Transcript Symphony - Eko Plastic

Symphony Environmental
July 2008
Polymer Structure
As explained in the previous presentation there are different types of
polymers.
We want to apply d2w to the simplest and most abundant types :Polyethylene and Polypropylene.
66 million tonnes of polyethylene per annum
60 million tonnes of polyprpylene per annum
35% used in packaging.
That’s just 44 million tonnes to go for!
Flexible packaging:-
Commodity plastic packaging -bags and sacks- EASY
Non food packaging
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NOT SO EASY
Food packaging
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EVEN LESS EASY
But the rewards are higher:Repeat business
Based on specification
Print content
The Benefits of Plastic Packaging
Lightweight
Flexible
Strong/Durable
Heat sealable
Impervious to moisture
Printable
Recyclable
By-product of Oil Refinery
Crude components
LPG 2%
Naptha 3%
Lubricants 5%
Aviation Fuel 15%
Petrol 45%
Diesel 15%
Heating Oils10%
Bitumen 5%
Crude Oil
Naptha is a by-product of crude oil
extraction.
We produce about 87 million barrels per day
It is about 3% of all global crude extraction.
50% is used to produce plastic products.
But…
Not degradable
The Plastic Problem
Consumers and Environmental Activists Drive Politics
Consumers want their waste picked up from them, but not put down
anywhere near them.
Consumers believe that household waste is predominantly plastic packaging
Plastic packaging is considered to be a mayor environmental pollution
problem.
Solution
Oxo-Biodegradable Plastic
Complete degradation 2 – 5 years after
the end of the pre-set service life*
* Depends on product type and exposure conditions
How does it work?
d2w additive put into basic polymer resin at the production stage (Normally 1%)
Breaks molecular chain
Plastic starts degrading at end of pre-set service life
Process of Oxidation – caused by light, heat and stress
Bio-degradation completed by micro-organisms
How does it work?
Long chains
Short chains / brittle
Flexible material
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H
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oxidation
oxidation
degradation is affected
by heat, light, stress and air
microbial
degradation
CO2 + H2O + biomass
Residues
Water
CO2
Biomass
NO ‘‘HEAVY METALS’’
How it works
How it works
It is well accepted that polyolefins that have undergone
oxidative degradation provide hydrophilic surfaces having
greatly reduced molecular masses.
Reduction of the molecular weight of the polyolefin to
around 40,000 combined with the introduction of oxygen
containing functional groups leads to bio-degradation.
These images are taken from a pieces of fragmented oxo-degraded
d2w film. They were subjected to immersion in water and a
compost mixture.
They were then examined in a Leo variable pressure scanning
electron microscope.
In an area of extensive cracking colonies of bacteria have arrived.
A closer look at the area highlighted in blue shows…..
How it Works
How it works
Numerous bacterial cells and fungal spores colonising the
cracked area and the whole depth of the film through the
crack is showing areas of microbial attack.
How it works
The transition metal salt generates free
radicals that in turn produce hydroperoxides in the form of aldehydes,
ketones, esters, alcohols and carboxylic
acids.
It is these that are bio degradable.
How it works
Transition metals:-
Cobalt, iron, manganese, copper,zinc,
cerium, nickel.
Food contact Test
Food contact test
Recycling of Degradable Plastics
The Recycling of oxo- degradable materials is not a problem.
Figure 1: Effect of d2w level in recyclate level on Elongation at Break after Thermal Ageing
900
800
Elongation at Break (%)
700
600
500
0 Hours
300 Hours
600 Hours
400
300
200
100
0
Control
10% d2w
25% d2w
50% d2w
Sample Referenece
75% d2w
100% d2w
Recycling of Degradable Plastics
EU funded BRITE-EURAM research project Aston University in collaboration
with Blaise Pascal University
“no change in melt flow index was observed on reprocessing”
Process aid stabilisation is finite and exhausted during manufacturing.
Transition metal salt is susceptible to shear temperatures.
Recycling introduces at least two more heat histories.
Bio-degradable plastic
It is important to distinguish between the different types of biodegradable plastic as their
costs and uses are very different
Oxo-biodegradable plastic is made from a by-product of oil refining
Hydro-biodegradable plastic is usually made from a food crop such as starch, derived
from agricultural crops
Why not Hydro-biodegradable
plastic?
These are very much more expensive and less durable.
Some of these plastics have a high starch content and it is claimed that they are therefore
made from renewable resources. However many of them contain more than 50% of synthetic
plastic derived from oil, and others are entirely based on oil derived intermediates.
“Based on”? Process aids?
In the depths of a landfill, these plastics can generate copious amounts of methane
A disproportionate amount of land will be required to produce the raw material to replace
conventional plastic and also a huge amount of water.
Already the use of crops to make bio fuels is driving up the cost of feed to chicken farmers, pig
farmers and other livestock industries.
Hydro-biodegradable plastics will emit methane and release carbon dioxide into the
atmosphere at a greater rate than oxo-biodegradable plastics.
Hydro degradables
Mater-Bi from Novamont
Eco-Flex from BASF
Bionelle from Showa Denko
Biomax from Dupont
PVOH- various sources
PCL / Capa from Solvay
Nature-Works from Cargill PLA
Nature-Flex from Innovia
Disposal
Typically there are Five Options:Incineration
Landfill
Compost
Recycle
Litter
Disposal
Incineration;- refined oil
Landfill;- breakdown -aid settlement
Compost;- will work in in-vessel
Recycle;- will recycle
Litter;- will disappear
Advantages of Oxo-biodegradable
plastic
Oxo-biodegradable film is certified safe for contact with any food type and is ideal for
frozen food packaging.
Oxo-biodegradable plastics are made from naptha which is a by-product of oil refining.
It makes good environmental sense to use the by-product instead of wasting it by ‘flareoff’ at the refinery
Oxo-biodegradable plastics can be recycled and can be made from recycled. They can
also be composted, and perform well in-vessel.
Oxo-biodegradable sheet is very useful in agriculture because after the harvest many
thousands of kilometres of dirty plastic has to be gathered and disposed of.
Manufacturing Oxo-biodegradable
plastic
No special machinery or workforce
No change of supplier or loss of jobs.
Compatible with polypropylene PP, polyethylene PE & most consumable plastic
packaging.
6 months to 5 years shelf life. Adjustable product life.
No compromises in functionality:
strength, clarity, barrier properties, seal ability, print.
Comprehensively tested and and proven
Standards for Oxo-biodegradable
New draft Standard BS 8472 (not complete)
ASTM (US) D.6954 testing protocol
AFNOR NFU 52-001:2005 (France) – Agriculture/Horticulture
Certification
Food Contact Safe – tested by RAPRA (US Owned)
Soil Safe – tested by OWS, Belgium (EN 13432)
Biodegradable – tested by PYXIS, UK
Oxo-biodegradable – tested by CSI, Italy; RAPRA, UK and UFSCar / UNESP Brasil
Products Available
PE, PP, (Not PET)
Carrier bags or ‘‘Shopper-bags’’
Refuse sacks
Aprons
Bags to contain dog faeces collected in parks, gardens, etc
Bin Liners
Gloves
Bread bags
Frozen food bags
Wrappers for cigarette packets
Shrink-wrap and pallet-wrap
‘‘Bubble-wrap’’
Rigid products such as bottles and cups
Products Available
PE, PP, (Not PET, PS or PVC)
Main Product Features
Reduce and Re-use
Recycle
Make from recycled
Incinerate
Compost (in vessel)
Landfill (no methane)
www.degradable.net
Oxo-biodegradable products and additive technologies