FRP (Fibre Reinforced Plastic) Recycling - Manitoba - PowerPoint PPT Presentation

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FRP (Fibre Reinforced Plastic) Recycling - Manitoba

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Alternative recycling method is required. Several unsuccessful attempts at ... Total of 52 recycled samples obtained for MB (and a further 44 from SIBC) ... – PowerPoint PPT presentation

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Title: FRP (Fibre Reinforced Plastic) Recycling - Manitoba


1
FRP (Fibre Reinforced Plastic)
Recycling - Manitoba 13 May 2009
2
  • Overview
  • Background Information
  • Recycling Processes for FRP
  • Recycled Material Properties
  • Possible Markets
  • Business Model Options
  • Conclusions
  • Next Steps

3
  • Background Information
  • FRP (Fibre Reinforced Plastic) scrap produced in
    large quantities across Canada
  • Estimated that 700 800 MT/yr in Manitoba
  • FRP trim and scrapped parts from production
  • FRP in MB is glass reinforced thermosetting resin
  • Cannot be melted and reformed as with
    thermoplastics
  • Alternative recycling method is required
  • Several unsuccessful attempts at developing
    recycling systems, based on two models
  • Regional recycling networks
  • In-house recycling

4
  • Background Information
  • Interest in finding solution for recycling from
  • Industry
  • Government
  • General public
  • Potential economic and green benefits from
    recycling FRP
  • Smaller environmental footprint
  • Lower landfill costs
  • Lower transportation costs to Landfill
  • Possible revenue opportunities
  • Project started in August 2008 to study potential
    FRP recycling solutions for Manitoba and Southern
    Interior BC

5
  • Background Information
  • FRP Recycling Project Milestones completed to
    date
  • Carried out research into FRP Recycling
    N.America/Worldwide
  • Polled all FRP producers in regions, to obtain
  • Scrap Material Type and Quantity
  • Cost of processing and landfilling scrap
  • Obtained buy-in to the project from 9 of the 10
    largest scrap producers in the regions
  • Collected, sorted and ground their highest
    volumes of scrap
  • Developed a business model and marketing database
  • Analyzed all information and recommended further
    testing
  • Currently Organizing testing for next stage of
    project

6
  • Recycling Process
  • Recycling Methods Available
  • Combustion
  • Fluidised Bed Process
  • Pyrolysis
  • Sub-Critical Water Hydrolysis
  • Chemical
  • Mechanical

7
  • Recycling Process
  • Down-selected Mechanical Processing
  • Most readily available process
  • Most cost effective to start up and run
  • Some proven use in FRP industry
  • Can be considered more friendly to the
    environment
  • No chemicals
  • No high temperatures
  • Low energy requirements

8
  • Recycling Process
  • Mechanical Processing Equipment

9
  • Recycling Process
  • 2 equipment suppliers selected
  • Fibre Recovery Products, Winnipeg
  • Seawolf Design, New Smyrna Beach, Florida
  • 13 samples of the highest volume scrap collected
  • 2 grades of fibres obtained from grinding
  • Coarse material using 1/4 screen
  • Fine material using 1/16 screen
  • Total of 52 recycled samples obtained for MB (and
    a further 44 from SIBC)
  • All samples were logged, photographed and bagged

10
  • Recycling Process
  • Mechanical grinding with screens

Recycled Material
Scrap Material
1/16 Screen
Fine Grind
Coarse Grind
1/4 Screen
11
  • Recycled Material Properties
  • Sorted by Type

Discrete Fibres
Non-discrete Fibres / Low Quality Fibres
No Fibre Content
Scrap collected represents over 80 of FRP waste
generated by MB companies
12
  • Markets

Thermoplastics
Cement Products
Thermoset FRP
LEED Building Products
Asphalt
13
  • Markets
  • Other specific uses for recycled FRP

Parking stall curbs Construction
barricades Temporary traffic barriers Vinyl
siding additive Tooling material
additive Insulation material Flow medium Aerating
material Patio stones Garden ornaments
Countertops Noise absorption material Viscosity
modification of polymer mixes Hardwearing
additive for road paint Recyclate and natural
fibre mat material Blast medium for removing
paint Wall/floor coverings Plastic wood
products Roofing shingles Roofing asphalt additive
14
  • Markets
  • Cement Additive
  • Benefits
  • Proven plastic shrinkage reduction in Europe
  • Large/very large volume market and varied
    products
  • Encapsulates material so safer for future
    generations
  • Can handle varied/imperfect materials and
    filler/resin/fibre mix
  • Competes with value added products that charge a
    premium
  • Risks
  • Cement degradation due to alkaline attack on
    glass fibers ? possibility of leaving voids over
    time
  • Supply too low for certain markets
  • Need to certify material before any widespread use

15
  • Markets
  • Thermoplastic Additive
  • Benefits
  • Short fibres provide slight reinforcement
  • Thermoplastic market is mostly unreinforced ?
    property gains
  • Process improvements demonstrated in Europe
  • Medium to large market and varied products
  • Can use short fibers and filler at high
    loadings (30)
  • Low risk of adverse chemical reactions with
    recycled material
  • Risks
  • Surface quality of thermoplastic is reduced ?
    limits market
  • Lower value use of material than cement

16
  • Markets
  • Preferred Applications

Cement
Thermoplastics
Flow Medium
17
  • Markets
  • Scrap Quantities by Market (Metric Tonnes/Year)
  • Note Quantities assume 50 of recyclate is pure
    fibre ? remaining is resin/filler

18
  • Business Model Options
  • Assumptions for setting up FRP Recycling
    Mechanism
  • Manufacturing companies are willing to pay the
    recycling company equivalent external costs per
    MT (transportation and tipping fees)
  • Material price (conservative) and volumes
    (min/max) used are per table below
  • Loan servicing and financing have not been taken
    into account
  • Amortization, interest and taxes have not been
    analyzed

19
  • Business Model Options
  • Standalone Recycling Facility

Thermoplastic Company
FRP Company

Short Fibre/Filler
Shredder / Grinding Equipment
Standalone Recycling Facility


Holding Bin
Long Fibre/Filler

Cement Company
20
  • Business Model Options
  • Standalone Recycling Facility

CM Contribution Margin CMR Contribution
Margin Ratio
21
  • Business Model Options
  • Standalone Recycling Facility

Breakeven MT gt 450 MT / year
Breakeven Revenue 550,000
22
  • Business Model Options
  • Shared Recycling Facility

Thermoplastic Company
FRP Company

Short Fibre/Filler
Shredder / Grinding Equipment
Shared Recycling Facility


Holding Bin
Long Fibre/Filler

Cement Company
23
  • Business Model Options
  • Shared FRP Recycling Facility

CM Contribution Margin CMR Contribution
Margin Ratio
24
  • Business Model Options
  • Shared FRP Recycling Facility

Breakeven MT 345 MT / year Breakeven
Revenue 281,484
25
  • Business Model Options
  • Preferred Option Shared recycling facility
  • Offset low volumes/downtime with another business
    that has facility space
  • Existing recycling company
  • Manufacturer
  • Low set-up costs for someone to start FRP
    recycling
  • Possible government grants/subsidies
  • Potential for high revenue if material can be
    sold as a value added product
  • Reinforcement material
  • Green material

26
  • Conclusion
  • FRP Recycling is technically feasible
  • Proven uses in Europe
  • However, technical risks ? testing required to
    verify
  • FRP Recycling has a market
  • Cement and thermoplastics are preferred
  • However, more markets are possible in the future
  • FRP Recycling has a feasible business model
  • Facility likely needs to be shared with another
    business
  • However, good revenue stream could be possible

27
  • Next Steps
  • Testing
  • Initial testing with cement and thermoplastics
    Jun/July 2009
  • Increase awareness of FRP Recycling
  • Obtain support from industry/government/academia
  • Develop relationships inside and outside Manitoba
  • Investigate post consumer scrap (boats, canoes,
    tanks, etc)
  • Develop business model and marketing data further
  • Carry out a technology demonstration Sep/Oct
    2009
  • Develop Commercialization Plan for recycling
    Dec 2009

28
CONTACT INFORMATION
THANK YOU Will Darracott M.Eng Engineer,
Composite Applications EIT
CIC Contact Information
Website
www.compositesinnovation.ca
Email
wdarracott_at_compositesinnovation.ca
Tel No. 204-262-3400 x208
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