Cradle-to-cradle recycling for PLA RENCONTRE TECHNIQUE & SCIENTIFIQUE- Strasbourg May 2012
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Cradle-to-cradle recycling for PLA
RENCONTRE TECHNIQUE & SCIENTIFIQUE- Strasbourg May 2012
www.loopla.org 2
FUTERRO: Company details
Missions:
Offering a new production technology for PLA.
Supply lactic-acid based products (oligomers,
lactide and PLA) for the polymer and commodity
markets.
Developing partnerships in new applications
Licensing its PLA-related technologies
Pilot Unit
(Escanaffles, Belgium)
Inaugurated in April 2010
Futerro is a joint venture established in September 2007
between two major actors in their respective field
www.loopla.org 3
World market ranking
# 2 for Lactic acid & derivates
Partners: GALACTIC
• A leading producer of lactic acid and lactates
• All products natural and biodegradable, based on
natural fermentation of sugar or corn glucose
• Production: 95.000mT installed capacity of lactic
acid & lactates
• Over 335 employees (Europe, China & USA)
• R&D: 10% of staff
Pharma & Personal Care
Feed Bioplastics Green Chemistry Food Additives
Main markets:
www.loopla.org 4
Partners: TOTAL Petrochemicals
A worldwide presence with almost 93 000 employees
Upstream: Exploration & Production
5th ranked integrated, listed international oil & gas company
Production 2010: 2.38 million boe/d*
Proven reserves at end-2010: 10.7 billion boe
Interests in 9 liquefaction plants and 6 regasification terminals
Supply-Marketing
European leader in marketing and sales of lubricants,
carburants, solvants and specialties
Network: 17,490 service stations
Refining – Chemicals
24 refineries: 2.38 million boe/day oil and gas production
Refining, shipping and trade of petrol products
A world-class integrated player in Petrochemicals, but also in
Fertilizers and Chemical Specialties (rubber processing,
adhesives and electroplating applications).
The 3 main business segments
World market rankings
# 2 for polystyrene
# 5 for polypropylene
# 3 for styrene
# 6 for propylene * boe/d: barrel of oil equivalent per day
www.loopla.org
“…. One of the main expected achievements of the Strategy was to make progress towards
an EU recycling society seeking to avoid waste and use waste as resource…”
“… Greater use of renewable resources is no longer just an option, it is a necessity. We must
drive the transition from a fossil-based to a bio-based society with research and innovation as
the motor… "
5
A word about Sustainability
Sustainable development « Development that meets the needs of the present without compromising the
ability of future generations to meet their own needs », Brundtland report, 1987
Commissioner for Research, Innovation and Science
Máire Geoghegan-Quinn
Strategy for Sustainable Bioeconomy in Europe
Thematic Strategy on the Prevention and Recycling of Waste
EUROPEAN COMMISSION
www.loopla.org 6
Sustainability: PLA proposals
Shift from hydrocarbons to
carbohydrates
Match between resources
use and their replenishment
Resources
Renewal
Environmental
Impacts
CO2 balance (material)
Additional End-Of-Life
options
PLA proposals
Sustainability Issues
www.loopla.org 7
PLA Waste: End-of-life Options
INCINERATION MECHANICAL
RECYCLING
INDUSTRIAL
COMPOSTING
CHEMICAL
RECYCLING
Each option has its pros and cons!
Waste origin will determine the best end-of-life scenario
www.loopla.org 8
Classic Lifecycle for PLA
PLA
Manufacturing
Lactic Acid
producers Sugar Lactic acid
Incineration Composting Landfill Consumers
PLA producers
Mechanical
Recycling
www.loopla.org 9
PLA
Lactic Acid
producers Sugar Lactic acid
The Chemical Recycling shortcut
Consumers
PLA producers
Manufacturing
www.loopla.org
PLA production
10
O
OHHO
Cyclization Ring Opening
Polymerization
O
O
O
O
H
CH3 H
CH3
L-Lactic
Acid
High MW
PLA
Lactide
O
OHHO
n
Saccharose
Fermentation
www.loopla.org 11
Type of PLA Waste Recovery
• Post-Industrial Regular streams
• Post-Consumer Various contaminants
• Closed-loop Easier waste recovery
www.loopla.org 12
LOOPLA® : Recycling process
Grinding Depolymerisation
Residues removal Purification step
Incoming waste Waste particles Crude solution
Non-PLA
fraction Purified Lactic Acid
CYCLISATION RING OPENING POLYMERIZATION PLA PRIME GRADE
www.loopla.org 13
Contaminants behavior
Input Output Residues
PLA Exhibition
carpet
Lactic Acid
Lactic Acid PLA Cards
Latex + dyes
Plasticizers, TiO2, Inks, etc.
www.loopla.org 14
Key advantages LOOPLA® process
1. Comparing to traditional L.A. route • Lower chemicals needed • Lower energy consumption
www.loopla.org 15
Key advantages LOOPLA® process
1. Comparing to traditional L.A. route • Lower chemicals needed • Lower energy consumption
2. Robust process • Very high recovery of PLA content • A large amount of typical contaminants
like sand, other plastics and additives can be removed
www.loopla.org 16
Key advantages LOOPLA® process
1. Comparing to traditional L.A. route • Lower chemicals needed • Lower energy consumption
2. Robust process • Very high recovery of PLA content • A large amount of typical contaminants
like sand, other plastics and additives can be removed
3. Cradle-to-cradle benefit
• Recycling process is practically endless • Quality recycled PLA = original PLA
Collection
LOOPLA
Manufacturer
www.loopla.org 17
Key advantages LOOPLA® process
1. Comparing to traditional L.A. route • Lower chemicals needed • Lower energy consumption
2. Robust process • Very high recovery of PLA content • A large amount of typical contaminants
like sand, other plastics and additives can be removed
3. Cradle-to-cradle benefit
• Recycling process is practically endless • Quality recycled PLA = original PLA
4. Environmental impacts
• Avoiding further land use, sugar production and partial lactic acid production (enhancing LCA profile)
www.loopla.org 18
A comparative LCA study: Traditional vs. Recycled way
Lactic Acid
Sugar Beet PLA waste (100% PLA)
IDENTICAL SCOPE
« PRIME » ROUTE RECYCLING ROUTE
www.loopla.org 19
COMPOSTING INCINERATION ANAEROBIC
DIGESTION
CHEMICAL RECYCLING
Gross Energy Requirement
Lactic Acid Production: Traditional vs. Recycled way
Politecnico di Torino, Italy
Materia Nova, Belgium Cut-off waste evaluation
www.loopla.org 20
COMPOSTING INCINERATION ANAEROBIC
DIGESTION
CHEMICAL RECYCLING
Global Warming Potential
Politecnico di Torino, Italy
Materia Nova, Belgium
Lactic Acid Production: Traditional vs. Recycled way
www.loopla.org 21
Targets with LOOPLA®
• Mapping and characterization of
PLA waste streams
• Designing an industrial recycling
unit (increased scope of
acceptable streams)
• Use of recycled lactic acid as
raw material for PLA production
www.loopla.org 22
Challenges of PLA collection
Global production volume of PLA resin still low (vs. oil-based polymers)
Some properties of PLA to be enhanced for high volume markets (eg: barrier
properties) > volumes in post-consumer streams still marginal
PET-focus recycling schemes; PLA need additional sorting capabilities
New End-Of-Life options for PLA waste (further segmentation of waste)
Plastic waste collection varies from country to country
Increased understanding required from recyclers/final consumers
www.loopla.org 23
Merci pour votre attention
From Waste to Prime.
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