facility.


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In emergency cases as firing and/or other chemical spilling, evacuation signboards and a warningsiren are also required to install in the facility area.

2) Health care and protection:

In pulping process as well as diluting of waste papers, the process water maybe contaminated withand/or without with caustic soda, therefore splashing of the process water (chemicals) may causeirritating eyes and/or skins. To prevent from such events, eye washing fountains and water basins arerecommended to install at the process areas and in addition, the first aid should be provided at thesame working area.

33..11..22 FFaacciilliittyy ffoorr wwaassttee mmeettaall ((ssccrraapp)) rreeccyycclliinngg

(1) Recycling process for typical steel scraps

Wide varieties of waste steels have being discharged into a market as scraped steels, which comefrom industries of iron mill, foundry, casting, metal machining, automobile, consumers and etc.However those steel scraps are commonly bulky, mixed with other metals, or strips, and grinded. Inorder to effectively utilize the scraps, those are separated, segregated, consolidated as well asbundled in prior to smelt at the factory.

The following are typical pre-treatment process for steel scrap recycling.

1) Bushy, stringy metal scraps (machined scraps):

Must be crushed or shredded into smaller chips to satisfy with following requirements:

• Effective extraction and reclamation of cutting fluids from machined scraps

• Reduce particle size (i.e.: max 75mm)

2) Bulky steel scraps:

Should be crushed or shredded in shoveling sized chip to satisfy handling and transportation.

3) Briquette metal chips:

Reduced scrap handling and transportation costs

Obtain premium price for scrap value

Reclamation of cutting fluids

Avoidance of environmental contamination issues


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4) Segregation of steel alloy scraps:

By adding of other metals or material elements such as chromium or carbon during themanufacturing process, different types of steel alloys can be produced. These however other types ofsteel include stainless steel, which resists corrosion, and certain alloy steels are natures of hightensile strengthen and/or thermal resistance. Those steel alloys must be segregated in prior smeltingand can be recovered from products and recycled.

5) Magnetic separation:

Scrapped steels can easily separate and sort out from the stream of domestic wastes by using of themagnetic force. In order to obtain higher quality steel scraps, recycled steel scraps are required touniform as mono steel nature.

(2) Waste aluminum-cans recycling process

The aluminum materials used for beverage cans are specified with different type of alloys either forthe body or for cup, as shown on the following table.

Body Aluminum-Manganese Alloy Approx.1-1.5%Cap Aluminum-Magnesium Alloy Approx. 4-5%

Reasons to use different type of the alloys are that the body material requires rather flexible andstrengthen nature so that the drawing method can be applied in manufacturing cans; instead thecap material requires easier breakage by shearing force as the pull-top mechanism to open.

Accordingly those types of materials should not be mixed when the recycled cans are going toreuse for re-manufacturing new cans as “Cans to Cans” process. But when the recycledaluminum metal is utilized by die-casting method for general-purpose, as cast frames, furnitureparts, handles, trays, general household products and etc. it is possible to let these materials tomix in some cases.

The following diagram shows typical aluminum recycling process.


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Recycled AluminumScraps

AluminumRaw Meterials

Pretreatment

Shredding

Degreasing

PaintRemoving

Segregation

Melting

Treatment inMolten-Al Bath

Casting

ReporoducedAluminum Ingot

Removing Slug

SlugTreatment

Remaing Ashes

RecoveringAluminum

Reusing

Disposing

1) Required facility and main equipment

• Waste aluminum-cans receiving facility• Magnetic separator (remove steel-cans)• Shredder• Degreasing system• Paint removing system• Segregating system• Melting furnace• Molten bath• Casting system• Ingot remover• Slug treater• Ash treater• Dust collector

(3) Environmental protection

1) Air protection:

Basically iron (steel) and aluminum metal are naturally stable, very safe and also non-hazardous


368

material. However oils, as fuels are required in melting process, as result, flue gases and smokes aregenerated with dusts/ashes. Therefore a dust collector is strictly required to install to remove excessfine dust in compliance with the environmental law and regulations to prevent the air quality fromthose dispersing.

2) Water and soil protection:

Some cases, metals contaminated with waste oils, especially irons/steel discharged from machiningwastes, they are required to handle carefully while in storing. The waste oils can easily pollute thesoil and water, or storing area. In the case, the surface of storage area is required to prevent from oilcontaminations. The surface is normally recommended to pave by non-penetration materials.

(4) Safety and health protections

1) Safety prevention:

Iron scraps, some cases are contaminated with small amount of chemicals as alkalis or acids. In acase, theses chemicals may cause irritations and/or burns with skins and eyes. Therefore it isrecommended to equip the first aid and washing fountains for hands and eyes in the working area.

When the aluminum powder is kept as waste metals, a caution signboard as “Do not use water”must be installed at the storage area.

2) Health protection:

a For iron scraps

As described, both irons (steels) and aluminum metals are safe materials. However the scrap iron cangenerate the heat if it is oxidized with adequate amounts of moisture and oxygen (air). Especiallyfine grinded irons powders, which are discharged from machining processes, are required withspecial care to keep moistures away, because the irons powder can generate high temperature undercertain conditions of the moistures under the atmosphere.

b For aluminum scraps

Aluminum scraps are safe and non-self activated as same as the iron. However the aluminumpowder can generate the hydrogen gas when the water is added in. When the aluminum powderis moisturized, it is converted into the aluminum hydroxide, and as a result, the hydrogen gas isgenerated and then easily flamed by fires. Therefore the powder aluminum is strictly required tostore at the isolated area from moisture water, rain, so that it is possible to prevent the accidentalfire.


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33..11..33 FFaacciilliittyy ffoorr wwaassttee ggllaassss rreeccyycclliinngg


The glass bottles for beverages as beer bottles have been called as a typical example of recycling,however recently share of “One-way Bottle” is increasing due to declining “Returnable Bottle”. Asthis result, a cullet production is expanding toward for an upward trend.

In a cullet production, it is extremely important to segregate all bottles by colors as well as types inprior shredding process. At present, it has been developed a new technology that variety of glassbottles can be automatically segregated by the electronic identification device, however it is requiredwith large invest costs. Therefore a manual segregation process is still more favorable process inPhilippines as well as other Asian Countries.

On the other hand, the quality of the cullet is basically lower grade than virgin glasses, but requireshigher costs in the cullet production. Additional problem is existed as that cullet production facilitiesare not always located at the nearest area from discharging points or manufacturing plants.

In advance, the latest technology can be applied to utilize the mixed culets (with variety of colors)using for pavement, materials for aggregates and concrete boards. These technologies can allowusing the mixed culets to mold mix color glass bottles as new products.

(2) Facility and main equipment

• Waste bottle receiving area• Wight scale and record station• Color segregation area (or bin)• Cullet shredder machine• Cullet storage bin by colors• Cullet washing system

Cullet Center

Segregation,Grinding, Washing

Bottle Making

Raw materials for New Bottles

Bottlers

WarehouseWholesaler

RetailersConsumers

Collection atRetailers

CommunitiesEtc.

Source: Japanese glass bottle recycling association


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The most of recycled glass bottles are naturally contaminated with remained organic materials(residues), or some cases, intentionally polluted with harmful chemicals and/or similar materialswith higher COD levels. In order to protect the environment, the wastewater discharged fromwashing/rinsing processes is strictly required to treat in compliance with the environmental law andstandards. In addition, the floor of washing/rinsing area is recommended to pave by non-penetratingmaterials.

(4) Safety and health issues

1) Safety prevention:

To protect skin and/or eyes, goggles and groves are strictly required to provide to all workers.

2) Health protection:

In order to avoid harmful irritation on skins or eyes caused by accidental splashing of thewashing/rinsing water, and contaminations with impurities and/or extremely small sized glasses, eyewashing fountains and basing should be equipped in the working area.

33..11..44 WWaassttee ppllaassttiiccss rreeccyycclliinngg ffaacciilliittyy


Recycling for waste plastics are fundamentally categorized by following 3 processes depend on itsobject. Basically the mechanical recycling is to reuse the waste plastics as raw materials, thefeedstock recycling is to chemically regenerate the waste plastics to other objects and the energyrecycling is to covert the waste plastics into the thermal energy as fuels.

Categories Recycling Methods Recycling Process

Mechanicalrecycling

• Convert into raw materials

• Make a products

Material recycling

• Monomerization

• Blast furnace reducing agent

• Coke oven chemical feedstockrecycling

Feedstock recycling

Chemicalfeedstock

Chemical recycling

• Gasification

• LiquefactionFuel

Energy recovery • Cement kiln

• Waste powder generation

• RDF

Thermal recycling


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In the mechanical recycling process, the collected wastes are transferred to recycle factories(enterprises). At recycling factories, impurities such as papers, metals are removed and then cleanedwaste plastics are fed into shredding process. After shredded, plastics materials are washed tocompletely remove impurities in purifying process. And then those plastic materials are turned intoflakes and/or pellets (flakes are granulated after heated) as using for raw materials. Those plasticmaterials are melted to utilize at textile and/or sheet manufacturing factories and also fabricatedproducts. For an example, the following process is typically applied for recycling of the PET bottle.

PET Bottle

Bottle Washing

Discharging WashedPET Bottle

Remove Base-Cup

Separate PVC Bottle

Remove Colored PETBottle

Shredded PET

Wash Flake PET

Shredded PET

Hydro-Cyclone

Flotation Tank

Flotation Tank

DehydrationAir-Separation

Separate Aluminum

RecoveredPET Flake

De-bailer

Effluent

ActivatedSludge

ActivatedCarbon

COD5,000ppm

COD8ppm

Effluents

Base-Cup Separation

Base-Cup Separation

X-Ray Auto Separation

Manual Separation

RemoveLabel GlueBase-Cup Glue

Separation Aluminum/Dirts

Remove Cup-Label peace

Remove Label Peace

Surge-Current /Static-Current Separation


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(2) Facility and main equipment

• Bailed waste plastics receiving area• Wight scale and record station• De-bailer/breaker machine• Bottle washing system• Base cup cutting machine• PVC separator• Colored PET separator• Bottle shredder• Flake washing system• Hydro-cyclone (separate Aluminum and dirt)• Floatation tank (remove labels)• Air separator (remove light materials)• Aluminum separator (static-current separator)• Wastewater separator• Sludge separator• Wastewater treatment system

(3) Environmental requirement

No requirements on the PET recycling facility are strictly to comply with the environmental law andregulations. But the cleaning process for used PET bottles are basically requires with large amount ofwashing and rinsing water. As this result, the wastewater is largely discharged as effluents. Thewastewater however is mostly contaminated with high COD caused by using of alkaline detergents.Therefore the wastewater cannot directly discharge without treatment into the environment. In somecases, shredder dusts and odors are generated depending upon type of machine in shredding process.If amount of dusts is exceeded than the environment standards, a dust collector is required to install.

(4) Safetty and health measures

1) Safety measures:

Plastics are basically combustible material and then it becomes smolders under a lack of air(oxygen) condition. Burning of plastics normally generates harmful gases with strong odors. Inorder to protect such accidental firing, the storage facility for waste plastics (i.e. PET) isrequired to install fire extinguishers and/or firefighting equipment. The goggles and masks, arerequired to protect eyes and a nose of workers in shredding facility.

2) Health care and protection:

In washing and rinsing processes, the process water may be contaminated with alkalinedetergents. The detergent water may become a cause of irritating eyes and/or skins.Consequently eye washing fountain and water basin are required to install at the working area as


373

well as the first aid. In addition, periodical health check for dust infections is required.

33..11..55 FFaacciilliittyy ffoorr rreeccyycclliinngg uunnuusseedd mmoobbiillee pphhoonnee

A million of unused mobile phone will be discharged in a market in a future, however at present,some amount of the unused those products are recycled and refurbished after testing, and re-soled ina market or exported. In order to recycle the unused mobile phones, the practical collection methodis to establish as “Recycle-box” at assumed points of discharging, such as the phone shops,distributors, repair shops and the phone company agents. The discharged mobile phones areperiodically collected recyclers or specified treaters and transported to those facilities. Then mobilephones are temporary stored at the recycler facilities until a certain volume of those wastes will beaccumulated for treating.

(1) Recycling process of the mobile phone

The mobile phone is consisted with a handset, lithium-ion battery and its charger as an accessory.And it is integrated with an electrical circuit board and a push-pad within a plastic case body (cover).The first, the components are manually separated and those parts are temporally stored untiladequate amounts for treating (recycling) will be accumulated. The electrical components and parts,which normally contains minimum quantities of precious metals, such as Gold, Silver, Platinum,Palladium and etc. on a circuit board. According to the mechanical estimation, approximately 150gof the gold can be recovered from 1,000kg; for example, however only 10g gold can be producedfrom 3,000kg of gold ore. Thus the unused mobile phone is called as the earthly gold mine. Howeverdue to the advancing technology can reduce drastically the use of such precious metals per a handsetcurrently. On the other hand the Copper and Cobalt can be recovered from the lithium-ion battery,and wastes electric circuit, waste fine-wires, nonferrous metals, irons and waste plastics from acharger, if properly separated.

The typical recycling process is shown as follows.


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Collection of Unused mobile phone

Segregation Process(Visual Inspection)

Out of condition Good condition

Refurbish

Re-sales

Recycling ProcessDismantling

HandsetBatteryChargerEtc

Material Recovery Parts Recovery

(2) Recycling process of the lithium battery in progress

The technology on recycling the lithium metal from waste lithium batteries has being studied indeveloping. But no effective and commercially economical processes have been developed at thepresent, however the following methods are experimentally studied in a market.

1) Incineration (baking) process

The waste lithium battery is fed into the incinerator to bake. After baking process the cobalt andlithium metals can be separated by a magnet separator and/or leaching method can be applied whencooling down process has been completely done.

2) Floatation separation process

The waste lithium battery is shredded and grinded until becoming fine powders, and then the CobaltAcid Lithium and Graphite (carbon) are recovered as a nature of mixing powder (black color).Theses recovered black powders are heated up to approximately 500?- to burn the binders, whichhave been fixed on the surface of the Cobalt Acid Lithium powder. When the binders are completelyremoved, the mixed powder with Cobalt Acid Lithium becomes the hydrophilic nature that isprecipitated by using of the coagulator and/or foaming agents. More than 92% of the Cobalt AcidLithium can be recovered with over 93% quality in the process.


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(3) Provisional measures in recycling facility

The waste lithium batteries are required to store at isolated areas and/or facilities where are can keepaway from the current environment until effective and practical recycling methods will becommercially developed. In order to achieve this provisional process, batteries manufacturers and/ortheir authorized dealers (sellers) should be responsible to collect and store the waste batterieswithout regenerating of new contamination. The storage facilities are recommended to comply withthe local environmental regulations and laws.

(4) Safety and health measures

1) Safety issues:

The lithium metal reacts with the water and oxygen to generate heat, and then ignites the generatedhydrogen gases, and it spontaneously may be ignited. It is a risk of igniting lithium metals in air if bemoisturized or splayed water.

• Do not use in case of firing

• Keep from moisture when storing

2) Health issues:

• Do not suck the air contaminating with lithium metals and/or powder

• When aspirate, quickly move to a location where is available with the fresh air

• Take a rest, if aspirate

• When dosed into mouth, wash/rinse a mouth with gargling

• When gotten into eyes, wash by clean water and immediately take a diagnose by adoctor

• When stacked on a skin, wash by clean water

• When clothes are contaminated, immediately cleaning is necessary

• Any exposure is existed, must consult by a doctor


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(5) Typical recycling flow

(Source: JBRC: Japan Portable Rechargeable Recycle Center)

Segr

egat

ion

Sorting Waste batteries

Ni-CdBatteries

Ni-HydrogenBatteries

Li-IonBatteries

Rec

yclin

gpr

oces

s

Dis

man

tling

Ther

mal

Trea

tmen

t

VacuumIncinerator

Rotary Kiln

Reu

sed

prod

ucts

Rec

ycle

d

Ni-Cd Stainless Magnet

Slugwith

Cobalt, IronAluminum, Copper

Iron/Nickel slugRecovered Cd


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33..11..66 FFaacciilliittyy ffoorr EE--wwaasstteess rreeccyycclliinngg

(1) Typical components of PC

The PC is assembled with a display and electronics components in a common cabinet. Thefollowing diagram is shown the typical components/materials to be recovered by recyclingprocess.

ReuseMagnetic Disk Unit

Power Supply Unit

Signal Cable

IC Tips

Disposable

RecycleFrame & Cable

Print Board Unit

CRT Display

Recyclable Plastic Parts

Non-Recyclable Plastic Parts

Fe, Cu, Al

Au, Ag, Pb

Glass Cullet

Pellet

Fuel

Recyclers

Reuse

Partsfor

Maintenance&

Repair

OverseasMarket

Reuse

LandfillIncinerationTreater

Disused PCDismantle

&Segregation

Dismantling waste (non-usable) PC is required to manually separate into the 3 main components,and then the recovered materials are segregated into recycling use and/or reusing parts.

(2) Typical components of TV

Same as PC, TV is also consisted with 3 major components as described on the following table.Recycled materials are the iron, normal glass, lead glass and plastics separated from thosecomponents.

Conponents Major recycled meterialsTV Tuve (CRT)• Shadow mask• Electric gun• Anti-maget band

Iron, Normal glass, lead glass

Electric parts• Circuit board• Cable

Copper, Silver, Plastics

Cabinet Plastic materials


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The waste TV is required manually to dismantle and is separated into several component parts. Andthen those are shredded and washed to recover valuable materials.

When the electronic circuit boards are compounded with plastics and metals like copper, suchcircuit boards should not be shredded in prior separation process. In a case, plastics materials,which are basically thin films or sheets, should be peeled off from the circuit boards so thatcopper materials are remained on the boards. Hence this process have being studied at thepresent, so that plastics and metals as copper are easily able to separate into two parts, and thenthe process can minimize the cost and energy consumption. Because of shredding processbasically requires with lots of energy consumptions.

(3) Typical components of refrigerator

Refrigerators are generally consisted with following 4 major components as described on thefollowing table. Recycled materials are iron, copper, aluminum and plastics from those parts.

Components Major recycled materials

Cabinet Iron, Plastics

Compressor Iron, Copper, Plastics

Electric parts Copper, Silver, Plastics

Inner parts Plastics, Alminum

(4) Decomposing of the electronics components

Basic technologies required in E-Waste recycling can apply the following 3 processes:

1) Low Temperature Shredding/Separation Process

Plastics materials are segregated by the nature of “brittle temperature”, which “embrittlement” ofmaterials is different depending on the temperature. The plastic materials are shredded and thensegregated into “Embrittlement” and “Non-embrittlement” materials.

2) Eddy current (EC) Separation Process

By providing of the rotational magnetic field (the eddy current) onto mixed metal materials, ferrousand non-ferrous materials can be separated into two kinds of the metals by repelling force.

3) Anti-dissolution Process

Such as shredder dusts, incinerated ashes, fly ashes and dust particles, which might be contaminatedwith heavy metals, are kneaded while in mixing of water and chemicals, and then these heavy metalscan be converted into non-soluble compounds in the alkaline solutions.


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(5) Required facility and main equipment for e-waste recycling

• E-waste receiving area

• Examination and recording

• Segregation by model, size and etc.

• Manual dismantling work area

• Separated storage facilities (for plastic cabinet, display, electronics parts)

• Shredder for plastics

• Shredder for circuit board

• CRT breaker system

• CFC recovering system

• Dust collector

(6) Recycled E-waste dismantle and mechanical recycling

The following diagrams show typical TV and refrigerator recycling system.


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Deflecting Yoke Print Circuit

DismantlingProcess

Front Panel Glass Back CabinetFennel

Separateof

FrontPanel/FennelGlass

Shredder/Plastics

Plastics material

Culet materialShredder/GlassWashingPanel glass

FennelGlass Shredder

Dryer/Cleaner

Culet materialShreddingWashing/Cleaning

SeparationProcess

(Source: Home appearances recycle association)


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(Source: Home appearances recycle association)

DismantlingProcessCFC Cylinder

Inner trayRecovering CFC/Oil

Dismantled

Primary shredding unit

Shredder/Plastics

Urethane foam

Air fanAir gravityseparator Secondary shredding unit

ShreddingWashing/Cleaning

SeparationProcess

CFC liquefied system

Magnet separator

Nonferrous separator Wet type gravity separator

Mixed plasticsNonferrous scrapsFerrous scrapsPlastics


382


Basically no strict environmental restrictions are required for recycling e-waste, but shredding dustsand fumes from CRT breaking process are required to treat preventing the atmosphere from thediffusion. When electronics components parts are going to remove from circuit boards, it is alsorecommended to carefully handle to avoid breakages. Some type of electronics parts may be usedwith hazardous chemicals and/or contaminated. When circuit boards are going to be grinded, thegrinded dusts are required to remove by a dust collector to prevent the air from dusts diffusion.

Especially in recycling of refrigerators, it is strictly required to recover the CFC withina compressor prior to dismantling.

(8) Safety and health protection

Eyes and skins are required to cover by goggles, masks and gloves in working area. Those grindingdusts may be irritated skins and eyes. Washing water fountain and first aids are strictly required toprovide at working area. Some cases, shredding noises are heavily affected for hearing; thereforeearplugs should be provided to workers.

33..22 TTeecchhnnoollooggyy RReeqquuiirreemmeennttss iinn RReeccyycclliinngg IInndduussttrriieess

33..22..11 TTeecchhnnoollooggyy rreeqquuiirreemmeennttss iinn rreeccyycclliinngg wwaassttee ppaappeerrss

The technologies in recycling wastes papers have been developed with a long history since inventedand also due to nature of papers, these can be easily regenerated as raw materials. A basic papermanufacturing system is consisted with simple processes such as soaking by the water, pulping,screening of produced pulps, and drying, and then finally papers are made. Consequently the mosteffective recycling system is quite a similar process as the new paper manufacturing except a rawmaterial.

However an effective and economical recycling system from the waste papers is quite dependingupon how consistent quality of wastes papers can be collected from the market. The followingrecycling network is typical and simplified diagram; however an actual system may be morecomplicated in reflecting of actual markets.


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(1) Reception and storage

• Delivered waste papers are measured with the volume, weight and then recorded

• Storing of waste papers is required to keep away from fires

• Keeping away from moistures is recommended

• Long term storing is recommended under a roofed area

• Storing should not be dirt environment

(2) Segregation

In order to regenerate the waste paper into consistent quality papers, there are some importantprocesses and conditions as follows. It is necessary to pre-treat as pre-segregation as well as semi-preparation in prior to start a basic paper process. The waste papers is required to segregate by typesand qualities, such as:

• Printed or non-printed papers

• Newspapers or magazines

• Cardboard or corrugate papers

ResidenceArea Collection Storage

Station

Localcommunities

Volantiers

MediumCollection

Comercial arerarail road station

Retailstore

Special Buyer

ContructRecycler

Large-scaleStorageStation

TransporterTrading Farm

PaperManufactuerer

Large CollectionCardboard MfcterPaper wear Mfctr

Printing CoPublisher

Newspaper CoDeperment store

Supermarket


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• Office papers or non-office papers

• General-purpose papers or wrapping papers

• Special art papers or high quality papers

• Plastic laminated papers or coated paper

• Mixed or other particular type of papers

(3) Sorting

In prior pulping and/or diluting process with the waste papers, sorting process is required dependingon types of finish papers. Either de-inking or bleaching process is required depending on quality offinish products as well as conditions of raw waste papers.

(4) Pulping and/or diluting of waste paper

All impurities, such as small plastic flakes and strings, dirt/earths, pieces of metals (iron, aluminum,or others), other rejections are required to completely remove while the wastes papers are inpulping/diluting in a preparation/rejection tank.

In the preparation/rejection tank, the waste papers are mixed and diluted (pulped) with a largeamount of process water, and then agitated by vortex action that is provided by a propeller mixerlocated on the bottom, or a whirlpool mechanism of the process water.

While in agitating process, lightweight impurities are floated up and forced toward outside of vortex,and then continuously discharged out of the tank. However heavy weight impurities, such as dirt andearths are naturally sunk on the bottom of the tank, and then discharged periodically.

(5) De-inking/Breaching process

It is necessary process to regenerate the waste papers, when printed waste papers are going to utilizefor recycling. At present, the most of collected wastes papers are mixed with heavily printed and/orcolored. This process consequently is very essential method to manufacture the best possible quality(non-colored) recycled paper. However the using of bleaching chemicals (aids) are cause of ageneration of new contaminations that pollutes the effluents when discharged.

When the de-inking/bleaching process is applied, an adequate wastewater treatment is strictlyrequired in prior to discharge into the environment.

(6) Paper manufacturing process

In a paper manufacturing process that utilizes waste (recycle) papers, some discrepancies are existedin the standard process. The pre-treatment process is necessary depending on qualities of the wastepapers (raw materials) and the quality requirements on produced papers. However mostly papermanufacturing is using of common process as a virgin paper processing.

(7) Wastewater treatment process

All the wastewater generated from the thickening processes is named as white waters, which are


385

contaminated with high COD. But some case, the wastewater are discharged with lowercontamination of alkaline/acid from the paper manufacturing, therefore these can utilize as recyclingprocess water after removing of small solids by screening process.

The most of white waters are required to treat by the neutralization and solids separation processsuch as aerations, filtrations, sludge-separations and skimming, which are similar processes as thegeneral wastewater treatment.

(8) Energy saving

Generally paper manufacturing utilizes lots of process waters and energies, such as the electricity fordriving paper mills and steams for drying process. To generate the steam, oils are the mostcommonly combusted. The generated heat energy should be recovered to recycle as the waste heat,which can use as a pre-heat energy.

33..22..22 TTeecchhnnoollooggyy rreeqquuiirreemmeennttss iinn rreeccyycclliinngg sstteeeell ssccrraappss

(1) Recycling of Steel Scraps

1) Advantageous of utilizing steel scraps

Waste steels, as metal scraps can be recycled through melting down with iron ore and limestone. Themolten metal is poured into a mould and then cooled down. However waste steels scraps aregenerated as a by-product through the metal manufacturing process so that it can be fed into anelectric furnace to melt and re-use as a raw material.

2) Transformation of Steel Scraps

The possible uses of recycled steels have wider range of applications because of that the steels canbe infinitely recycled. Same of applications are shown as follows.

• Bicycle frames

• Pipes

• Train tracks

• Ship hulls

• Steel-cans

3) Necessary technologies for pre-treatment of Mixed Steel Scraps

Wide varieties of waste steels are discharged into a market as scraped steels, which are fromindustries of iron mill, foundry, casting, metal machining, automobile and etc. However those steelscraps are commonly bulky, mixed with other metals, or strips, and grinded. In order to effectivelyutilize the scraps, those are separated segregated, consolidated as well as bundled in prior to smelt at


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the plant. The following are pre-treatment process for steel scrap recycling.

a Bushy, stringy metal scraps (machined scraps):

Must be crushed or shredded into smaller chips to satisfy with following requirements:

• Effective extraction and reclamation of cutting fluids from machined scraps

• Reduce particle size (i.e.: max 75mm)

b Bulky steel scraps:

Should be crushed or shredded in shoveling sized chip to satisfy handling and transportation.

c Briquette metal chips:

• Reduced scrap handling and transportation costs.

• Obtain premium price for scrap value.

• Reclamation of cutting fluids

• Avoidance of environmental contamination issues

d Segregation of steel alloy scraps:

By adding of other metals or material elements such as chromium or carbon during themanufacturing process, different types of steel alloys can be produced. These other types of steel,however include stainless steel, which resists corrosion, and certain alloy steels are high tensilestrengthen or thermal resistance. Those steel alloys must be segregated in prior smelting and can berecovered from products and recycled.

e Magnetic separation:

Scrapped steels can be easily separated and sorted out of the domestic waste stream by the magneticforce. In order to obtain higher quality steel scraps, steel scraps should be uniformed in a singlenature of steel.

The following diagram shows the typical steel manufacturing process from iron ore tosteel products (Source: Japan Steel can Recycle Association 2006)


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Process of Steel Manufacturing with utilizing of Scrap Steel

Iron Ore

Coal

Lime Stone

BlastFurnace

Pig Iron

Converter Rolling

Electric Furnace Refining Continuous Casting Rolling

Pro

duct

s

Steel-cans

Plate

Coil

Pipe

Flange beamScrap

Continuous Casting


388

(2) Recycling of waste steel-cansSince steel-cans were commercially manufactured, there are many varieties of steel-cans as for containers,such as fruits, vegetables, soups, meats, condiments, juices, pet foods, cleaning agents, paints, adhesivebandages, shoe polishes, coffees, cookies, and etc. However used (scrap) steel products as for construction,automobile, machinery, cans and etc. are commonly recycled and turned into raw metals as smelting withvirgin metals.

On the other hand, the current steel manufacturing process is 2 methods as Blast Furnace andElectric Furnace to produce steel materials. By using of scrap steels, the consumption ofthermal energy can be saved by almost 75% than that of from the original iron ore process.

1) Technologies in steel-cans recycling

• The waste steel-cans are turned into same steel-cans as reusing as raw materials

• The steel-cans are able to separate by a magnet forces

• Sorted and segregated in different types, then pressed in a common size

• In a steel mill plant, the bales are fed into the furnace with other recyclablesteels

2) Steel can recycling network

The waste steel-cans are recycled as show following network, which is referred from “Japansteel can recycling association”.


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33..22..33 RReeccyycclliinngg ooff wwaasstteess aalluummiinnuumm--ccaannss

(1) Advantages in recycling aluminum-cansUtilizing of recycled aluminums is required with only 3% of the thermal energy when is refining from theore (bauxite). Consequently recycling of waste aluminum-cans enable to reduce material resources but alsothe total energy in can manufacturing process. The following diagram shows a typical collection networkfor the aluminum-cans recycle system, which is referred from Japan aluminum can recycling association.

Steel Mill Factory

Residence

Collection by School& Volunteer parties

Can Manufacturers

Recycle Center Steel Bars, Pipes &Construction

materials

Collection Bin atSupper Markets & Stores New Steel

Cans

Other Applications

Railway Station

Commercial Complex

Office Building

Collection Bin atLocal Government


390

(2) Receiving, weight measuring and recording

When the recycled cans are delivered at recycler plant, weight measuring and record are required.

(3) Remove steel-cans (metals) and plastic impuritiesSome cases, aluminum-cans are mixed with the recycled steel-cans and/or other type of plastic materialssuch as strings, packages and films. The steel-cans (metals) are strictly required to remove and therefore amagnetic separator can allow effectively applying as an inexpensive process. If those waste cans aredelivered by compressed style, steel-cans may be mixed within pressed cans, and then the iron metal willbe remained in the molten. Consequently it is impossible to mechanically separate the wastes steel-cansfrom them, however only the metallurgical method can remove irons. However no plastic impurities willbecome directly bothering remaking aluminum-cans, because these can be varnished in combusting whilein melting process, or can be removed as slugs.

(4) Compress the waste cansThe waste aluminum-cans are completely pressed after removing of the steel metals. A compressed size isrecommended with a cubic of 60 x 60 x 60 cm or similar as a practical size for transportation.

(5) Quality of Aluminum

The body and cap uses completely different types of materials as shown the following table.

Residence

Collection bySchool& Volunteerparties

CanManufacturers

Recycle Center ExtractionBars,Molding &

Die-castingmaterials

Collection BinatSupper Markets &

StoresNew Cans

OtherApplications

Railway Station

CommercialComplex

Office Building

Collection BinatLocal

Government

AluminumSmelter


391

• Body• Cap

: Aluminum-Manganese Alloy (Approx.1-1.5%): Aluminum-Magnesium Alloy (Approx. 4-5%)

A body material requires rather flexible and strengthen because of that manufacturing is applied by drawingmethod; instead a cap material requires easy shearing force to open by the pull-top mechanism. Thefollowing table shows a typical comparison of those material compositions.

Cu Si Mg Zn Fe Mn Ti Cr

Body % 0.15 0.37 1.39 0.15 0.36 0.79 0.01 0.01

Cap% 0.05 0.07 3.80 0.01 0.21 0.36 0.00 0.02

(6) Body coating/paintingThe outer/inner surface of can-body is normally coated and/or painted; those materials contain pigments,which are Titanium for the white and Cadmium for the yellow color. However those colorants materialsshow similar melting temperature as the aluminum, so that these are melted together in the molten metal.However the colorants are re-crystallized through cooling down process; as this result, the re-crystalline arenever separated and remained as impurities in the aluminum base metal.

(7) Removing of the impuritiesIn order to purify the recycled aluminum metal, it is necessary to completely remove those impurities inprior smelting process, but it is difficult to remove the colorants completely by mechanical process becauseof that the inks/paints are thermally baked on the surface. One of effective methods to remove theseinks/paints is the thermal treatment process as the incineration. But it is required with higher investmentcost and then not applicable method in a recycling business.

(8) Utilize of high quality cap materialsThe cap material, on the other hand, it basically contains least impurities in the aluminum material andtherefore it can recover higher quality metal when re-melted. As this result, selling value is higher than abody, but the separation of caps from bodies is not economical process due to requiring a lot of energies forseparations. Therefore when currently caps and bodies are melted together in a same process, and the purityvalue goes down slightly lower level as the result. Consequently if the body and cup aluminum metal ismixed, it is not applicable method for the “Can-to-Can” System.

(9) Current situation on use of recycled aluminum for cansAs the result, if the recycled aluminum metals are mixed with a virgin aluminum metal, it can utilize onlyfor manufacturing the body process, which is named as a partially “Can-to-Can” System. But for capmanufacturing, 100% virgin aluminum (Aluminum/Magnesium) alloy must be used.

(10) Can-to-Can SystemBy developing of effective recycling process with the waste aluminum-cans, it is possible to establish arecycling-oriented network society, which can employ with a Life-Cycle System. As a result, it can save themaximum 97% of the energy that is required to smelt the aluminum metal and then can reduce theenvironmental load.

The following diagram is shown with one of the example of the Aluminum Life Cycling.


392

End C up production (Slab)

New AlIngot

ProduceSlab

Slab RollingEnd C upM aterial

End C upProduction

End C up

O therM etal

New AlIngot

?á?ñ?ñ?ñ?i

RecycledAlIngot

O therM etal

Body Production (Slab)

ProduceSlab

Slab RollingBody

M aterialBody

ProductionB ody

NewAlC an

Bottling Sold Disposed C ollection

SegregationPre-

Treatm ent


392

(11) Aluminum-cans recycling process

The following are shown with the typical recycling process from collection of wastes aluminum-cans to manufacturing of new cans.

Process Working

Collection By local communities, Volunteers,Recyclers

Remove of irons andother impurities

By magnet separator, irons areseparated completely

Shredding Shredded in certain sizes

Paint removing Incinerated by Kiln after shredding

Smelting Constant feeding into furnace

Casting of slug Melted aluminum metal is cast as asize for rolling process


393

Hot rolling Aluminum is rolled until a specifiedthickness

Cold rolling Remove the oxidized film on thesurface, and cold rolled

Trimmed for body size(Stamping)

Adjusted with size of cans

Can manufacturing Body drawing

Washing, Inspection Remove lubricants and oils,solvents, and cracks, lines, deforms,pinholes, etc.

Paint (Print) Done at Bottling company

(áPhoto: Catalog of M. Materials)T

33..22..44 TTeecchhnnoollooggyy rreeqquuiirreemmeennttss iinn rreeccyycclliinngg ooff ggllaassss bboottttlleess

Since manufacturing of the glass bottle was developed in Phoenicia in around 3000 years ago, thoseproducts are widely used for various containers for liquids, grain powders and others materials, suchas water, wine, oil, medicine, and other products. As those results, the glass bottles have being re-used as returnable containers.

There are many varieties in glass bottle types; shapes, sizes, colors and etc. being used to containliquors/beers, beverages, medical supplies and/or supplements in a current market. Some types ofbeverage bottles, such as beers and juices are already in the recycled/re-used system as the “bottle-to-bottle”. Basically there are 2 types of recycling system such as “Returnable” and “One-way” in a


394

current market.

(1) Recycling flow of returnable glass bottle

The returnable bottles, which are collected by “Treater” or other “Contractors” and/or at “RecycleCenter”, are segregated into types, size and colors, and then these recycled bottles are delivered toeach bottlers and/or beverage manufactures.

The following diagram is described a typical recycling mechanism for the returnable glass bottles.

(2) Necessary treatments for recycled glass bottle

At first, bottling facilities preliminary diagnose breakages/cracks, scratches/chips and any otherunacceptable defects on the delivered bottles prior refilling. The defect bottles are segregatedthrough an inspection process, and then only qualified bottles are transferred to washing/rinsingprocess. The qualified bottles are checked again whether any impurities are existed in bottles; finallysanitized, and then only cleaned bottles are transferred to bottling process lines, if no impurities arefound. The rejected bottles are re-used as raw materials for molding of new bottles as same as “One-way” system.

(3) Recycling Flow of One-way Glass Bottle

One-way glass bottles are used at one time only. After bottling, the glass bottles are distributed in amarket and delivered to consumers. In order to carry out effective recycling on the wastes glassbottles, these must be segregated in colors and types upon collection points. The collectedcolored/segregated bottles are grinded into flinders as cullet, which can be utilized as raw materialsto mold new bottles. Same kind of colored bottles can be molded with original colors by using the

Japan Glass Bottle Recycling Association


395

same colored cullet, so that it is possible to develop “Bottle-to-Bottle” mechanism.

The following diagram shows a typical mechanism for the “Bottle-to-Bottle” system.

(4) Treatment Technology for Waste Glass

The glass bottles have been called as a typical recycling example as beer bottles, however recentlyshare of “One-way Bottle” is increasing instead of declining of “Returnable Bottle”. As the result,the cullet production is expanding toward upward trend.

1) Segregation by colors and types

In the cullet production, it is extremely important to segregate all bottles by colors and types in priorshredding process. A new technology has been developed that variety of glass bottles can beautomatically segregated by the reorganizing device. However it is required with higher invest costs.Therefore manual segregation process is still more favorable process in Philippines as well as otherAsian Countries.

2) Utilize for pavement materials and new glass products

Current technology can utilize the mixed culets (variety of colors) for pavement materials, materialsfor aggregates and concrete boards. The technologies can also use the mixed culets to mold color-mixed glass bottles as new products.

Cullet Center

Segregation, Grinding,Washing

Bottle Making

Raw materials for New Bottles

Bottlers

Warehouse

1. W

RetailersConsumers

Collection atRetailersCommunities Etc.

Japan Glass Bottle Recycling Association


396

(5) Other concerns in producing quality recycled glass products

• The quality of the cullet is slightly lower grade but higher cost than a virgin glass. Inaddition, further problems are existed, as cullet production facilities are not alwayslocated at the nearest area from discharging points of glass bottles or at bottlers.

• Colored plate glass should be segregated from the non-colored glass bottle, because ofthat these colored glass bottles are tinted with some element of metals. Basically the tintmetal is extremely high temperature resistance metal as titanium. In addition, the hightempered glass is hardened by other additive metals, which become impurities inrecycling glass.

• A general glass wear is also utilized with the high temperature resistance materials, asnot same nature of the glass. Therefore it cannot melt at same temperature of glassbottle materials.

33..22..55 TTeecchhnnoollooggyy rreeqquuiirreemmeennttss iinn rreeccyycclliinngg ooff wwaassttee ppllaassttiiccss

Mostly waste plastics are mixed with different type of materials that are collected at collection pointin a market. Those can be mechanically recycled for utilizing as raw materials. However thosematerials are not normally segregate in different type of plastics since discharged/collected.Therefore those waste plastics are recommended to manually segregate at discharge/collection pointsand/or recycler stations prior shredding in the recycling facility. However the recent technology ispossible to shred without prior segregation, and then after the shredding process the segregation iscarried out by using of the “mutual classifying technology”, which can separate different types ofplastic materials from the mixing nature. But it is required with higher investing costs on equipmentand system, therefore this system is not always economical nor recommended in the developingcountries.

When the recycled PET mixed with other type of plastics, such as polypropylenes and polyethyleneand also urethane foams, these can transfer into new products, like insulations, floor materials,inertia materials for automobiles, sound acoustic insulations, a new type of technology is beingdeveloped.

In addition, a new technology to decompose FRP (Reinforced Resin Plastics) materials, which arevery difficult to recycled, into resin solutions, glass fibers and fillers are recently being developed.This new technology has been studied and will be able to manufacture a new FRP by using disposedFRP materials in a near future.

Thus many different types of technologies involved in recycling and segregating waste plasticmaterials are being developed in recycling business. However those technologies are still verypremature and/or higher cost requirement processes at this moment.


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(1) Type of Plastic materials and the Contents

Following table shows type of plastics materials and usages (contents).

Shape Use/Contents Type of resin

Soft Drinks Juice, Cola, Drink-water, Tea,Alcohol-drinks

PET

Beverage

BottlesLactic acid& beverages

Yogurt Polystyrene

Food & Condimentbottles

Cooking oil, Salad oil, Soy-source, Others condiment

PET, Polystyrene, Polypropylene

Condiment bottles Mayonnaise, Ketchup,Dressing, Mustard, Etc.

Polystyrene, Polypropylene

Bot

tles&

Tube

s Bottles & Tubes fordaily products

Toiletry, Gardening supplies,Car care products, Liquiddetergent, Fabric softener,Toothpaste, Cosmetics,Shampoo, Hair conditioner,Bleach, Body shampoo

PET, Composite plastics,Polystyrene, Polypropylene

EPS PolystyreneFood packages (EPS &Non-EPS)

Margarine, Fruits, Vegetables,Process foods, Prepared foods,Packed snacks & lunches Non-EPS PET, Polystyrene,

Polypropylene

EPS PolystyreneFood cups (ESP & Non-ESP

Soup, Yogurt, Noodles, Jelly,Custard pudding, Desserts

Non-EPS PET, Polystyrene,Polypropylene,Polyethylene

Pack

s&C

ups

Cup & Pack lids PET, Polystyrene, Polypropylene,Polyethylene

EPS PolystyreneESP & Non-ESP tray Meat, Fish, Sliced ham,Vegetables,

Non-EPS PET, Polystyrene,Polypropylene

Blister pack Drugs (tablets), Processedmeat & fish products, Roastham, bacon, Curry roux,Household tools,Toothbrushes, Cosmetics

PET, Polystyrene, Polypropylene,Polyethylene PVC

Tray

s&Bl

iste

rspa

cks

Egg boxes PET, Polystyrene

Bag

s

Large, Medium & Plainbags

Rice, Gardening bags, Fishes,Fruits Confectionery, Frozenfoods, Noodles, vacuum-packed foods, Pickles,Cooked/Boiled foods, Bread,Dry fishes, Cleaning bags

Polypropylene, Polyethylene


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Shape Use/Contents Type of resin

Carrier bags Polyethylene

Rubbish bags Polyethylene

Small bags Quail’s eggs, Ginger, Pickles,Condiments, Noodles, Stock,Cakes, Candy, Wafers,Chocolate

Polypropylene, Polyethylene,Composite plastics

Cap

s&St

oppe

rs

Beverages, Foods, Dailysupplies, Other bottles

Polypropylene, Polyethylene

Cellophane Polyvinylidene chloride resin,PVC, Polyethylene

Films Foods, Curry roux, Plasticfood decorations, Cakes,Cheese, Frozen foods, Codroe, Sausages, Frozen noodles

Polypropylene, Polyethylene,Composite plastics

Cel

loph

ane

&Fi

lms

Labels Bottles, Caps PET, Polystyrene, Polypropylene,Polyethylene

Box

es&

Cas

es

Detergent boxes & lids, Foods,Underwear, Power compacts,Lotion cases, Dehumidifier,Deodorizers

Polypropylene, Polystyrene,Polyethylene, PVC

Prot

ectio

n&

Fixi

ng

Urethane sponge, Foamproducts, Nets, Air caps

Polystyrene, Polyethylene

Oth

ers Baskets, handles, Multi-packs,

Sieves, Replanting potsPolypropylene, PET, Polystyrene,Polyethylene, PVC

Plastic Waste Management Institute (March 1999)

(2) Basic Recycling Process

The plastic wastes have a great potential being able to convert into raw materials, feedstock andalternative energies by using of advanced technologies. Those technologies are involved, such asMechanical recycling, Feedstock recycling, Energy recovery are categorized as following table.

Categories Recycling Methods Recycling Process

Mechanical

• Convert into raw materials

• Make a products Material recycling


399

recycling

• Monomerization

• Blast furnace reducing agent

• Coke oven chemical feedstock recyclingFeedstock recyclingChemicalfeedstock

Chemical recycling• Gasification

• LiquefactionFuel

Energy recovery • Cement kiln

• Waste power generation

• RDF

Thermal recycling

It is very important factor to select the adequate recycling process, so that it can effectively to reduceinput of new resources as well as impact onto the environment.

(3) Recycling of PET materials and use as resources

The following diagram shows an example of the mechanism from a collecting of PET to makingnew products. (Source: Council for PET Bottle Recycling in Japan)


400

(4) Mechanical Recycling Process (Material recycling)

Waste plastics are normally compressed and transferred to recycling facilities (enterprises). Atrecycling facilities, non-plastics materials such as impurities as papers, metals are removed and thenthe plastic materials are segregated by colors and types in prior feeding into shredding process.

Then after shredded the plastics materials are washed and purified to remove any impurities, such asirons, aluminums, dirt/earths, and other materials. After completion of purifying process, the plasticmaterials are modified into flakes and/or pellets (flakes are granulated after heated) and then turnedinto reusing. Those raw materials are normally melted and utilized at textile and/or sheetmanufacturing factories and also fabricated products.

1) Typical Plastics Molding Processes:

The following are typical molding process widely applied in molding industries.


401

Type of Molding Process Main Products

Extraction Molding Resin is melted andcontinually extracted into amolded product by molder.

Pipes, Sheets, Films, CableCapsulation

Injection Molding Heated melted resin is injectedinto a mold to solidify a product.

Small product: washingbasin, bucket, Plasticmodel

Large products: Bumper,Pallets

Blow Molding An extracted or injectedparison is clamped into amold, and inflated by airmaking a bottle.

PET Bottles, ShampooBottles

Vacuum Molding A heated-softened sheet issandwiched in a mold, and theair is vacuumed between asheet and a mold.

Cups, Trays

Inflation Molding A melted resin is inflated into acylinder to foam a film. It is atype of extraction molding.

Shopping Bags

(5) Feedstock Recycling

1) Monomerization:

The monomerization process can apply for chemically decomposing PET materials into themonomers states (depolymerization process) for reusing as raw resins to make new PET bottles.

The following flow diagram is show of the decomposition process of combining the Ethylene Glycol(EG) and Methanol to break the wastes PET materials and turn down into the DimethyleTerephtalate (DMT), developed by Teijin Ltd in Japan. Applying this technology, the wastes PETbottles can be broken further into the Purified Telephthalic Acid (PTA) from DMT, and then able tomake PET resins.


402

2) Blast Furnace Feedstock Recycling Process:

At a steel mill factory, the iron is produced together with iron ore, cokes and other auxiliary rawmaterials in a blast furnace and then the iron ore is melted and produce pig irons. While in meltingprocess, the coke is combusted as fuels to increase the process temperature in the blast furnace. Andalso the coke acts as reducing agent by removing the oxygen from the iron oxides, which are mainconstituents of the iron ore.

On the other hand, main composition of plastics is the carbon and hydrogen elements; therefore thewaste plastics can be utilized as a reducing agent in a blast furnace. A process of using the wasteplastics as a reducing agent is as following processes.

The waste plastics collected from residence and industrial areas must be removed impurities such asmetals and non-combustible materials. And then those are shredded in small sizes and compacted toreduce the total volume. The plastic materials, which are removed PVC, are granulated, then afterfed into the blast furnace. Rejecting of PVC is a reason of that the PVC can damage the blastfurnace due to emissions of the hydrogen chlorides gases. However, though the plastic wastes thatare contaminated with PVC can be fed into the Blast furnace at approximately 350?û in the absenceof the oxygen, by which the hydrogen chlorides are removed, the hydrogen chloride can berecovered and composed as the hydrochloric acid treatment process in a steel finishing line of the hotmill process.


403

The following process is developed by JFE Steel Corporation in Japan under NEDO Program in1999.

3) Coke Oven Chemical Feedstock Recycling Process:

When the coal is baked to make cokes, the hydrocarbon and coke oven gas are generated fromthe volatile components. As similar reaction process occurred by the waste plastics, the cokesand hydrocarbon oils also can be produced. The waste plastics collected from residence andindustrial areas are shredded in small sizes and removed with impurities such as iron metals atthe recycling facility. And then those are heated at100?Ð to make granularity sizes and fed intothe carbonization chamber of the coke oven furnace by mixing with coals. The carbonizationchamber of the furnace is an indirect heating mechanism by sand witch construction, and thenthe waste plastic materials are decomposed at a high temperature in the absence of oxygen andturned into cokes as reductions for the blast furnace as well as the hydrocarbon oils, which areused for chemical feedstock, and coke oven gases for generating electricity.

The following flow diagram is typical process, developed by Nippon Steel Corporation in Japan.


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(6) Energy Recovery

1) Gasification Process:

Because of the main component of plastics are the carbon and hydrogen, the carbon dioxides(CO2) and water are normally produced when be combusted. The gasification process isactivated when the waste plastics are heated, under controlling of the oxygen and water, thenmajority of the plastics are decomposed with the hydrocarbon, carbon monoxide (CO) and waterunder limited the oxygen supply.

At the first stage in a lower temperature gasification furnace, feeding plastic materials are contactedwith high temperature sands that are circulated heated up at approximately 600~X800?X todecomposed with the hydrocarbon, the carbon monoxides (CO), hydrogen, char and etc. But thechlorine-contaminated plastics generate the hydrogen chloride gas. In a case of containing of metalsand glasses are melted and solidified to be collected as impurities.

At the second stage in a high temperature gasification furnace, which is heated up at approximately1300 to 1500?–, the gasses that are taken from the lower temperature gasification furnace aredecomposed with mainly the carbon monoxides (CO) and hydrogen. The flue gasses at the exit offurnace are chilled down lower than at 200?® by cooling water to prevent forming of the Dioxin.And produced granulated slugs can be utilized in civil engineering and construction materials. Theproduced hydrogen chloride gasses are neutralized by alkaline and removed. As a result, the


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generated gasses can be utilized to produce such as the hydrogen, methanol, ammonia, acetic acidand etc in chemical industries.

2) Liquefaction Process:

Because of the plastics are made by the petroleum as a raw material, it is possible to produce thepetroleum through taking reversed process as manufactured. Therefore the liquefaction process hasbeen studied since 1970, however proven technologies with cost effective, applicable and practicalprocesses are not yet developed. At present, technologies may be applied for relatively easier wastesplastic only, which are collected from industries, but no development for residential waste plastics isprogressed for waste plastic materials discharge from residences. This area is more rapidly requiredto develop and especially process for PVC contaminated plastics should be developed to convert intothe petroleum.

(7) Energy Recovering Process

Energy Recovery is the basic treatment processes in recycling of wastes plastics, however theEnergy Recovering is the second option as same as status of the Mechanical Recycling.

The waste power generation is generally carried out by Stoker Oven, Gasification and MeltingFurnace, and also Gasification Reformer. Rotary Kiln Type Furnace, that is employed with typicalgasification and melting process can gasify wastes at high temperature. And then the pyrolysis gasand char as fuels to produce steams to drive a steam turbine and generate the electricity whileincinerated ashes are melted and solidified. As a result, the gasification process reforms thepyrolysis wastes with adding gasses containing some oxygen and steams (vaporized water) to thecombustible gases as fuels. This process is the most typically operated by the Shaft Furnace andRotary Kiln.

The following diagram is shown an example of gasification and melting furnace with powergeneration system as applying of Rotary Kiln Furnace, which provided from NEDO (New EnergyDeveloping Organization) in Japan.


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(8) Technology requirement for PET recycling

Recently the PET production has being increased sharply, and then the recycling rate is alsogradually increasing in the recycling industries. Main application areas are resources for fibers,textiles and packages for eggs (Egg-Pak) and etc. On the other hand, “PET to PET” technology hasbeing developed and on study for applying in some beverage industries, but it is not yet to developcompletely proven technology as feasible and practical at this moment. However the study on the“monomerization process” is being progressed, so that the “supercritical methanol process”, whichcan reuse disposed PET materials to manufacture new PET bottles without contaminations ofimpurities as same quality as virgin PET, can apply. It is becoming a real “PET to PET” processnow on. Requiring technologies in recycling of PET materials are shown as follows.

(9) Segregation process:

Beside, as a segregation technology, use of the “near-infrared ray guidance system” has beendeveloped to recognize PET materials. This technology can apply effectively to separate thePET materials from other mixed plastics.

(10) Shredding/Separation process:

In order to precisely separate PET from the mixed plastic materials, the “Selective ShreddingTechnology” should be developed, which can shred only materials that need to shred Therefore thisprocess is more effective and practical as well as cost effective method. However the current processis still the “Premixed Shredding Method” that all plastic materials have been mixed in priorshredding.


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(11) Pellet and Flake process:

Already shredded-PET, if non-contaminated can turn into pellets and/or flakes, or granules that aremade of flakes thermally processed by granulator.

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(1) Basic technology required in recycling Mobile phone

If the millions of unused mobile phone without properly being treated will be abandoned in theenvironment, it may cause serious threats into the human society. The mobile phone basicallyemploys with a few amounts of toxic chemicals and metals, which contain within tiny littleelectrical components/parts and also the rechargeable batteries, such as the Lithium-ion or Ni-cdbatteries as old models. These wastes (products) however contain valuable materials used inmanufacturing mobile phones, and then these can be recovered and reused as raw materials, ifproperly recycled. The Lithium and Cadmium, which are key element metals for therechargeable batteries, are dangerous toxic nature as well as carcinogenic substances. As thisresult, landfill sites will be suffered from significant and the inevitable effects by contaminatingof the toxic metals into the surrounding soil, if discharged without the desirable stabilizationprocess. However on the other hand, many of good conditioning mobile phones are separatedand currently exported to the developing country, or resoled in local markets.

1) Typical recycling process

The mobile phone is consisted with a handset, battery pack and its charger, which are integratedwith an electrical circuit board and a push-pad within a plastic case body (cover). The weight forprevious models are around 100 to 300gr per a handset, however the latest modes have beenachieved to reduce that the total weight is almost less than 100gr because of employing smallersized lithium-ion battery, which is relatively light weight. In addition, use of the precious metalsis also declining. The following diagram shows the typical recycling procedure, currentlyapplied.


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2) Construction of the Lithium-ion battery

Negative TerminalSealing tab

Negative tab

SeparatorNegative plateSeparator

Positive plate

Gasket

Positive tabGas exhaust valve

Positive(Aluminum can)

Japan Battery Recycling

Firing Furnace Grinding Process Separator Plastics

Metals

Melting

Refining Copper

Recovering

Gold

Silver

UnusedMobile Phone


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3) Characteristics of Lithium Metal

The lithium metal is mined as one of the rare metals at only limited countries on the earth. Thefollowing are some typical nature and applications.

• Main component is the (Li2O·„Al2O3·„SiO2)

• Produced at very limited area as Chili that reserves more than half on the earth.

• Alkaline, Silver-White Metallic color. Oxidized by the atmosphere and turn to black color

• Density is 534kg/m3

• Which is lightest in metals

• Melting point is 453.5K, Boiling point is 1,620K, which are relatively lower among themetals

• Aggressively react with water and generate the hydrogen gas, then form the lithiumhydride (LiH)

• Easy bonded with the Halogen family and form salts

• The lithium metal and its compounds are used for the Lithium battery and terminal partsfor the Lithium-Ion battery, Additive for glass absorbing heating/cooling agent for the gasabsorption heating/cooling unit, Construction materials for aircraft structure

• Catalytic for synthetic rubber, Fluorescent materials, surface acoustic devices (SAW)made by fine ceramics as wide applications

4) The technologies on recovering of the Lithium Cobalt Acid

Generally recycling of waste batteries is determined depending upon whether the followingconditions is effectively achieved.

• Impact on the environmental loads

• Possibility on effective use of materials

• Consumption of the energy

• Economical efficiency

Since an effective recycling technology/process has not been developed in recovering of the lithiummetal from waste batteries, no large amount of discharged batteries are able to recycle, and inaddition, recovering process cost is rather expensive than that of the normal battery. Accordingly thewaste lithium batteries, or within the mobile have been discharged without treatments at present.However the use of the lithium battery in mobile phones, digital cameras, and other applications hasbeing increased, and as a result, the waste lithium batteries are sharply increased. Under thiscircumstance, the technology on recycling of the lithium metal has being developed to recover the


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lithium metal because of valuable rare metals. At the moment, no effective/practical process hasbeen developed, however the following processes are experimentally studied in a market.

A. Incineration (baking) process

The waste lithium battery is fed into the incinerator, and then baked. After baking process the cobaltand lithium metals are separated by a magnet force (separator) and/or leaching method after coolingdown process.

B Floatation separation process

The waste lithium battery is shredded as fine powder and then Cobalt Acid Lithium and Graphite(carbon) are recovered as the mixed power (black color). The recovered black powder is heated upto approximately 500?Ì to burn the binders that is fixed on the surface of the Cobalt Acid Lithiumpowder. After removing of the binder, the mixed powder of Cobalt Acid Lithium has become thehydrophilic nature, so that it is possible to precipitate by using of the coagulator and/or foamingagents. This process can recover the Cobalt Acid Lithium more than 92% with over 93% quality.

Waste Lithium-ion Battery

Baking

Grinding

MetalRecover

Iron

Melting

AcidDissolution

Solvent

Extraction

CobaltChloride

NickelChloride


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(2) Technologies in E-waste recycling

E-wastes such as PCs, TV and refrigerators are similar construction and then those wastes can bedismantled by manually. The dismantled E-wastes are recycled to obtain some valuable materials bythe physical and/or chemical separation processes.

Basic technologies required in E-Waste recycling can apply with the following 3 processes:

1) Low Temperature Shredding/Separation Process

Plastics materials are segregated by the nature of “brittle temperature”, which “embrittlement” ofmaterials is different depending on the temperature. The plastic materials are shredded andsegregated into “Embrittlement materials” and “Non-embrittlement materials”.

2) Eddy current (EC) Separation Process

By providing of the rotational magnetic field (the eddy current) onto mixed metal materials, ferrousand non-ferrous materials can be repelled, and as a result, those materials are separated into twokinds of the metals.

3) Anti-dissolution Process

Such as shredder dusts, incinerated ashes, fly ashes and dust particles, which might be contaminatedwith heavy metals, are kneaded while mixing of water and chemicals, and then these heavy metalscan be converted into non-soluble compounds in the alkaline solutions.

On the other hand, in recycling of refrigerators, it is strictly required to recover theCFC within a compressor prior to dismantling.

Thus necessary technologies in recycling of E-wastes are basically similar as applying in itsproduction, however such technologies are becoming more complex because of employing of morechemical materials, especially employing various type of plastics materials. But such materials arenormal products, but these are consisted with the synthetic materials. Lately especially uses ofplastics are becoming more wide varieties and sophisticate natures. Consequently technologies inrecycling of E-wastes are required with more advance processes in segregation, dismantle,shredding, separation, refining, extraction, material resource, re-productions and etc.

4) Decomposing of the electronics components:

Since the electronic circuit boards are compounded with plastics and metals like the copper, suchcircuit boards should not be shredded in prior removing the electrical component parts. All electricalparts and plastic materials should be carefully removed without breakage by hands. Plasticsmaterials, which are basically thin films or sheets, should be peeled off from the circuit boards, sothat the plated copper materials are remained with a bit of solders on the boards. Then the copperwith solder can be separated, and then by gravity sorting process when these has been grinded. But


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shredding process basically requires with lots of energy.

Hence new experimental process is being studied that the plastics and metals like copper caneconomically be separated into two parts as from the mixed nature. As a result, this process canminimize the cost and energy consumption.

5) Utilizing of recycled materials:

(3) PC Recycling

The following flow diagram is shown with PC dismantling and turn into resource of materials.

PlasticsABS, PP

Mixed Plastics

Steels

Non-FerrousAluminium, Copper,

Stainless Steel

Circuit BoardGold, Silver, Vanadium,

Platinum

Glass

PlasticsReproduction

Blast Furnace

Steel Recycleror Wholesalers

Non-Ferrous WholesalersNugget Production

Mining

MiningSmelters

CulletManufacturers

Material Resources

Reduction Materials

Steel Mills

Material Resources

Material Resources

Material Resources

Material Resources


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DischargedPC

De-Pack

Cardboard

PaperRecycler

PackageMaterialsStyrofoam

Recycling

ManualDismantling

Diskette

PowerUnit

Harness(Cable)

Cabinet

Hard DiskDrive

MotherBoard

CRT(Display)

Scrap plastics

Scrap steel

Steel

Coil, Circuit board

Steel

Aluminium

Circuit board

Electric gun

Steel

Aluminium

Circuit board

Coil, Base

Glass

CPU

Contacts

Capacitor

Ceramic IC

Scrap circuit board

ABS, PP, Etc.

Other type of plastics

Japan Electronics Appliances Recycling Association


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(4) TV Recycling Flow

TV is generally consisted with 3 major components as described on the following table. Recycledmaterials are iron, normal glass, lead glass and plastics from those parts.

Conponents Major recycled meterialsTV Tuve (CRT)• Shadow mask• Electric gun• Anti-maget band

Iron, Normal glass, lead glass

Electric parts• Circuit board• Cable

Copper, Silver, Plastics

Cabinet Plastic materials

Recycling of discharged waste TV is carried out basically by manual dismantlling to remove theabove componens. After this process, separated component parts are shredded and washed, and thenvaluable materials are recovered. The following diagram shows typical dismantlling and recoveringmaterials.


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(Source: Electric appearances recycling association)

(5) Refrigerator Recycling Flow

Refrigerator is generally consisted with following 4 major components as described on the followingtable. Recycled materials are iron, copper, aluminum and plastics from those parts.

Deflecting Yoke Print Circuit

DismantlingProcess

Front Panel Glass Back CabinetFennel

Separateof

FrontPanel/FennelGlass

Shredder/Plastics

Plastics material

Culet materialShredder/GlassWashingPanel glass

FennelGlass Shredder

Dryer/Cleaner

Culet materialShreddingWashing/Cleaning

SeparationProcess


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Components Major recycled materials

Cabinet Iron, Plastics

Compressor Iron, Copper, Plastics

Electric parts Copper, Silver, Plastics

Inner parts Plastics, Alminum

Recycling of discharged waste referigerator is carried out basically by manual dismantlling toremove the above componens. After this process, separated component parts are shredded andwashed, and then valuable materials are recovered. In additon, old types are employed with CFC forcooling media as well as forming material that is inflated by CGC gas, so that the CFC must berecover properly in prior dismantlling.

The following diagram shows typical dismantling and recovering materials


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(Source: Electric appearances recycling association)

DismantlingProcessCFC Cylinder

Inner trayRecovering CFC/Oil

Dismantled

Primary shredding unit

Shredder/Plastics

Urethane foam

Air fanAir gravityseparator Secondary shredding unit

ShreddingWashing/Cleaning

SeparationProcess

CFC liquefied system

Magnet separator

Nonferrous separator Wet type gravity separator

Mixed plasticsNonferrous scrapsFerrous scrapsPlastics


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(6) E- Waste controlled by manifest management

In order to properly control waste E-Waste, applying of manifest is essential process that can controlbetween discharger and recycler, and treatment facility. The following diagram shows the example ofmanifest management. (Source from Japan Electronic Appliances Association)

Metals

Measuring weight forevery kind of materials

Dismantle

Weightmeasuring

Data loggingfrom manifest

Registration ofProduct informationWeight data

Database for

Clients,Workers,

Data control & Management


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(7) CFC Recovering System

The following diagram shows an example of recovering CFC from refrigerators and air-conditioningunits. The system is consisted with CFC weight measuring, CFC/Oil separation and Data logging &control by PC system. The CFC cylinders are strictly control and stored in the CFC storeroom.(Source from Japan Electronic Appliances Association)

Recovered CFC

storage

tank

Data loggingWeight

Data

Management&

Control SystemData

CFCCylinder

Mixed

CFC/Oil

Wt measure

CFC

CFC

Mixing of

FC/Oil Recovered Oil

Recovered Oil strange

tank

DrumAir-Con

Refrigerator


Documents

Volume III: Guidelines