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Description
Polska Korporacja Recyklingu (Polish Recycling Corporation) operates in the field of household waste management, mainly waste electrical and electronic equipment and waste batteries (including car batteries). The project objective is to manage process waste generated in our company and to create a product with high commercial potential. We plan to introduce an automatic sorting process and an intelligent regranulation system for plastic waste from the processing of waste cooling equipment. The project will result in the implementation of an innovative product - plastic regranulate (mainly from polystyrene), which has so far been a waste product in our business.
The project is in line with the zero-waste principle. About 185.5 tons of regranulate will be obtained monthly, i.e. 2,226 tons per year. The project will also reduce electricity consumption by 0.45 GWh and reduce annual CO2 emissions by 328.05 tons.
We will implement the project in cooperation with the Norwegian company TOMRA Sorting, which is the world leader in sensor-aided sorting. Our cooperation will result in exchange of experience and know-how, including evaluation of waste data, verification of the concept and conducting tests of waste sorting.
Summary of project results
The need to implement an investment project involving the implementation of a new innovative technological process for recycling polymer waste was a direct result of the analysis of processes carried out in the enterprise from the point of view of the basic criterion of productivity. Development and implementation of a new technological process in the field of recycling of polymer waste resulting from waste treatment processes carried out at the Polska Korporacja Recyklingu Sp. z o.o. was a manifestation of our organization''s desire to fully use resources to increase development opportunities and competitiveness in the context of global mega-trends, which are undoubtedly eco-innovations, mechanization and automation of processes, including increasing the use of renewable raw materials from recycling.
The research problem of the technological process developed at the Applicant''s Re&D Center, was the maximization of the fully recyclable use of plastic waste resulting from the mechanical process of destruction (grinding) of waste electrical and electronic equipment waste carried out at the plant. Methods of recovering metals from the electro-waste stream are widely known and widespread, while sourcing polymer raw materials is difficult and requires complex and expensive technologies. This requires the involvement of qualified specialists from different industries (chemical industry, optical industry, mechanical industry). The state during application preparation was the selective (organoleptic and manual) isolation of large pieces of used equipment made of homogeneous polymer materials for recycling - the possibility of using only a small fraction (e.g. homogeneous containers made of polyethylene in refrigerator or polymer (ABS, HIPS,) TV and monitor housings) - constituting 20% of the plastic fraction. The emaining part of plastics as a result of processing processes was directed as a filler for the production of "alternative fuel", while the mass share of this waste in the fuel fraction was limited by the level of chlorine content in individual types of plastic waste. The research and analytical process showed a high level of diversity used by producers of consumer products in their products - types of polymers with different own characteristics, differentiating mass (MFR) and volume (MVR) flow coefficient, different impact resistance and other specific features, containing flame retardant additives, UV resistance, coloring metallic pigments.
The project has been divided into two main tasks:
1. Purchase of construction works and materials as well as installation works
2. Optimization of technological process as well as delivery, assembly and commissioning of fixed assets necessary for its implementation - a task was carried out in cooperation with a Norwegian partner.
As par of the planned cooperation with the Partner, the composition / morphology of the waste – the type of input waste was evaluated. The Partner carried out the work based on samples provided by the Beneficiary. In addition, there were testing by TOMRA Sorting at their test center. The scope of tests concerned in particular sorting of plastics for their type of PS, ABS, and metals in the form of a printed circuit board and electric wires.
In the next step, the technological concept of the sorting process was verified in close cooperation between the Appliant and the Partner. It is assumed to introduce possible optimization activities of the technological process. This stage was related to a significant exchange of know-how and experience between the Beneficiary and the Partner.
Within the framework of the task, fixed assets necessary for the implementation of the planned project were acquired, including in particular:
• Sorter - using near infrared NIR sensors, visible light and electromagnetic radiation - 1 item
• Specialized extruder for granulating recyclate PS, HIPS, PS + PC, PP, ABS, ensuring an effective filtration system and double process degassing - 1 pc.
• Vibrating feeder - 1 item
• Transmitting station for automatic sorting with rising feeder - 1 pc
• Operational fraction feeder - 2 pcs.
In cooperation with the Partner, training, technological start-up was conducted, as well as provided service support.In addition, the Beneficiary worked closely with the technology partner responsible for the providing the extruder for granulating (waste evaluation, testing, technological process optimization). asks related to the communication plan were also implemented to increase public awareness of the existence of the Norwegian and EEA Funds and their objectives, particularly among the applicant''s employees and potential suppliers.
As a result of the implementation of the Project, Polska Korporacja Recyklingu has introduced a technological process for the automatic and simultaneous sorting and intelligent regranulation system of waste plastics from the processing of used refrigeration equipment.
The implementation of the innovative technological process has made it possible to start the production of plastic regranulate (primarily polystyrene) and, as a result, diversify PKR''s offer and attract new customers. The regranulate obtained by the planned technological process is aimed at a wide range of customers and is an excellent material for the production of packaging, parts of refrigeration containers, cups, as well as other products.
The benefit of implementing the results of the completed project is the possibility of reusing plastics that are obtained from recycling used cooling equipment and putting them into further processing, so we can replace the existing method of their management which includes energy recovery through combustion in a high-temperature calcination furnace in a cement plant and reducing the consumption of non-renewable raw materials (crude oil) needed to produce primary polymer raw materials.
Norwegian partner - Tomra Sorting AS, in cooperation with Polska Korporacja Recyklingu, also benefited from a number of advantages. The cooperation allowed in-depth analysis of data on waste composition and morphology, which made it possible to share expertise and experience, directed toward further development of the technology. The technology dialogue conducted during the cooperation was aimed at improving waste sorting technology.
Tomra Sorting AS conducted tests at the test center, specifically focusing on sorting plastics, metals and electrical wires. This allowed for the identification of areas for optimization and the exchange of knowledge, resulting in further improvement of the technology. Also, the partnership enabled a thorough verification of the technological concept of the sorting process, which made it possible to identify directions for process optimization.
The cooperation has had a positive impact on both the implemented technology and the development of the Company''s staff. The implemented activities and exchange of know-how will allow further optimization of the technology, including, in particular, areas for further improvement, perhaps further development of cooperation with the partner (for now there are no concrete plans).
Summary of bilateral results
Thanks to the partnership with the Norwegian company, PKR gained access to a base of specialized knowledge, many years of experience and know-how, as well as to specialized research equipment within the test center - representatives of the Beneficiary took part in tests performed at the test center. Thanks to the partnership with Tomra Sorting AS, it was possible to scale the technology from the laboratory scale to the industrial scale - it became possible to transfer innovative solutions to practical application. The partner not only provided a high-end device and trained the Beneficiary''s staff, but also participated in the work of optimizing the technology for PKR''s needs. Combined with the internal analyses performed, we were able to effectively optimize the machine settings for separated materials, debris removal and throughput control. After the tests were performed, we received a comprehensive report describing all the performance with photos.The main result of the bilateral cooperation was an exchange of knowledge and experience that allowed two different perspectives, skills and experiences to be juxtaposed, contributing to a better understanding of the technology and aspects of its implementation. As part of the bilateral cooperation, Tomra Sorting AS participated in studies that helped optimize the technology strictly for PKR''s needs, providing valuable information and suggestions for improvements and adjustments. Another aspect is risk reduction - bilateral cooperation has reduced the risks associated with implementing new technology by combining the years of experience of two specialized entities. In addition, the partnership with the Norwegian entity undoubtedly contributed to greater interest in PKR''s business environment in the implemented project and its results.