polypropylene recovery of carpets - carpet recycling uk gardner_pp_carpet_rec · •fibres for non

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  • Polypropylene Recovery of

    CarpetsCarpets

    6th September 2010

    Jane Gardner

  • Estimated PP Carpet Waste arising

    Off cuts, 10,000 t

    Post industrial, 5,000 t

    Post consumer, 224,000t

  • Existing End Markets

    Equestrian Surfaces

    additive to sand based

    all weather surfacesall weather surfaces

    Fibres for non woven

    products

    Energy recovery

    Need for high volume, higher value end markets

  • PP Recovery Trials funded by

    Envirolink NorthwestTrial aims:

    To develop a process

    for recycling

    polypropylene carpetspolypropylene carpets

    To assess commercial

    viability of the process

    Laboratory scale trial

    followed by commercial

    scale up

  • Axion recycling trials

    NIR ID sorting

    Size reduction Size reduction

    Screening

    Extrusion

  • NIR ID sorting

    Identification of PP

    carpets using handheld

    NIR machine

    Carpets should be:Carpets should be:

    Tufted PP

    Woven carpets - warp

    and weft threads can be

    of different polymer

    type

    http://www.fine-flooring.com/TuftedDiagA.gif

  • Granulated PP carpet

  • Screen to remove dust, fines

    High energy

    flip-flop

    screen

    12x12mm 12x12mm

    deck

    Alternative

    technique

    dry

    cleaning

  • Results

    Extruded pellets of both

    post consumer and post

    industrial pp carpet

    successfully moulded successfully moulded

    into test bars

  • Trial resultsPhysical

    properties

    test

    Units

    Post consumer

    sample

    Post industrial

    carpet

    Virgin PP used for injection moulding

    MFI (at 230C, 2.16kg) 52 19.5 12

    Tensile strength MPa 23 22 32

    10.1 7.3 10Elongation @ Yield % 10.1 7.3 10

    Elongation @ Break % 28.9 35.1

    Density g/cm3 1.023 1.15 0.905

    Ash % 10 15 0

  • Trial conclusions

    Straight forward processing route:

    Rigorous PP identification and sorting, tufted Carpet works best

    Size reduction

    Screening Screening

    Extrusion

    Finished PP:

    Good physical properties,

    Suitable for use in medium to low grade applications, Eg injection moulded plant pots

  • Commercial scale trials

    Successful recovery of industrial PP carpet at large scale

    Closely matches lab scale results

    Potential feedstock for injection moulding Potential feedstock for injection moulding

    Further work needed to perfect feed

    Confidence in product to scale up to post consumer use

  • Commercial conclusions

    Critical success factor - correct identification of all polymer fibres within the carpet

    Economics of the recycling process Economics of the recycling process

    are promising

    Next step: Commercial scale testing

    of post consumer carpets

  • OUTLETS, OUTLETS, OUTLETS

    CRUK disseminates trial

    results to encourage

    entrepreneurs to take

    up carpet recycling

    Currently 16 Specialist

    Recyclers accepting a

    range of carpet types

    Important to present

    material correctly for

    recycling

  • Collecting Carpet Tiles for reuse

    4 Reuse companies in

    the UK:

    Spruce Carpets, Glasgow

    Cleanstream Carpets,

    Cardiff

    Establish suitability for reuse

    Contact Reuse company to confirm

    quality and volume of material

    Uplift

    Uplift early to ensure that material

    remains clean and uncontaminated

    Cardiff

    Scout Enterprises, Bristol

    Colwyn Furniture Reuse

    Capacity to take large

    volume of tiles

    Prepare for collection

    Stack tiles on pallets

    Secure tiles using shrink wrap

    Call reuse organisation to

    arrange collection

  • Collecting Carpets for other outlets

    Carpets should be:

    Kept separate from

    other waste

    Not heavily Not heavily

    contaminated (paint,

    nails)

    Acceptable for handling

    Ensure highest

    possible end use

  • Carpet Recycling UK running innovative trials to

    develop more outlets

    Number of outlets increasing

    Supply chain needs to work together to ensure

    Summary

    Supply chain needs to work together to ensure

    highest value outlet is achievable

    Local links are best

    We invite you to join our effort

  • www.carpetrecyclinguk.comwww.carpetrecyclinguk.com

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