Asia Pacific Conference on Recycling of Plastics Current Status of Containers & Packaging Plastics Recycling in Japan February 2007 Yoshimi Ozaki General Manager, General Planning Dept. Plastic Waste Management Institute, Japan Email: ozaki@pwmi.or.jp Web site: http://www.pwmi.or.jp
Presentation Topics 1á. A Legislative & Voluntary Framework 2� . � Flow of Plastic Products, Wastes and Recycling 3ñ. ñ Status of Recycling under C & P Recycling Law 4• . Summary (5. Introduction of PWMI) PWMI 2
Legislative framework Legislative Framework to Form Sustainable Development Society (Basic framework law) (Jan 2001) Fundamental Law for Establishing a Sound Material-Cycle Society (Proper waste management) (Promotion of recycling) (Apr 2001) (Apr 2001) Law for Promotion of Effective Revised Waste Management Law Utilization of Resources (Individual product recycling law) (Jan 2005) ( Full enforce. : Apr 2000) (Apr 2001) (May 2002) (Apr 2001) Containers & Home Construction Food End of Life Packaging Appliance Materials Recycling Law Vehicles Recycling Law Recycling Law Recycling Law Recycling Law (Apr 2001) Green Purchasing Law Source: Ministry of Economy, Trade and Industry 3
Legislative framework I ndustrial Structure Council Guidelines for Waste and Recycling The guidelines Indicate measures to be taken by businesses for waste treatment and recycling with aim of promoting voluntary actions, with respect to 35 product categories and 18 business sectors. <Example> Plastic product category: PET bottles Collection rate 80% (2014) EPS fish boxes and packaging for home appliance Recycling rate 75% (2010) PVC agriculture films Recycling rate 70% (2006) PVC pipes and fittings Recycling rate 70% (2010) Distribution business sector: Japan Franchise Association Reduction of shopping bag 35% (2010 vs 2000) Japan Department Stores Association Reduction of packaging materials 25% (2010 vs 2000) PWMI 4
Legislative framework Position of Guidelines in Legislative Framework Others ( PC, etc.) Municipal Industrial Waste Furniture Solid Waste Clothes Home appliance Law for Promotion of Effective Construction Home Appliance Utilization of Resources Construction: Materials Recycling Law Recycling Law 18% 2% 2% 2% ELV Automobiles: Recycling Law Reducing waste Reusing parts Recycling as ca. 10% Law for generation etc. raw materials Management of (‘Reduce’ p} (‘Reuse’ policy) (‘Recycling’ policy) Agriculture: Animal Excrement olicy) 22% Paper: Industrial Structure Food Recycling ca. 25% Council Guidelines Food processors: Law by Product Category 3% Product Related Measures Electricity, gas, heat, - Save resources water - Design for environment Containers and - Selectively collect and recycle products, etc. utilities: Containers/ Packaging 22% Packaging: Recycling Law By-products (waste) Related Measures ca. 25% Pulp/paper: Industrial Structure - Prevent by- product generation 9% Council Guidelines - Promote recycling of by- products, etc. By Industry Sector Steel: 8% Kitchen waste, Food recycling Law (Business waste, Chemical: 5% Effective use of resources Household waste): Mining: 7% (business waste only) Source: METI ca. 30% Others: 10% Green Purchasing Law 5 Annual total: ca. 50 million t Annual total: ca. 400 million t
Flow of Plastic Products, Wastes, Plastics Flow and Recycling (2005) Utilized: 6,280 (62%) Export Import Mechanical Recycl. 1,850 (18%) Liquefaction/Blast Domestic Post-use Resin Production Consumption Discharge Furnace 290 (3%) 14,510 11,590 9,140 Solid Fuel 620 (6%) Unit: 1000t Incinerat. with Power Gen. 2,310(23%) Total Discharge 10,060 Processing waste Incinerat. with Heat 690 Municipal Utilization 1,210 5,200 Production waste (12%) 230 Industrial 4,860 Unutilized: 3,780 (38%) Reclaimed Incineration only Products 1,230 (12%) 960 Landfill 2,550 (26%) 6
Plastics Flow Breakdown of Plastics Waste Discharge (2005) Municipal Plastics Waste Industrial Plastics Waste (5,200 Kt) (4,860 Kt) Containers & packaging accounts Electric & machinery and for 71% containers & packaging account for 25%, and 23% each. 6% 19% 25% 3% 4% 20% 71% 3% 4% 23% 7% 15% Containers & Pac kaging Household Elect ric & Machinery Cont ainers & Packaging Elect. & Machinery Building Transport at ion Others Agricult ure Household Ot hers Product ion loss PWMI 7
Recycling under C&P Recycling Law Containers and Packaging Recycling Law June 1995 Promulgation April 1997 Partial Enforcement (Glass bottles, PET bottles) April 2000 Full Enforcement (Glass bottles, PET bottles, Paper C&P, Plastic C&P ) ê (Driver: Concern about remaining space of disposal sites) 1997 2000 Glass bottles, PET bottles Large sized company Paper C&P, Plastic C&P Glass bottles, PET bottles Medium sized company Paper C&P, Plastic C&P Small sized Not applied company 8 Source: METI
Recycling under C&P Recycling Law Containers and Package Recycling Law Designated Business entities utilizing manufactures/users recycled products Payment of recycling costs The Japan C&P Recycling Association Payment of recycling costs Supply Supply Declaration for amount of sorting Bidding plastic waste price Consumers Recyclers Municipalities Sorted collection Transportation and recycling Sorted discharge of “items to meet sorting criteria” 9
Recycling under C&P Recycling Law Method of Plastics Recycling Category Method of recycling Positioning under law Recycling to make Prevail over chemical - Plastic raw material Mechanical recycling recycling - Plastic product Degradation to monomer Blast furnace ( as reducing agent ) Chemical recycling Coke oven ( Feedstock recycling ) Chemical Gasification, feedstock Liquefaction Fuel Cement kiln Not specified as recycling method. Energy recovery Incineration with power (Cement kiln and, RPF are generation included as an emergent and supplementary method in the Solid Fuel (RPF, RDF) amendment made recently.) 10
Recycling under C&P Recycling Law Recycling of PET Bottles PET bottles are mostly recycled to make Fibers, × 1000t Sheets, and recently PET bottles as well. 160 2 4 2 140 6 23 12 2 120 4 11 2 5 100 3 59 Ot hers 55 5 50 46 80 Molded produc t 38 3 4 Bot t les 60 23 Sheet 40 3 64 64 Fiber 12 59 57 49 1 20 5 38 25 1 17 1 6 0 1997 1998 1999 2000 2001 2002 2003 2004 2005 Source: Japan Containers and Packaging Recycling Association PWMI 11
Recycling under C&P Recycling Law Monomerization Process Process outline PET bottle flakes Methanol Hopper DMT Ester PTA separation/ exchange production refinement Liquid-state polymerization Solid-state polymerization Resin for PET bottles BHET refinement (decoloration/ distillation, etc.) Depolymerization Reference: Teijin and Aies pamphlets PWMI 12
Recycling under C&P Recycling Law Recycling of Plastic C&P by Method Currently mechanical recycling shows a big increase. Take back volume by JCPRA for Recycling (x1000t) As a result, chemical recycling is being depressed. 700 Mec hanic al (594) rec yc ling 600 Liquefac t ion (529) Blast furnac e 500 Source: Japan Containers and (447) Packaging Recycling Association 287 Coke oven 176 (368) 400 113 Gasific at ion 13 12 (260) 86 47 8 300 76 12 53 52 83 (169) 200 15 197 Chemical 160 23 65 181 18 Recycling (67) 140 100 59 12 103 7 95 86 58 66 34 47 24 11 12 0 2 2000 2001 2002 2003 2004 2005 2006 ( ð plan ) ‰ PWMI 13
Recycling under C&P Recycling Law Large Scaled Chemical Recycling Facilities ( á complied with C&P recycling law, 2005) 15 Facilities: Sapporo Plastic Recycling Monomer 2 Liquefaction: 12,000t Blast furnace 3 Coke oven 5 Nihon Steel (Muroran) Gasification 3 Coke Oven: 20,000t Liquefaction 2 (Total 470 Kt/y) JFE Steel (Chiba) Rekisei Oils (Niigata) Gasification: 20,000t Liquefaction: 6,000t Nippon Steel (Kimitsu) JFE Steel (Fukuyama) Coke Oven: 20,000t Blast furnace/Coke Oven : 40,000t JFE Steel (Kawasaki) Ube ( _ Ube) 40,000t/30,000t Gasification: 30,000t Blast furnace/Coke Oven Nihon Steel (Yahata) Showa Denko ( � Kawasaki) Coke Oven: 20,000t Gasification: 60,000t Nihon Steel (Oita) PET Reverse(Kawasaki) Cokes Oven: 25,000t Monomer B to B: 22,000t Teijin Fiber (Tokuyama) Kobe Steel (Kakogawa) Nihon Steel (Nagoya) Monomer B to B: 62,000t Blast furnace: 10,000t Coke Oven: 50,000t PWMI 14
Recycling under C&P Recycling Law Breakdown of Usage of Recycled Product by Mechanical Recycling Miscellaneous daily Industrial parts goods & Others 6% 1% Gardening & Agriculture 2% Building & Pallet Construction 31% 7% Electricity/ Communication 8% Plastic Bar, Survey & board Resin Boundary Marker/ 20% 13% Imitation wood post Source : õ Japan Container and 12% Package Recycling Association PWMI 15
Recycling under C&P Recycling Law Wood Plastic Recycled Composites JIS (Japanese Industrial Standards) for WPRC was set in April 2006 (JIS A5741:2006). Accelerated growth of application/demand is expected. Wooden waste + Compounding Crushing Molding Applications: Exteriors with Plastic waste + resistance to decay, weathering, (PE, PP, PVC, PS, and termite attack ABS) Additives Source: HP of Ecowood Co., Ltd. HP of Misawa Homes Co., Ltd. PWMI 16
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