Recycling Technology note

8/21/2019 Recycling Technology note

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RECYCLING TECHNOLOGY

BKC 3833


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BACKGROUND

Wasteunwanted material from a process.

Manufacturing processes and biological

processes.

Type of waste:

Scheduled waste

Non scheduled waste

Scheduled wastetoxic, hazardous, pollute theenvironment, harmful to human and living things

Non scheduled wastenon toxic.


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Handling of waste

Non scheduled wastecan send to landfill,

does not impose danger or pollution to

environment

Scheduled wasteneeds proper handling, e.g.

from cradle to grave.


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Types of scheduled waste

SCHEDULED WASTES FROM NON SPECIFICSOURCES.

Spent oxidizing agents

Spent oxidizing agent

Contaminated soil, water, debris or matter resulting

from clean-up of a spill or chemical or scheduled

waste

Contaminated soil, water, debris or matter resulting from clean-up of a spillof chemical or scheduled waste

Immobilized scheduled wastes, including chemically

fixed or encapsulated sludges

Immobilized scheduled wastes


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Discarded drugs except living vaccines and euphoric

compounds

Discarded drugs except living vaccines and euphoric compounds

Pathogenic and clinical wastes and quarantined

materials Pathogenic and clinical wastes and quarantined materials

Containers and bags containing hazardous residues

Used containers or bags contaminated with cyanide, arsenic, chromium orlead compound or salts

Mixtures of scheduled wastes

A mixture of schedule wastes

A mixture of scheduled and non-scheduled wastes


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Types of scheduled waste

Scheduled waste from specific sourcesMineral oil and oil contaminated wastes

Waste oil or oily sludge from wastewater treatment plant of oil refinery or

crude oil terminal

Oily residue from automotive workshop or service station oil or grease

interceptor

Oil contaminated earth from re-refining of used lubricating oil

Oil or sludge from oil refinery maintenance operation

Tar or tarry residues from oil refinery or

petrochemical plant

Tar or tarry residues from oil refinery or petrochemical plant


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Discarded or off specification batteries containing lead,

mercury, nickel and lithium

Discarded or off specification batteries from battery manufacturing plant

Pharmaceutical wastesWastewater from washing of reaction vessels and floors of pharmaceuticalproducts manufacturing plant

Spent acqueous inorganic acid solution

Wastewater from acid and battery manufacturing plant

Waste from manufacturing or processing or use of explosives

Waste from manufacturing or processing or use of explosives


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Handling of Scheduled Waste

DOE provides comprehensive regulations to the

management of the scheduled waste that based on

the cradle to grave principle.

Scheduled waste generator must appoint a licensedthird party contractor to dispose the waste.

There must be certain that the waste is directed to,

and actually reach, a permitted disposal site.


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ENVIRONMENTAL QUALITY (SCHEDULED WASTES)

REGULATION 1989

Under the regulations, 107 categories of wastes havebeen classified as scheduled wastes

Scheduled wastes can be stored, recovered and treated

within the premises of a waste generator.

Waste generators shall also keep up-to-date inventoryof scheduled wastes generated, treated and disposedoff.

In the case of transporting the waste from the wastegenerator to the treatment and disposal facilities, shallbe monitored until it reaches the approved destination.


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Environmental Quality (Prescribed Premises) (Scheduled

Waste Treatment and Disposal Facilities) Order, 1989

6 types of premises prescribed under the order that require written

permission and license from the DOE.

- Land treatment facilities such as sludge farming for oil waste or sludges.

- Off-site recovery facilities such as a solvent recycling plant.

- Off-site treatment facilities such as a centralised physical/chemicalwastewater treatment plant.

- Scheduled wastes incinerators.

- Off-site storage facilities including the premises of waste transport

contractors.

- Secure landfills designated for the disposal of scheduled wastes.


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ENVIRONMENTAL QUALITY (PRESCRIBED PREMISES)(SCHEDULED

WASTES TREATMENT AND DISPOSAL FACILITIES) REGULATIONS, 1989.

Procedures of

License application

Renewal and ownership transfer

Requirements for record keeping

Submission to the Department of Environment.


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TREATMENT TECHNOLOGIES

Biological Treatment

Chemical Treatment

Physical Treatment

Incineration


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BIOLOGICAL TREATMENT

Biodegradation

Novel microorganisms for biological treatment of

anthropogenic compounds is a new concept

Certain organism biodegrade certain waste

e.g. trickling bed filter, maturation pond, aeration

pond, activated sludge.


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Aeration via overhead

propeller

Aeration viabubbling

Clarifier-settler


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CHEMICAL TREATMENT

Convert the waste to another form which areless problem than the starting material

Spectrum of chemical methods:

Neutralization Oxidation

Precipitation

Reduction

e.g. coagulation/flocculation using PAC, Alum, PE


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CHEMICAL TREATMENT-

NEUTRALIZATION

Application of the law of mass balance to

bring the waste to acceptable pH pH between 6 to 8


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CHEMICAL TREATMENT - OXIDATION

The cyanide molecule is destroyed byoxidation

Electrolytic oxidation Carried out by anodic electrolysis at high

temperature

Wet air oxidation

Zimmerman process

Oxidized by oxygen at sufficient temperatureand pressure


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CHEMICAL TREATMENT-PRECIPITATION

E.g. Removal of metals from plating rinse waters

Application of the solubility product principle


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CHEMICAL TREATMENT- REDUCTION

Some metals have to be reduced before it can

be precipitated

Exp:

Hexavalent chromium used in plating solutions

must be reduced to trivalent chromium


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PHYSICAL TREATMENT

Not detoxified but only concentrated for

further treatment or recovery

Carbon adsorption

Distillation

Ion exchange

Reverse osmosis

Solvent extraction


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Ion exchange system

Solvent extraction plant


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PHYSICAL TREATMENTCARBON

ADSORPTION

Adsorption is a mass transfer process inwhich gas vapors or chemicals in solutionare held to a solid by intermolecular

forces Adsorbents

Activated carbon

Molecular sieves

Silica gel

Activated alumina


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PHYSICAL TREATMENTDISTILLATION

Separation of more volatile materials from less

volatile materials by a process of vaporization

and condensation

The larger the vapor pressures differences,

more efficient the separation


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PHYSICAL TREATMENTION EXCHANGE

Metals and ionized organic chemicals can be

recovered by ion exchange

Ion to be removed is passed through a bed of

resin


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PHYSICAL TREATMENTREVERSE OSMOSIS

Solvent is forced to pass through a semi-

permeable membrane from concentrated

medium to less concentrated medium


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PHYSICAL TREATMENTSOLVENT RECOVERY

Liquid extraction and liquid-liquid extraction

Contaminants migrate from the wastewater

into the solvent


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INCINERATION

Most efficient means of dealing with many

wastes

Reduce in volume and weight

Completely destroy even the most hazardous

materials

Heat can be recovered


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Chemical waste incinerator


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FROM WASTE TO WEALTH

Why do we recycle/recover product from waste?

- minimize pollution, generate income, save naturalresources

What are the requirements to do recycling activities?

- raw materials, knowledge, purpose.

What type of waste can be recycled/recovered?

- scheduled and non-scheduled wastes

Why recycling activities in Malaysia are not widelypracticed?

- lack of awareness, lack of knowledge


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RECYCLING OF LUBE OIL


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Introduction

What is used oil ?

Refined from crude oil and has been used.

No longer useful to the original purchaser(extended storage, spillage or contaminationwith non-hazardous impurities such as dirt

and water).


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Where does used oil come from?

Used Oil sources :

Automotive 70%

Industrial 15%

Mixed (Other) 15%


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What is used lube oil?

Produce from refined heavy fraction of crude oil orother hydrocarbons.

Additives are blended (detergents, corrosioninhibitors, and rust inhibitors).

Lubricants applications: engine and transmission

lubricants, hydraulic fluids, metal working fluids,greases.


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2 5 quarts

lube oil =

42 gal crude

oil


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What is used lube oil:

Hazardous Waste During service the lubricant collects heavy metal (lead,

cadmium, zinc, and barium), iron steel particles and copper.

These contaminants are toxic and harmful to the

environment.

The hazards associated with used oil result from variousadditives used in its manufacture and from the heavy metalcontaminants picked up from use in internal combustionengine.


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Impact .

Illegally disposed of oil can pollute thegroundwater with contaminants : lead,magnesium, copper, zinc, chromium,arsenic, chlorides, cadmium andpolychlorinated biphenyls (PCBs).

One quart of oil can pollute 250,000gallonsof drinking water.


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Impact

Used oil from a single oil change can ruin a million

Gallons of fresh water

a one years supply for 50 people !

One quart of used motor oil will pollute up to 40,730

square feet of soil

making it non-productive for farming or plantgrowth for up to 100 years!


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Impact

Look at any back label of Petroleum or SyntheticMotor Oil after 1985, and you will find followingstatement :

"CAUTION: Avoid prolonged or repeated skincontact with used motor oil. Used motor oil hasbeen shown to cause skin cancer in laboratoryanimals. Thoroughly wash exposed areas with soapand water."


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So

RECYCLE !!


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Benefits of recycle

Used lubricating oil has an inherent value. To savescarce resources, this inherent value should berecovered, economically justified.

Back to useful product: furnace fuels, power stationstart-up fuels, diesel fuel extenders.

Reduce pollution issues.


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What Really happens with Recycled Oil ?

The well intentioned and well sounding

"theory" that is propagated by

environmentalists, State agencies and many

other entities is a fact illustrated below:


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So in theory using similar "slightly" deceptive

presentation it appears that recycling oil from

two typical automotive oil changes would

"save" 84 gallons of crude oil.


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Recycling Technology


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Lubricants undergo changes in physical and chemical

properties with service.

These changes may include contamination with water, other

fluids, such as coolants, and particulate matter (e.g., dirt,

wear metals), formation of oxidation products resulting from

air and high temperatures, and the loss of performance by the

depletion of additives.

Recycling is a generic term that involves a variety of types of

oil purification methods that restore spent oils to a useful

material.


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Recycling Techniques

Acid / Clay Treatment

Distillation / Clay Treatment

Distillation / Hydro Treatment(Vacuum Distillation)

Solvent Extraction


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ACID / CLAY TREATMENT

Acid/clay process is one of the successful methods inrecovering the used oil for the last three decadesago.

This treatment is most dominated process in re-refining of used oil (Figure 1).

It consist five stages of processes, which the oil isfirstly dehydrated in flash dehydrator.

The overhead product is condensed and separatedfrom light oil, while the bottom product is thetreated in wastewater disposal system


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Used oil

Flash Dehydrator

Acid Treatment

Clay Treatment

Fractionation

Filtering

Spent Clay

Oil Residue

Lube Oil


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The dehydrated oil is treated with 98% sulphuric acid, which

results in large quantities of acid sludge.Acid sludge is then separated, and the remaining oil is then

treated with clay and filtered.

The treated oil is dark in color with some odor, while the acid

sludge and oil-soaked clay are disposed to environment inacceptable manner.

The lube stock yield is 45-75% depending upon the operatingcondition and the feed composition.

However, this method is inhibit to operate even the quality of

the base oil produce is good.The process ends up with production of acidic sludge in large

volume.


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DISTILLATION / CLAY TREATMENT

Thin-film distillation under high vacuum allows the separationof gas oil, lube oil and an asphaltic residue containing most ofthe additives and contaminants from the used oil.

The lube oil stream is finished by clay treatment.

Compare to acid/clay treatment, this process need highenergy due to vacuum distillation, but removes the additives

and the contaminants easily with little generation ofhazardous waste.


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DISTILLATION / CLAY TREATMENT

In this method, the used oil is dehydrated at 300OF atatmospheric pressure for water and light hydrocarbonsremoval.

The bottom product from distillation is mixed with 20% by oilvolume of light oil and small amount of caustic 0.2-2% tobreak the oil water emulsion and precipitate solids.

It is then separated by centrifugation.

The centrifuged oil is heated to 700OF, producing the naphtaoil to be used as fuel in the plant.

The bottom product is used as fuel also, while the remainingoil is treated by clay as lube blending stock.


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DISTILLATION / HYDRO-TREATMENT

Kinetics Technology International (KTI) and Mohawk processesare the two that used the fundamental concept in the

process.

In this process, the base oil fraction is hydro-treated under

moderate condition after pre-treatment and thin-filmdistillation.

A final distillation step yields a range of base oil streams of

different viscosity.

By-products are produced, which are low boiling distillate, gas

oil, and a non-hazardous asphaltic residue.


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In KTI process (Figure 2), the oil is first distillated via adistillation column to separate water and light ends fraction.

The pre-treated oil is then mixed with a hydrogen-rich gas,heated and passed through a reactor holding a fixed catalystbed.

Hydrogen is added to the oil to saturate or rebuilds the oilto bring it back to specification, where it reacts with oxygenand nitrogen-containing impurities and unsaturated.

The yields are claimed to be between 80-85% (Klamann,1983).


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Residue

Dewatering Gas Oil Stripping Lube Oil Distillation

Hydro-finishing

Fractionation

Used Oil

Gas-Oil

Hydrogen

Refined Oil

Light Neutrals


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SOLVENT EXTRACTION

In re-refining of base oil from used lubricant oil, solventextraction is defined as a refining process to separate reactivecomponents (unsaturated hydrocarbons) from lubricantdistillates in order to improve the oils oxidation stability,viscosity index (VI) and additive response.

This method has been reported to be well suited for re-refining multi-grade motor oils formulated with highconcentration of additives and containing large amounts ofresidual compounds generated by heat and friction during

use.Basically, there are two types of solvent extraction method,

either using a solvent or composite solvents.


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SOLVENT EXTRACTION

Using solvent/s can overcome such a problem that occurswhen using those conventional methods;

such as eliminating the requirement for hydrogen

reduce the production of environmentally problematic byproducts

(acid sludge formation), the need of high temperature or high pressure operations

need for periodic catalyst replacement and handling

In solvent extraction process, the base fluid is extracted using

various selective types of solvents, sometimes composite or

the solvent alone.


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SOLVENT EXTRACTION

In Institut Francais du Petrole (IFP) process, propane is used asthe extracting solvent.

This process combines the solvent extraction method andacid/clay process (Kimball, 1975).

Nevertheless, acid and clay amount is reduced in this process,thus removing the color and the odor.

Propane extracts the base fluids from the additives andimpurities.

The asphaltic residue is generated, which contains the mostadditives and other impurities.

Dirt and insoluble sludge are settle out and are withdrawn off(Klamann, 1983).


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SOLVENT EXTRACTION

The main purpose of using solvent as extracting agent is torecover the base fluids, as well as to remove the additives and

particulate matter. The solvent/s must (Reis, 1988a):

Miscible with the base oil contained in the used oil

Reject the additives and disperse particles from solution

Stable, easy to recover and low price


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NEW TECHNOLOGY TO RECYCLE

USED LUBRICANT OIL


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Re-Refining Used Lubricant Oil: Pilot Scale Rig

T3

T2

Activated

clay

V305

L1

TI2

V309

T4

V101

V115

V112

T5

V105

V102P1

V110

V104

V103 V201V302

V303

V307

V304

V202

CWout

P2

P3

CS1

C1

F1

CE1

CU1

P4

M2

M1

FP1

T6

Filtered

base oil

Lubricant Oil

Additives

CWin

Wet Sludge

Waste Treatment

VC1

P5

V301

V311

Y STRAINER

PRESSURE GAUGE

PUMP

VALVE

TEMP. GAUGE

RELIEF VALVE

T1

T3

T2

EXTRACTION TANK

COLLECTION TANK

ADSORPTION TANK

T5

T6

Used Lube Oil, KOH,

n-hexane, isopropanol

T1

M1

M2

P5

P4

P3

P2

P1

VC1

FP1

CU1

C1

CS1

CE1

FILTER PRESS

CENTRIFUGAL UNIT

CONDENSER

CLIMBING EVAPORATOR

CYCLONE SEPARATOR

VACUUM CHAMBER

H1

H2

MEMBRANE FILTERF1

BLENDING TANK

EXPANSION TANK

MIXER 2

MIXER 1

PUMP 1

PUMP 2

VACUUM PUMP

PUMP 3

PUMP 4

T4 SOLVENT TANK

HEATER

H2

H1HEATER 2

HEATER 1

DRAWN BY : SHAHROM IRWANI MOHD. SANI

UNIVERSITI TEKNOLOGI MALAYSIA

FAKULTI KEJURUTERAAN KIMIA DAN KEJURUTERAAN SUMBER ASLI

APPROVED BY: PM. DR. ROSLI MOHD. YUNUS DATE : 10 JAN 2004

DATE : 10 JAN 2004

RECOVERED BASE OIL FROM USED


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LUBRICANT OIL

SOLVENT EXTRACTION

Solvent extraction is a process to separate additives from used

lubricant oil and produce base oil using composite solvent.

The composite solvent used in this process are n-hexane and

2-propanol.

Certain amount of KOH used to enhance the flocculation

process.



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LUBRICANT OIL

SOLVENT EXTRACTION

Ratio used lubricant oil to solvent 1:4

Ratio 2-propanol to n-hexane 3:2

Amount of KOH 4 g/L 2-propanol

Time for mixing 30 minutes

Retention time 1 hours


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SOLVENT RECOVERY FROM WASTE

SOLVENTE.G. PAINT AND

ELECTRONIC INDUSTRIES


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Sources of Solvent Wastes

Mainly from washing of electronics and semi-

conductors.

Printing industry

Paint manufacturing

Pharmaceutical industry

Tank cleaningdegreasing, desludging etc

e.g. in 2007, 119,000 tons of Irelands hazardous

waste generated were organic solvent


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APPLICABLE SOLVENT

Hydro carbon of petroleum group

Chlorinated Hydro carbon

Ketone group

Ester group

Ether group

Alcohol groupPolymerized monomer

APPLICABLE SOLVENT


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APPLICABLE SOLVENT

Hydro carbon of petroleum group

Benzene

Toluene

Xylene

Trimethylbenzene

n-Hexane

Heptane

Naphtha

Rubber OilsCyclo-hexane

Thinner

APPLICABLE SOLVENT


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APPLICABLE SOLVENT

Chlorinated Hydro carbon

Trichloroethylene

Perchloroethylene

1.1.1-Trichloroethane

Methylene chlorideDichlorobenzene

Trichlorobenzen

Carbon tetrachloride

Chloroform

Dichloropropane

Freon

APPLICABLE SOLVENT


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APPLICABLE SOLVENT

Ketone group

Acetone

MEK

MIBK

Cyclohexanone

Ester group

Ethyl acetate

Butyl acetate

APPLICABLE SOLVENT


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APPLICABLE SOLVENTEther group

Ethyl ether

Dioxane

THF

Furfural

Methyl cellosolve

Alcohol group

Methanol

Ethanol

IPA

Butanol

APPLICABLE SOLVENT


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APPLICABLE SOLVENT

Polymerized monomer

Vinyl chloride,

Vinyl acetate,

Acrylic acid,

Acrylonitrile, Styrene,

Ester acrylate group

APPLICABLE INDUSTRIES


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APPLICABLE INDUSTRIES

Automobiles

ElectricalPrinting Painting

Rubber

Adhesion

FilmTextile

Plastics

Synthetic leather

Pharmaceuticals

Dry cleaning

Fermentation and chemicals

SOLVENT RECOVERY


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SOLVENT RECOVERY

Activated carbon fiber which

is much superior toconventional activatedcarbon as an adsorptivematerial and also made itpossible to utilize for thesolvent recovery apparatus.

This solvent recoveryapparatus has beenappreciated in manyindustrial sectors for thepurpose of theenvironmental protectionand of the saving resources.

Basis of separation is different in boiling point (distillation/evaporation)

Commercial system

R S l t f E h t G


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Recover Solvent from Exhaust Gas

Exhaust gas

MICROWAVE RECOVERY SYSTEM


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Similar to other types of solvent recovery systems, the goal of

the microwave system is to recover clean usable solvents fromwaste solvents contaminated with ink and othercontaminants.

However, the microwave recovery system is more versatilethan traditional recovery systems.

As can be seen in the attached diagram, the microwavesystem works in a one-step process subjecting the printtowels and blanket wash to intense microwaves that breakthe emulsion between the water and solvent.

Breaking the emulsion allows the clean solvent to berecovered and reused without any additional processing.

The recovered water and solvent mixture is collected togetherand then separated into separate containers.



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After being treated by the microwave unit, the soiled print

towels are then ready to be laundered by a commerciallaundry.

The wastewater, which ends up as distilled water, generallymeets the local regulatory requirements and can bedischarged to the local sewer authority.

It is important to recognize as with any discharge to a sewerauthority, it is imperative to contact them to ensure theacceptability of the discharge.

Discharges of industrial wastes to septic systems are generally

prohibited.



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(recover solvent from contaminated ink)


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POLYETHYLENE TEREPHTHALATE (PET)

PLASTICS : WASTE RECOVERY ANDRECYCLING PROCESS

BACKGROUND


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BACKGROUND PET is a particularly high quality plastic for use in the

packaging industry and in particular for the production of

bottles. Transparency ensures optimum product presentation.

Low weight means that customers carry only the drink andnot the packaging.

Strength ensures sturdy, practically unbreakable, and safepackaging.

PET can also meet the strictest hygiene requirements forthe packaging of cosmetics and foodstuffs, where productpurity is paramount. It is a material with a great future,

offering a unique combination of benefits throughout thevalue chain in preform and bottle production, and also forconsumers.

PET has excellent material properties. It is not only veryli ht it i l t d PET b ttl ti ll


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p p y ylight, it is also very strong and PET bottles are practicallyunbreakable. As transparent as glass, PET is alsotasteless, satisfying very strict regulations for packagingfood and drink.

PET provides a protective barrier in both directions,preventing oxygen penetrating from the outside andkeeping in carbon dioxide for sparkling beverages.

A further advantage is that PET is 100% recyclable anddiscarded packaging can be re-used in other applicationsthrough a variety of recycling procedures.

Compared with glass bottles, the low weight of PETbottles means that the same amount of beverage can betransported with much less packaging weight. This results

in better transport utilization and economics through thevalue chain, with lower fuel consumption and reduced noiseand pollution.

THE MARKETS for polyethylene terephthalate (PET) and


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THE MARKETS for polyethylene terephthalate (PET) andpolyester fiber are experiencing pricing volatility. Demandin China is still disrupted, and exports from Asia are

pressuring prices in Europe and the US.

Edgar E Acosta, polyester manager at DeWitt & CompanyInc., Houston, says it is unclear why demand in China hasdropped off so sharply, although the SARS epidemic isgenerally blamed.

Operating rates at PET bottle plants in South Korea haveplummeted to as low as 50 to 60 percent, and Asian

producers, especially in China, are exporting polyester andPET at prices that are well below domestic levels.


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PET is around $900 to $1,000 per ton in China, but theChinese are exporting it for around $650 to $700. SouthKorea is exporting at around $700, but its domes- ticmarket is around $750 to $800.

Falling Asian export prices have forced Europeanproducers to lower their prices for bottle-grade resinfrom $1,100 to $1,200 per ton a month ago to around$800 to $900. The impact on the US market has beensimilar, although the US is less susceptible to imports.

Domestic PET producers announced price increases of 5

cents per pound for January 1, 5 cents for March 1 and 8cents for April 1, followed by a decrease of 5 cents forMay 1.

GLOBAL OUTLOOK


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GLOBAL OUTLOOK

Producers are seeking price increases for polyethylene

terephthalate (PET) of 3 cents per pound in the US and[euro]70 to [euro]100 per metric ton in Europe.

Of the 5 cent increase announced earlier in the year,producers have realized about 3 cents. List pricing for

bottle-grade PET is 56 cents to 62 cents per pound.

Analysts note that paraxylene pricing has cooled off and isno longer pressuring the PET market, but Asian purified

terephthalic acid pricing has surged to $650 per metricton for spot material and $635 to $650 for June contractnominations.

MALAYSIA OUTLOOK


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MALAYSIA OUTLOOK

Chemical company which involve in the production PET Hualon Corporation at Gebeng

MPI Polyester Industries at Selangor 20,000 tpy

Petlin Malaysia 30,000 tpy

The capacity production of PET about 50,000 MT/yr.

The demand for PET in Malaysia market in 2001 are quite

high. It is about 70,000 MT/yr


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RECOVERY AND RECYCLING OF

PET PLASTIC WASTES

Th t t d d i li PET l ti t


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There are two stages needed in recycling PET plastics waste.

Stage 1 is physical process while stage 2 is chemical process or

solid state polymerization (SPP) process.

COLLECTION / RETRIEVAL

SEGREGATION

CLEANING

GRINDING / FLAKING

DRYING

LOW GRADE OF PET FLAKES


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COLLECTION AND RETRIEVAL SYSTEM

The PET plastic wastes are collected together with other

recyclables such as cartoons, papers, tin cans, scrap metals,

glass and other types of plastic wastes by scavenging.

This is practice of collecting solid waste by means of sorting

recyclables from different public sites as a way of making

living

SEGREGATION


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SEGREGATION

The segregation of sorting is conducted manually.This is a process of separating PET plastics from other plastics.

The selection is based of any of the following: plastic

type/number, color, processing method, brand and product

type.This is critical for PET.

Contamination with PVC I very common when the sorting

process is not rigidly done.

Sorting is commonly based on color and processing method


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CLEANING

The cleaning process is also done manually. It involves thefollowing steps:

1. Removal the plastic caps

2. Removal of label and rinsing

For some PET recyclers/processors, rinsing/washing is done

during and after grinding/flaking

GRINDING / FLAKING


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GRINDING / FLAKING

The cleaned bottles/container are fed into grinder.

These are two types of grinding: the wet and dry method

In the dry grinding, the materials are ground to the desiredsize and bagged normally in a 30kg or one ton capacity plasticsacks

In wet grinding, water is continuously fed on the materialduring and after grinding is performed.

The dirty liquid or overflow is discharged as wastewater fortreatment.

In some cases, detergent is added efficiently remove thestubborn dirt, additives or glues in the plastic waste.

DRYING


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DRYING

A centrifugal dryer is used to dry the flakes.

Water is expelled through the fine holes of

the dryer by applying centrifugal forces.

The flakes are bagged after drying.

Alternatives Process


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Alternatives ProcessDescription of the process

1) Shreadding and washing2) Separation of PE/PP and drying of the flakes3) Heating by means of extrusion and addition of the

reaction additive

4) Addition of extra ethyleneglycole5) Separation of the non reacting plastic material6) Separation reaction of terephtalic acid7) Filtering and washing of the acid substances8) Drying

9) Storage of the terephtalic acid10) Recuperation of ethyleneglycole11) Storage of ethyleneglycole

Advantages of PET


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Advantages of PET Inexpensive

Excellent transparencyits clarity enhances the presentation valuesof a product.

Lighter weightreduces your transportation costs and improves yourmargins.

Outstanding processabilityallows it to be processed reliably at high

speeds. Good impact resistancestrong and practically unbreakable.

Protective barrier in both directionsacts as an effective barrier foroxygen and carbon dioxide (for sparkling beverages).

Design freedomfeatures great design flexibility.

100% recyclabilitycan be recycled for other applications using avariety of recycling procedures.

Product Application


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pp The flakes and pellets of cleaned postconsumer recycled PET

are in heavy demand for use in spinning carpet yarns and for

producing fiberfill and geotextiles.

PET is the fastest growing plastic used in household applications.PET has a wide variety of packaging applications as soft drinkbottles, water bottles, sports drink bottles, beer bottles,mouthwash bottles, peanut butter containers, salad dressingcontainers, juice bottles, vegetable oil bottles, ketchup bottles,pickle jars, jam and jelly jars, and other similar container uses.Its properties make it particularly useful for films that coverfood products that can be used in ovens and microwave ovens.

PET is in high demand as a recycled product for the manufactureof yet other extremely valuable commodities. Among theproducts that are manufactured with recycled PET, are fiber,tote bags, clothing, film and sheet, food and beveragecontainers, carpet, strapping, fleece wear, luggage and bottles.

Prospects of Malaysian Plasticsd


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Industry

Despite the challenges of reconstruction andconformity with the economic situation inEurope and US, MPMA has forecasted thatthe Malaysian plastic industry will grow by 3percent in 2003. the sector is anticipated toachieve a higher growth of 8 percent in 2004as a result of the development in the E&E,

automobile and construction industries(source MPMA)

Types of Pet
http://www.sonepa.com/available/pet1.jpg


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Types of Pet

PET-401Used PET bottles,80%clear 20%colour

PET-402PET x-ray film, silverremoved, washed

PET-403PET bottles grinded,clear, blue and green
http://www.sonepa.com/available/pet1.jpghttp://localhost/var/www/apps/conversion/tmp/Sholeha%2004/PET/PET%20(Polyethylene%20Terephthalate)_files/petbtgrid.jpg


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PET-404PET fiber onrolls natural

PET-405POLYESTER TIRE

CORD WASTE, mixed

colours belt
http://www.sonepa.com/petfiber.jpg


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Recovery of Oil from Spent

Adsorbent

Introduction


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Introduction

Spent adsorbent - by-product of thepalm oil refining industry

Spent adsorbentactivated carbon & spent bleaching clay(SBC)

Clay & activated carbonuse in bleaching process

Spent adsorbent contained an average of 20%-26% mineral oil

Due to its toxicity it is classified as a Scheduled Waste,requiring special handling and disposal

Performance feature and benefits of SBC:


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Performance feature and benefits of SBC:

removes colours from a variety of lauric acids

minimizes free fatty acid rise during bleaching

does not contain mineral acid, which can damage

oil


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Bleaching


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Bleaching

Is a refining process where oils are heated at 90120C for1030 minutes in the presence of a bleaching earth (0.22.0%)

In the absence of oxygen by operating with nitrogen or steamor in a vacuum

To remove colours and suspended material from crude palmoils


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Global Trend

world production of oils 2004 ('000 tonnes)Palm Oil


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Palm Kernel Oil

Soyabean OilCottonseed Oil

Groundnut Oil

Sunflower Oil

Rapeseed Oil

Corn Oil

Coconut Oil

Olive Oil

Castor Oil

palm oil (28% )


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Most efficient oil crops -yields are higher than other edible oil

crop

Remain strong in 2005

It is expected to exceed other vegetable oil

contribute more fatty acids & energy to diet of the growing

world population

The increase of oleo chemical industries

WORLD MAJOR PRODUCERS OF PALM OIL :

2004 ('000 TONNES)

Malaysia

Indonesia


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2004 ('000 TONNES)Nigeria

Colombia

Cote d'Ivoire

Thailand

Papua New Guinea

Ecuador

Costa Rica

Honduras

Brazil

Venezuela

Guatemala

Others

Malaysia (48%) %)

WORLD MAJOR EXPORTERS OF PALM OIL:Malaysia


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WORLD MAJOR EXPORTERS OF PALM OIL:

2004 ('000 TONNES)Indonesia

Papua New

GuineaCote

d'IvoireColombia

Singapore*

Hong Kong*

Others

Malaysia

(54%)

World Petroleum Consumption


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LOCAL TREND

Malaysia


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Malaysia

Worlds largest producer and exporter of palm oil

In 2003, 17 oleo chemical companies were in operation inMalaysia with a total production capacity of 1.9 million tonnes.

1.55 million tonnes of these oleo chemicals were exported.

PALM OIL PODUCTION : 1995-2004 ('000 TONNES)


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0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

16,000

1995 1996 1997 1998 1999 2000 2001 2002 2003 2004

Spent adsorbent used mostly in palm oil refineries


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Oil refineries use around 2wt% adsorbent in bleaching process

Expected that 20-26wt% of oil will be recovered from spentadsorbent

Recovered oil can be mainly for industrial purposes and asoleo chemical feedstock.

The spent adsorbents were disposed by incineration, in animal

feeds, in landfills or used in concrete manufacturing.

Besides, it can also be regenerated and reuse as secondaryadsorbents.

TECHNOLOGY


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TECHNOLOGY

Injection of compressed air and/ or steam

Solvent extraction

Ultrasonic assisted extraction



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o Oil can be extract from spent earth by injecting compressedair, or steam or compressed air followed by steam injection inthe filter.

o This way, oil content in the spent earth can be reduced from40% to 30%, if only compressed air is used.

o If compressed plus steam are used, it can be reduced from 25%to 20%.

o The recovered oil can be reintroduced in the process atbleaching.

o Considering this last option (with final oil content of 22%),possible savings can be estimated to be about 0.18 ton of oil /ton of spent earth.

Solvent extraction


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Solvent extraction

Total oil content of the spent earth can be decreased to only5wt%

SolventHexane

The colouring substances remain in the spent earth, while theoil is separated and is extracted forming a miscella with thesolvent.

The spent earth can be sent back to the supplier and can beused, as a raw material for the preparation of new fuller'searth.

Hexane and oil can be separated by distillation.


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The oil can be re-processed and the hexane can bestored for reuse in future extractions.

Annual savings by industry by means of solventextraction of oil can be roughly calculated assuming

that the oil content in the spent earth would bereduced from 40% to 5%, thus resulting in a 35% ofoil recovery (on the total spent earth weight).

It gives a saving of about 0.35 ton of oil /ton of spentearth

Ultrasonic assisted extraction (UAE)


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Ultrasonic assisted extraction (UAE)

Extraction technique - ultrasound wave

Ultrasonicsound waves having frequencies about 16kHz

The presence of high intensity ultrasound wave fieldsenhances the extraction process by accelerating the extractionrate and increasing the product yield.

Uses less solvent and energy than conventional techniques,hence reduce the volume of solvents required for extraction.

How the Ultrasonic improves the

t ti ?


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extraction process?

Produce cavitation in the liquid solution, especially at theinterface of solid-liquid

Implosion of microbubbles disrupt concentrated layer near thesurface, create turbulent and vacuuming effect.

Decrease flux resistance, hence increase diffusion rate

Maintain high diffusion rate by continuously controlling thesolute concentration in the solvent

Ultrasonic Cavitation


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Oil recovery using Ultrasonic andS l t E t ti


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Solvent Extraction

0

10

20

30

40

50

60

70

80

90100

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5Extraction time (hr)

M

ineralOilExtracted(%)

Ultrasonic extraction Soxhlet extraction

Schematic diagram of Ultrasonic SolventExtraction System


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Advantages of UAE


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g

Extracting nearly 100% solute

Extracting approximately 8 to 40 folds faster than the

conventional method

Reduce the amount of solvent used (up to 75%)

Reduce overall operating time tremendously (up to

88%)


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Economic Potential

Kewalram Oil Sdn Bhd


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Plant capacity60,000tonne/year

Collect all the SBE in Pasir Gudang

Charge RM45/tonne

Use Soxhlet extraction

Recovered oillubricant oil, animal feed

Spent adsorbentincinerated to produce ash

K liti Al


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Kualiti Alam

Disposal or incinerated

Charge RM 2970/tonnes

NUMBER OF REFINERIES APPROVED AND CAPACITY : 2004 (TONNES /YEAR )


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State In Operation Not in Operation Under Planning Total

No. Capacity No. Capacity No. Capacity No. Capacity

Johore 17 6,975,400 0 0 0 0 17 6,975,400

Penang 3 532,000 2 16,200 0 0 5 548,200

Perak 3 789,000 2 216,000 1 825,000 6 1,830,000

Selangor 10 2,482,000 1 240,000 1 60,000 12 2,782,000

Other States 3 624,000 0 0 0 0 3 624,000

P.Malaysia 36 11,402,400 5 472,200 2 885,000 43 12,759,600

Sabah 9 4,169,000 0 0 4 1,574,000 13 5,743,000

Sarawak 3 1,090,500 0 0 4 1,004,000 7 2,094,500

Sabah/Sarawak 12 5,259,500 0 0 8 2,578,000 20 7,837,500

MALAYSIA 48 16,661,900 5 472,200 10 3,463,000 63 20,597,100

Note :Source by MIDA

Year 2004


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Total oil capacity in Malaysia = 16,661,900 tonnes/year

Spent adsorbent = 0.02 *16,661,900 tonnes/year

= 333,238 tonnes/year

Recovered oil = 0.26*333,238 tonnes/year

= 86,642 tonnes/year

Cost Saving


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g

Period(Year)

Amount ofWaste

Generated

(tonne)

Disposal Cost DisposalCost

Saving

(RM)Before

Treatment

(RM)

After

Treatment

(Solidwaste

reduced =

26%)(RM)

1 333,238 989,716,860 732,390,476 257,326,384

Saving In Palm Oil Cost


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g

Period(Year)

Amount ofRecovered Palm Oil

(tonne)

*oil recovered= 26%

Saving (RM)*Palm oil price

=RM 1400/tonne

1 86,642 121,298,800

Future Trend


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Palm oil consumption keepgrowing up in the future

market

Adsorbent used in palm oilrefineries will also increase

Conclusion


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Generate saving for the plant in term of disposal costand repurchasing of oil

Oil recovery using Ultrasonic Assisted Extractionsave time and amount of solvent used

Oil recovery from spent adsorbent is a feasibleproject


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RECOVERY OF PRECIOUS METALS

FROM PHOTOGRAPHIC WASTE

INTRODUCTION


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Film is used in a variety of businesses and for a variety of purposes.

Silver is a precious metal which used in photo film because of its

photosensitive properties.

Film development cause photographic waste of spent fixer/bleach solutionand rinse water containing1000-10,000 and 50-200 mg Ag/l, respectively,

in the form of silver-thiosulphate complexes.

Silver is classified as a hazardous substance by the Department of

Environment.

Several technologies exist for recovering silver

metallic replacement


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metallic replacement

electrolytic recovery

chemical precipitationIon exchange and

reverse osmosis

There are several reasons to be interested in the recovery of silver from

photo-processing waste.

Silver is a valuable natural resource of finite supply, it has monetary

value as a recovered commodity and its release into the environment

is strictly regulation

Limited number of companies have established a business by picking

up fixer solution and rinse water and accumulating profitable

quantities which are sent off-site for the recovery of the silver

Silver Recovery from the Photo-Processing

Solution


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Solution

The primary sourcesfix (dilute aqueous Na2S2O3/NaHSO3)

bleachfix solutions (dilute aqueousNa2S2O3/NaHSO3/NaFeEDTA).

Silver halide is removed from the film or paper and is carried out in thesolution.

The reaction involve as equation below:

3

232322 )( OSAgNaIAgIOSNa

In film processing operation

the fixer bath is continuously augmented with fresh fixer solution to maintain


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its quality and strength

The concentration of silver compounds depending on

the type

and amount of film being processed(frequently exceeds 5,000 parts per

million (ppm).

Because of this high silver concentration, silver recovery from fixer

solutions is very cost effective.

Environment Regulations


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Environmental Quality Act 1974(ACT 127) and SubsidiaryLegislation

First Schedule (Part 1 Scheduled Wastes from Non SpecificSources)

N141: Spent aqueous or discarded photographic wastefrom film processing or plates making.

The fixer process typically contain high amounts of silver

(3,000-8,000 ppm) and designate as a hazardous waste.


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The bleach solution contain 3 ppm silver, which exceeds the sanitary

sewer discharge limit of 0.2 ppm.

It is illegal to put bleach solution into the septic system, storm drain,

dry well, or on the ground.

BusinessesWhichever system was decide to purchase, it must comply with local discharge

regulations by ensuring that the wastewater never exceeds 0.2 parts per

million (ppm) total silver

Thus, all fixers must be treated on-site or properly disposed or recycledoff-site.

Types of Systems


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On-Site Recovery Systems

Off-Site Recovery Systems

In this business its preferred to used On-Site Recovery Systems.

The advantages of this On-Site Recovery Systems

Treated waste will not count towards your 220 lb. SQG limit

Reclaimed silver is valuable and may offset some of your treatment

system costs

Convenience

Eliminates liability risks associated with off-site shipment

There are downsides to sending the waste Off-Site Recovery Systems


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Need utilize a company to pick up the waste

Need to purchase storage containers, which require extra space and

will add to your maintenance costs.If produce small quantities of waste, may need to store the materialfor a long time before filling the container.

Storing waste on-site for long periods increases the risk of spills orleaks.

Even if the waste is managed by a third party, are still responsible

for the proper disposal of the material, so be sure to carefully selectthe right company.

But in Off-Site Recovery Systems still has certain advantages such as:

No start-up costs

No need to worry about equipment failure or maintenance

T h l f R f


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Technology for Recovery of

Silver from Photographic Waste

Photographic Waste Focus On:1.Fixer Bath solution/bleach solution

2.Rinse solution

The Most Common Methods:


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The Most Common Methods:

1. Metallic Replacement

2. Electrolysis

3. Precipitation

4. Reverse Osmosis

5. Ion Exchange

1. Metallic Replacement


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1. Makes use of the factthat iron is more activethan silver

2. Available for all silver-

rich solution3. Low capital costs

4. Low maintenance

5. 99% removal possible

with 2 units6. Purity 30-50%

Oxidation :

eFeFe 2

2

Reduction:

2

32

3

232 2)( OSAgeOSAg

2. Electrolysis


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2

32

3

232 2)( OSAgeOSAg

most efficient

Silver is deposited on thecathode and stripped off

for sale or reuse

Low refining costs

Moderate capital costs

Obtain >90% pure silver

95 percent of the potential

available silver can be

recoveredCathode (Silver plat):

3. Precipitation


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-additional of alkaline sodium sulfide-resulting precipitation of silver sulfide

Advantages

a) >99% consistent removal

Possible

b) Moderate capital costs

c) Little maintenance

Disadvantages

a) Higher smelting cost than

electrolytic

b) Ongoing chemical usage

Moderate to high

operation costs

c) Treatment chemical

required

4.Reverse Osmosis


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- uses high pressure to force a liquid solution through a

semi-permeable membrane

- separate larger molecule substances from smaller

molecule substances

Advantages Up to 90% efficiency on

dilute streams

No treatment chemicals

required

Disadvantages High capital costs

Frequent maintenancerequired

Works best on dilutesolutions

Large installations noisy

5. Ion Exchange


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Used for effective recovery ofsilver from dilute solution

Involves the exchange of ions inthe solution with ions of a similarcharge on the resin

Silver is removed from the resincolumn with a silver complexingagent such as ammoniumthiosulfate

Silver is then recovered from thethiosulfate regenerant with anelectrolytic recovery cell

Advantages Disadvantages


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g

98-99.99% removal

efficiency from dilute

solutions

g

High capital costs

Fouling problems

May require use of

hazardous chemicals

Works best on dilutesolutions

Monitoring required

for replacement orregeneration


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electrolysis is chosen

GLOBAL SILVER SUPPLY


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-Minesmajor global supplies of silver

-10 producing countries responsible for 70% of

total mine production :-

-Peru, Mexico, China, Australia, Poland,

Canada, Chile, US, Kazakhstan, Bolivia

World Silver Mine Production,

2003

Peru, 15%

Mexico, 14%

China, 13%

Australia,

10%Poland, 7%

Canada, 7%

Chile, 7%

Other, 27%

World's Leading Primary Silver Mines in 2004

(millions of ounces)


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Rank Mine/Country Operating Company Prod.

1 Cannington, Australia BHP Billiton 45.91

2 Fresnillo (Proao), Mexico Industrias Peoles SA de CV 31.60

3 Dukat, Russia Polymetal OAO* 12.06

4 Uchucchacua, Peru Compaia de Minas Buenaventura SA 9.83

5 Greens Creek, U.S. Kennecott Minerals/Hecla Mining Co 9.71

6

Arcata, Peru Minas de Arcata SA

7.94

7 Rochester, U.S. Coeur d'Alene Mines Corp 5.67

8 Imiter, Morocco Socit Mtallurgique d'Imiter 4.95

9 Huaron, Peru Pan American Silver Corp 4.08

10 Lunnoye, Russia Polymetal OAO 3.70

11

Galena, U.S. Coeur d'Alene Mines Corp

3.52

12 Tayahua, Mexico Grupo Carso 3.38

13 Tizapa, Mexico Industrias Peoles SA de CV 3.04

14 Cerro Bayo, Chile Coeur d'Alene Mines Corp 2.94

15 Quiruvilca, Peru Pan American Silver Corp 2.53

-Other silver supply comes from silver scrap

-Silver scrap is generated primarily in industrialized


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countries

-Sources of silver-bearing scrap :-

-electronics -jewelry

-spent catalyst -silverware

-photographic waste

-dental alloys

-In 2004, annual supply for silver from scrap recycling150

million ounces

-In USA (2000), about 1800 metric tons of silver contained

in electronics, photographic waste and spent catalyst were

recycled

GLOBAL SILVER DEMAND


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World Silver Demand (in millions of ounces)

Demand

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

Fabrication

Industrial Applications

295.7

297.7

320.8

316.4

339.2

375.4

336.3

340.1

350.5

367.1

Photography

202.9

210.1

217.4

225.4

227.9

218.3

213.1

204.3

192.9

181

Jewelry & Silverware

236.9

263.7

274.3

259.4

271.7

278.2

287.1

262.7

274.2

247.2

Coins & Medals

26.1

25.2

30.4

27.8

29.2

32.1

30.5

31.6

35.8

41.1

Total Fabrication

768.6

796.8

842.9

829.1

867.9

904

867

838.7

853.4

836.7

Net Government Purchases

-

-

0.7

-

-

-

-

-

-

-

Producer De-Hedging

-

14.3

-

-

16

27.4

-

24.8

21

-

Implied Net Investment

-

-

-

-

-

-

17.8

-

8.7

42.5

Total Demand

768.6

811.1

843.6

829.1

883.9

931.4

884.8

863.5

883.1

879.2

For silver demand, fabrication place a major demand

GLOBAL SILVER PRICE


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2005 Monthly Silver Prices

London Fix

(US dollars per ounce).

Month

High

Low

Average

June

7.53

7.07

7.31

May

7.18

6.85

7.02

April

7.29

6.94

7.12

March

7.57

6.92

7.26

February

7.55

6.49

7.03

January

6.81

6.39

6.61

Silver Price (London US$/oz) from 2000 to 2004

DEMAND OF SILVER FROM PHOTOGRAPHIC

WASTE


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o Photographic demand - 3rdlargest demand for silver

- represents approximately 22% - 25%

of total silver

o 25% of worlds silver comes from recycling & 75% of this is obtained from

photographic wasteo Sources of recoverable silver - photo-processing

solutions/fixer solutions

- spent rinse water

- scrap film

- scrap printing paper

o 80% of total silver processed for black & white negatives and 100% of

silver processed in colour will end up in fixer solutions

U.S. Recoverable Silver in Photographic IndustryCoating

h

US Silver


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weight

(gram

per square

meter)

Consumption

(millions)Content

(metric tons)Photographic material Recoverable silver

Percentage Metric tons

Films :

Colour negative 5-8 1030 262 100 262

Colour reversal 4-6 51 11 100 11

Black and White 5-7 40 10 40-50 4

Motion picture 5-7 27.4 165 100 165

Plates :

X-ray (medical, industrial, dental) 4-6 110 550 40-50 248

Graphic arts 3-5 53.1 212 20-80 138

Paper :

Black & white (C.T.) 1-5 14.1 56 40-60 28

Black & white (line) 1-5 8.645 35 20-80 21

Colour 0.7-1/2 572 572 100 572

Total 1870 1450

SILVER RECOVERY IN MALAYSIA


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2 silver recovery industries available in Malaysia

1) Victory Recovery Industries Sdn. Bhd., KrubongIndustrial Park, Melaka

2) Universal Cyclone Sdn. Bhd., Sungai Buloh,

Selangor

Both industries collect and recover silver from photo-processing solutions

(bleach-fixer solution)

But, Victory Recovery Sdn. Bhd. also recover silver from scrap films and

scrap printing papers

The products are with 99.9% purity and mainly exported to local

The price according to world market price

Silver sold for jewelry, silverware & industrial applications (electronics,

coating, batteries)

FUTURE TREND


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FUTURE TREND

the use of digital film- growing digitalphotography market will have little overall

effect on silver demand

will order less prints but larger sizes

the number of prints goes

down, the usage of silver

halide paper will go up

Demand for New Silver


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Demand for New Silver

Photography accounts for 24% of

worldwide use of silverDigital photography will not drive

the use of silver down

less silver required -do not print


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less silver required do not print

images; send over the Internetit seems silver use will decline-under

detailed analysis, it will

remain steady

Silver Recovery from Photographic

Waste in Malaysia


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Waste in Malaysia

limited company

1) Victory Recovery Sdn.Bhd-Melaka.

-recover silver and gold2) Universal Cyclone Sdn.Bhd-Sg Buloh

- recovery silver from

photographic waste

In Malaysia-at low level

feasible to be built up


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feasible to be built up

why the business should be done inMalaysia????????

i) limited company involve

ii) raw material is easy to getiii)the global price of silver-increase

CONCLUSION


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Business of recovery silver from photographic waste -

feasible to be built up in Malaysia

Silver is a valuable commodity and it is a regulated

environmental contaminant The global price for the silver is increasing; that

means the market or the requirement of silver is still

wide

In Malaysia, there are only a few company

l h f ld h bl


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involve in this field. So there are no problems in

the competition to get the raw material (fixersolution) and market for the recovery silver

Although the digital camera is introduces, but it

just little effect on the market of film. As a result,

there is not much effect on the market of silver.


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USED COOKING OIL INTO BIODIESEL

Introduction


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Definition of used cooking oil (UCO): Oil-based substances consisting of animal and/or vegetable matter

that have been used in cooking or preparing foods and are no longer

suitable for human consumption.

Resulted from the cooking of food by food manufacturers and cateringestablishments such as restaurants and industrial kitchens.

Chemical Structure of Used Cooking Oil


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Glycerin

TriglycerideFatty acid

portion

Problem Encountered

Pose significant disposal problems in many parts of the world.


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Why cant dump?????

- UCO are often in liquid or semi-liquid form and disposal of liquid

wastes in quantities of one gallon or more is prohibited in municipal

solid waste landfills.

Why cant drainit????

- To protect the environmentform a film on the surface of river or

underground, which prevent oxygenation. If oils are disposed of via

drains, sinks or with ordinary waste, they are likely to seep into

nature. Oils also impair the efficiency of sewage treatment plants.

- Because pipes may be blocked by oils poured directly into the sink

even if diluted with hot water.


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Thus, one of the alternatives to solve this

problem is to RECYCLE the USED

COOKING OIL

Useful Products from UCO


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Animal FeedTo produce high energy diets for certainintensive livestock enterprises.

Lubricant

Soap

Direct burning for power generation Biodiesel as fuel additive

Which product

should be chosen to


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should be chosen to

be produced and

which technology?

In term of economic aspect and

environmental factor, the

production of Biodiesel is the

most popular topic to be

discussed recently

Biodiesel


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Definition: A renewable substitute fuel for petrol diesel made from

vegetable or animal fats.

Can be used in any mixture with petrol diesel as it has very

similar characteristics but it has lower exhaust emissions.

Production of Biodiesel from UCO


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There are three basic routes to biodiesel production fromUCO:

i. Base catalyzed transesterification of the oil with alcohol

ii. Direct acid catalyzed esterification of the oil with

methanol

iii. Conversion of the oil to fatty acids, and then to Alkyl

esters with acid catalysis.


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The majority of the alkyl esters (Biodiesel) produced today are

done with the base catalyzed reactionbecause it is the most


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economic for several reasons:

1. Low temperature (150 F) and pressure (20 psi)

processing.

2. High conversion (98%) with minimal side

reactions and reaction time.

3. Direct conversion to methyl ester with no

intermediate steps.

4. Exotic materials of construction are not

necessary.

Process Description


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Glycerin

Biodiesel

Triglyceride

NaOH (aq)

CH3OH

A fat or oil is reacted with an alcohol,like


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methanol, in the presence of a catalyst toproduce glycerin and methyl esters or

biodiesel. The methanol is charged in excess

to assist in quick conversion and recovered for

reuse. The catalyst is usually sodium or

potassium hydroxide which has already been

mixed with the methanol.

Process Flow


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Filter Heating

UCO

Alcohol

Catalyst

Reactor Washing Purification Evaporation

Alcohol Recovery

SettlerUCO

NeutralizationDistillation

Settler EvaporationMineral acid

Biodiesel

GlycerinFatty acid

Alcohol

Advantages

Main Product (Biodiesel)

Off i d l b i it t l di l


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Offers improved lubricity over petrol diesel

Runs in existing unmodified diesel engines Higher cetane ratingthan petrol diesel for better engine

performance

Higher flashpoint than petroleum diesel makes it safer to

handle Exhaust emissionsare reduced

Integrates with the existing fuelling infrastructure

Low-risk - simple to phase in and out of use

Local renewable source of energy

Reduced toxicity to plants, animals and humans

Biodegradable

By-product (Glycerin)

used for medicines(pharmaceutical), tinctures, hand
http://www.planetfuels.co.uk/glossary/http://www.planetfuels.co.uk/emissions/http://www.planetfuels.co.uk/emissions/http://www.planetfuels.co.uk/glossary/


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p

lotions(cosmetics), dried plant arrangements andwax.

Market Survey

Source of raw material (UCO):


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- Fast food restaurant:

1. Kentucky Fried Chicken (KFC)

2. McDonalds and etc..

- Food manufacturing factory such as

Maggi, Mamee, etc..

- Household kitchen.

As to be more practical, the survey was done based on theraw material from the fast food restaurants (KFC and McD).

Competitor: The cooking oil company that provide cooking oil

for the particular outlet such as NEPTUNE, EAGLE and etc..------sell to recycling company (Kewalram).

KFC:

f /f h

Rough Calculation


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Amount of UCO : 40 tins/fortnight

Volume : 18L/tin

Impurities : 30%

Number of Outlet : 700

Amount of raw material (UCO)/year

=

= 4,586,400L/year

0.5outlets700purity3.01Tin

L18

year

Fortnight

2

52

outletFortnight

Tins40

McDonalds:

Amount of UCO : 40(0 3) tins/fortnight


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Amount of UCO : 40(0.3) tins/fortnight

Volume : 18L/tin

Impurities : 30%

Number of Outlet : 700(0.5)

Amount of raw material (UCO)/year

= 1,965,600L/year

The total of UCO generated

= 2,260,440L/year


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2,260,440L/yearSeems like too little

raw material to

commission a UCO recycle

Plant to produce

Biodiesel..HOW??????

Group 1Never mind, there is another alternative

MOBILE UCO RECYCLING MILL

Mobile Biodiesel Mill

Mobile UCO Recycling Mill

It has already been introduced in USA by a person named

Mike Pelley


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Everything is just on a truck

Mike made front page new in

The Seattle Time.

September 30, 2002.

Mikes mobile Biodiesel mill


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Mike and Joe, an organic farmer

who makes 40 gallons of biodiesel

a week for the farm truck and tractor.


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So, why dont we

try this mobile technology

in Malaysia

View of sodium methoxide


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mixer (left) and

transesterifyer vessel (right).


being drained into

transesterifyer vessel.

Valve on bottom of transesterifyer


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vessel user to decant out more

dense glycerin from less dense esters.

Fuel pump and filters -- these are

used last, after soapy residues

and lye have had time to

settle out of biodiesel.


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Overview of trailer-mounted processor The finished product.

Economic Potential

Neglecting the price of methanol and caustic


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g g p

Assuming the price of biodiesel is equal to the price of diesel~RM1.80/L

2,260,440L/year of UCO can produce

approximately 2,000,000L Biodiesel / year.

Profit = 2,000,000L/year x RM1.80/L

= RM3.6million/year


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Recycling of Used Tyres

Sources of Used TyresTwo basic sources of used tyres:

Retail businesses collecting old tyres - includes tyre manufacturers (scrap


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Retail businesses collecting old tyres includes tyre manufacturers (scraptyres), tyre retail stores, and tyre collectors, sometimes called tyre jockeys.

Existing piles

Other main sources of used tyres are:

Used car importers (some of the tyres on used imports are thrown awaywhen the vehicle arrives as they are unsuitable to be used)

Re-treaders (scrap) Vehicle wreckers Large transport companies (some transport operators have their own

workshops and replace their tyres themselves, which means that the usedtyres are not automatically returned to the tyre retailer).

Worldwide of Used Tyres


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In the UK:

It is estimated that 427,000 tonnes of waste tyres wereproduced in 2000 (Used Tyre Working Group, 2001).

This annual figure is now estimated to be approximately440,000 tonnes (Used Tyre Working Group, 2004)

- 26% are reused as retreads- 46% are reclaimed for other forms of reuse or recycling;

or are incinerated for 'energy recovery'

- The rest (28%) are landfilled or stockpiled, and represent

a major waste problem

In the US:

In 2001, 292 million scrap tyres were generated. Of

the 292 million car supply two thirds of scrap tyres


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the 292 million, car supply two-thirds of scrap tyres,

the remainder are from trucks, heavy equipment, air-craft, off-road and scrapped vehicles.

From the total of 292 million, 78 % were recycled.

The U.S. Environmental Protection Agency estimatesthat 250 million scrap tyres are generated in the

United States each year, not counting another 45

million scrap tyres that are used to make 34.5 million

automobile and truck tyre retreads every year.

In Australia:

170,000 tonnes of waste tyres are generated


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each year.

In Europe:

Around 250 million tyres generated each year.Of these tyres, around 60% are reused in someway and the rest end up in landfills.

In 1994, the figures were almost the other way

round, with over 60% of tyres ending up inlandfills.

Country Used Tyres Tonnes / Year Population

Netherlands 65.000 15.492.800

Belgium 70.000 10.143.000


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Spain 330.000 39.241.900

Ireland 7.640 3.591.200

Great Britain 400.000 58.684.000

Italy 360.000 57.330.500

Austria 41.000 8.045.800

Greece 58.500 10.474.600

Luxembourg 2.000 412.800Portugal 45.000 9.920.800

France 380.000 58.265.400

Sweden 65.000 8.737.500

Germany 650.000 81.845.000

Finland 30.000 5.116.000

Denmark 38.500 5.251.600

Total 2.542.640 372.552.900

Table 1.1 The annual accumulation of used tyres in EU-countries

Malaysia


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Year Number of vehiclesEstimated Scrap Tyres

Generated Two Years

Later (9kg per tyre)

2002 12,021,939 432,790 tonnes

2003 12,756,986 459,251 tonnes

2004 13,866,289 499,186 tonnes

2005 15,406,987 554,652 tonnes

Used Tyres in Malaysia


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almost 450,000 tonnes of used tyres,

equivalent to 12.5 million vehicles a year

are generated.

over 70% of these tyres are collected.

CityPassenger

(tyre / year)Truck

(tyre / year)Total

(tonnage)

Kuching 200,000 30,000 2,750

Sibu 84,000 12,600 1,155


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Miri 84,000 12,600 1,155Bintulu 50,000 75,00 917

Kota Kinabalu, Sabah 200,000 30,000 2,750

Total number of tyres 618,000 92,700 8,727Average weight kg / tyre

7 45

Annual tonnage, Sarawak2,926 2,484 5,410

Total tonnage 4,326 4,172 8,498Table 1.2 Used tyre generation (major towns in Sabah and Sarawak)

AreaCollection Percentage


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Kuching 75

Other parts of Sarawak55

Kota Kinabalu, Sabah

55

Table1.3Percentage of used tyres collected

Composition of Rubber Tyres

Component Weight %


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p g

SBR 62.1

Carbon black 31.0

Extender oil 1.9

Zinc oxide 1.9

Stearic acid 1.2

Sulfur 1.1

Accelerator 0.7

Total 99.9

Table 1.4 Rubber compounding composition


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Environmental Problem

Associated with WasteTyres

Mosquitoes

Disease


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Fire Hazards

Disease

Storage of Whole Tyres

Retreading


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A tyre which worn tread has beenremoved and replaced with new material

having similar charasteristic to tha

original


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Inspection Buffing

Repair

Trimmingandpainting Final Inspection Recuring

RECOVERY OF SECONDARY RAW

MATERIAL FROM OLD TYRES

I) Mechanical treatment


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I) Mechanical treatment Tyres are cut or ground into pieces or crumbs to use either

the composite materials as a whole or to separate thedifferent materials from each other

II) Thermal treatment Leads to depolymerisation or decomposition to recover

synthesis gas, liquid hydrocarbonsor soot. 4 types of thermal treatment process:

i) Regeneration of waste rubber(devulcanised)

ii) Depolymerisation by microwave

iii) Co-refining with crude oil

iv) Depolymerisation by hydrolisis

ENERGY RECOVERY OF USED

TYRES


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I) Combustion of Used Tyres Used tyres make an excellent fuel since they have a

fuel value 20% greater than that of coal, about

12,000 to 16,000 Btu per pound compared to coal

(12,000 Btu per pound) and wood (5000 BTU perpound).

As an energy source, used tyres can be used as fuel

either in shredded form (Tyre Derived Fuel (TDF))

or whole, depending on the type of combustion

furnace.

The important advantages of TDF are a

compact and consistent composition and low

moisture content


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moisture content.

In United State, the Scrap Tyre Management

Council reports that over 57% of scrap tyres were

used as fuel in 1996.

The energy recovered from used tyres in the U.Kis approximately 27%, which is low when

compared with other European countries, such as

Finland, Germany, Austria and Sweden, where

between 50% and 80% of used tyres contribute to

energy recovery.

The use of tyres and TDF in various

combustion facilities to recover the


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energy included:i) power plants

ii) cement kilns

iii) pulp and paper plants

iv) boilers

v) small package steam generators

vi) lime kilns

Market of TDF in US, 1996:


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However, from the perspective of

economic feasibility as well as


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environmental reason: A researcher point out that burning of used tyres as TDF

is not as preferable as reusing, retreading or recycling

tyres.

Crumb rubber prepared for recycling sells for $200 to$400 a ton, as much as 10 times the price paid for TDF

chips.

II) Pyrolysis

Offers another route for high temperature resource

recovery from tyres.


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It involves the thermal decomposition of asubstance into low molecular weight products

under an inert atmosphere.

Tyre pyrolysis produces:

char or carbon black (22%) oil (30%)

gas (28%)

steel (10%)

a small quantity of inorganic slag or ash (5%)

Market for Pyrolysis Markets exist for all of the products of pyrolysis but

product quality limits the potential commercial values.


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A number of pyrolysis plants operating around theworld (none of which are in Australia), apparently

none have been particularly successful and the

economics of pyrolysis appear to be marginal.

An examination of current practice reveals thatalthough more than 30 major pyrolysis projects have

been proposed, patented or built over the past decade,

none have been commercially successful.

As of 1997 no tyre pyrolysis plants were operating in

the United States (STMC, 1997).

Civil Engineering Projects


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Lightweight fill for embankments and retaining walls

Leachate drainage material at municipal solid wastelandfills

Alternative daily cover at municipal solid waste landfills

Insulating layer beneath roads and behind retaining walls

In civil engineering, used tyres are applied for:

Artificial tyre reef structure


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y

Road surfaces

Lightweight fill in civil engineering

applications

Paving Applications

Reuse through landfill engineering

Highway Noise Barriers

Other Civil Engineering


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Overpass fillLevee slurry wall (mix with concrete)

Retaining wall fill

Roadway base fillBridge abatement fill

CRUMB RUBBER

Crumbing is a process which reduces rubber


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compounds to a fine granular or powdered formThe scrap tyres are ambiently reduced in size with

the use of shredder, grinder and cracker mills

Referred to as ground rubber, is a wire-free finerubber particle made by size reduction from scraptyres

Various size reduction technique can be used toachieve a wide range of particle sizes down to 600microns or less

Surface modicationtechnology


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Scrap/waste tyre Crumb rubber

Granule

Truck Tyre Buffings

Buffing Dust

-manufacture ofmats/matting andplaygrounds

PROCESSING OF CRUMBRUBBER

Divided into 2 major processing categories


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Divided into 2 major processing categories

Mechanical Grinding

Cryogenic reduction

I) Mechanical grinding

Most commonly used process

Consists of mechanically breaking down the rubber

into small particles using a variety of grindingtechnique

~cracker mills, granulators

The steel components are removed by amagnetic separator

~centrifugal, air classification,density


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ce ug , c ss c o ,de s y

The fiber components are separated by airclassifiers or other equipments

These systems are well established and can

produce crumb rubber at relatively low costAlso easy to maintain and require few people

to operate and service

Replacement parts are generally easy toobtain and install

II) Cryogenic reduction

Consists of freezing the shredder rubber at an

extremely low temperature (far below t

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