Kompositter kan gjenvinnes Paal Fischenich Daglig leder Norsk Komposittforbund Polymerdagene Gardermoen 2009

IntroduksjonIntroduksjon Pilotanlegg (Miljøtek NO, Ercom DE) har vist at mekanisk gjenvinning av kompositter er teknisk mulig: Som vist i presentasjonen til SINTEF har dette har blitt verifisert gjennom forskningsprosjektet GjenKomp. Kjemisk gjenvinning Er også belyst under forrige presentasjon. Så langt virker det å være et meget interessant potensial for kjemisk gjenvinning. Energi produksjon vil i fremtiden få økt betydning. Nye teknologier gjør kompositter mer attraktiv som energibærer og som sekundær råvare. Cement industrien representerer her en interessant samarbeidspartner.

Kompositter brukt som sekundær råvare ved sement produksjon Kan kompositt avfall brukes som alternativt brensel og sekundær råvare i sement industrien, og vil dette bli akseptert av myndighetene?

Norcem sement har to produksjons enheter i Norge. Disse ligger Brevik og Kjøpsvik. Produksjonen i Brevik = 120 t/h Kull forbruket = 16 t/h Eies av Heidelberg Cement Group

Norcem ønsker å erstatte 60% av kullet med alternativ energi. Fra avfall kan de bruke tonn farlig avfall og tonn FAB. FAB = Alternative solid energy

Kvalitetsparameter for avfall Begrensninger i klor og brom innholdet Ønsket kalorimetriske verdier > 3000 kcal Kan akseptere ned til 2000 kcal Kalorimetrisk verdi for kull = 6500 kcal Avfallet må ikke inneholde metaller Maksimum partikkel størrelse 50 cm

Cement Production

Hvordan kan de bruke avfallet? 1.Blåse det som et fint støv inn i brenn sonen. Max partikkel størrelse 10 – 15 mm. 2.Bruke det i kalsinatoren (forbrenning av klinker) Max partikkel størrelse 50 mm. Selskapet har egen Schredder for knusing.

Sammensetning av klinker: Tricalsium silicate: 3CaO.SiO2C3S Dicalsium silicate: 2CaO.SiOC2S Tricalsium aluminate: 3CaO.Al2O3C3A Tetracalsium aluminoferrite: 4CaO.Al2O3.Fe2O3C4AF Calsium Oxide: CaOC Magnesium Oxide: MgOM Sammensetning av en typisk kompositt: Resin( polyester = energi ) Filler( mest brukt er CaCO 3) Glassfiber( denne inneholder SiO2 og Al2O3)

Er det myndighets aksept for en slik gjenvinning? Den Europeiske bransjeorganisasjonen EuCIA publiserte i juni 2009 sitt ”POSITION PAPER” vedrørende gjenvinning av kompositter i sement ovnene. Dette dokumentet viser at kompositter oppfyller de krav direktivene stille til bærekraftig gjenvinning. Dokumentet lyder som følger: Position Paper on Recycling of Thermosetting Composite Parts in the Automotive Industry Introduction In the manufacturing of transport vehicles like cars, trucks and trains many different materials are used. The choice between metals, rubber, plastics, composites and many other materials depends to a large extent on the material properties, but price, availability and life cycle considerations also play an important role

Composites are composed of a fibrous material and a resinous matrix. In many cases glass fibres are used as reinforcement materials. The resinous matrix is frequently a thermosetting polymer, such as unsaturated polyester resins or epoxy resins. Many composite parts are produced from Sheet Moulding Compound or Bulk Moulding Compound. These intermediate formulations (in short SMC/BMC) are used in compression moulding or injection moulding. A typical base formulation for SMC is as follows: Fibre20 – 40 % Inorganic fillers 25 – 40 % Resin 25 – 35 %25 – 35 % Various additives 10 – 20 % For the car industry there are two very important European Directives that are important drivers when selecting construction materials. The End-of-Life of Vehicles Directive (Directive 2000/53/EC) (ELV Directive) gives rules for the dismantling, reuse, recycling and recovery of components/materials/energy from vehicles that have been junked or totalled. New vehicles must be 85% reusable or recyclable (by mass) and 95% recoverable by December 15, A type-approval in the European Union is needed before vehicles can be manufactured, imported or registered.

The Waste Framework Directive (Directive 2008/98/EC) (WFD) sets the conditions for handling of waste. An important activity in waste handling is recycling. The WFD has been revised in In the new WFD recycling is defined as follows: Recycling means any recovery operation by which waste materials are reprocessed into products, materials or substances whether for the original or other purposes. It includes the reprocessing of organic material but does not include energy recovery and the reprocessing into materials that are to be used as fuels or for backfilling operations. Recycling of Composites The recycling of thermoset composite parts has been studied extensively in the last years.It is important to prove that all studied recycling routes fit to the definition of recycling in the new WFD. ECRC has commissioned several projects to prove that composite materials can successfully be fed to a cement kiln. In recycling thermoset composites through the cement kiln route, most of the material (approx. 2/3rd) is transferred into raw materials for cement. A small part of the waste, the organic part (approx. 1/3rd) is burnt, generating energy. This would mean “energy recovery“ according to the above definition.

If the emphasis in this recycling process is put on energy recovery, it would make recycling of composites through the cement kiln route impossible. However, the cement kiln route is not used with the intention to generate energy from burning composite waste. When feeding composite waste to a cement kiln, the major part of the material is turned into cement or a useful part of the cement composition. In the definition of recycling this is described as “reprocessing into materials or substances whether for the original or for other purposes”. This is an approved way of recycling according to the definition. As a side effect, a minor amount of energy is generated by this process. As the cement kiln uses anyhow a high amount of energy in the form of oil or gas firing, the end effect of feeding composite waste to the kiln would be that the energy bill for the kiln is reduced slightly Conclusion: The cement kiln route for processing composite waste is in no way a means to reprocess waste material into materials that are to be used as fuels. On the contrary, composite waste is turned into valuable new material, that finds it way in the final cement. A minor side effect of the cement kiln route is a slight reduction in the energy costs to run a cement kiln. Recycling of composite waste through the cement kiln route is a technically proven process that fulfills the conditions for recycling as laid down in the Waste Framework Directive 2008/98/EC.

Oppsumering og konklusjon Kompositt industrien har nesten 20 års erfaring fra gjenvinning av kompositter. Vi besitter derfor kompetanse innen alle områder av gjenvinning. Kompositter kan: -Energigjenvinnes. -Kjemisk gjenvinnes -Materialgjenvinnes. -Brukes som sekundær råvare i sement industrien.

Det er ikke slik vi vil ha det

men slik RYD 550 GTS produsert med 21 % resirkulat. Fotografert på Hvaler sommeren 1997

Ønskes ytterligere informasjon så kontakt: Paal Fischenich Norsk Komposittforbud Kasernegaten 47, 1632 Gamle Fredrikstad /