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Carpet Recycling PowerPoint Presentation

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Slide 1 - Recycling polypropylene carpets In association with Carpet Recycling UK Funded by Envirolink Northwest Jane Gardner
Slide 2 - Presentation Summary Project aims Types of carpet Current recycling routes Demonstration trial results Economic assessment Project conclusions
Slide 3 - Project aims To develop a process for recycling polypropylene carpets To assess commercial viability of the process
Slide 4 - UK Carpet sustainability Over half a million tonnes/year of carpet enters the UK waste stream Recycling rate currently less than 2% Carpets have high carbon footprint due to use of virgin materials – big sustainability gain if recycled
Slide 5 - Carpet materials Polymers: Polypropylene (PP); Polyester/Polyethylene terephthalate (PET); Nylon; Chalk-filled elastomers; Natural fibres: Wool; and Hessian/Jute.
Slide 6 - Types of carpet - woven Made by weaving the carpet pile into warp fibres with a loom http://www.armelcarpet.com/images/WovenDiag.gif Warp fibres can be polyester or PP, whilst the pile tends to be PP
Slide 7 - Types of carpet - tufted Pile fibres attached to a backing layer http://www.fine-flooring.com/TuftedDiagA.gif Pile fibres - wool or PP Elastomer compound bonds fibres to the backing layer Second backing layer – made from hessian or manmade fibre such as PP
Slide 8 - Carpet recycling initiatives America: CARE – Carpet America Recovery Effort – founded 2002 Europe – late 1990’s: RECAM - Recovery of Carpet Materials CRE - Carpet Recycling Europe Polyamid 2000 in Germany UK – late 2000’s: Greenback Recycling Reeds Carpets – exhibition/temporary floors
Slide 9 - Existing end markets Typically low value Equestrian surfaces – additive to sand based all weather surfaces Plastic cannot be recovered once used as equestrian surface Other applications: Horticultural market http://www.equestriansurfaces.co.uk/aboutus.html
Slide 10 - Axion recycling trials NIR ID sorting Size reduction Screening Extrusion
Slide 11 - Size reduction Granulation 15mm screen Alternative options: Shearing Shredding
Slide 12 - Granulated PP carpet
Slide 13 - Screen to remove dust, fines High energy flip-flop screen 12x12mm deck Alternative technique dry cleaning
Slide 14 - Screening results Oversized fraction cleaner and less dusty than feed High yield loss - due to screen size of granulator (15mm) relative to flip-flop (12mm) For 12mm flip-flop - granulator needs to be 20-25mm For 15mm granulator screen - flip-flop needs to be 6-8mm
Slide 15 - Lab scale extrusion Sorted PP carpet samples: Post industrial Post consumer Material prepared for extrusion by partial melting then granulation
Slide 16 - Extrusion problems Initial batch of carpets could not be extruded Presence of un-melted fibres made from different polymers – nylon and PET Problem due to different types of carpet – woven and tufted Second batch of tufted carpet processed successfully
Slide 17 - Moulded polymer Post industrial – injection moulding applications Post consumer – lower grade injection moulding, for example plant pots and buckets
Slide 18 - Physical properties
Slide 19 - Commercial assessment Feed stock in Northwest - estimated at over 6,000 tonnes per annum meeting specification of: Tufted construction; Positively identified PP pile and backing fibres; Dry and with no heavy contamination; Suitable for manual handling.
Slide 20 - Overall recycling scheme
Slide 21 - Processing option 1
Slide 22 - Processing option 2
Slide 23 - Payback calculation
Slide 24 - Technical conclusions Straight forward processing route: Rigorous PP identification and sorting Size reduction Screening Extrusion Finished PP: Good physical properties, Suitable for use in medium to low grade applications, Eg injection moulded plant pots
Slide 25 - Commercial conclusions Critical success factor - correct identification of all polymer fibres within the carpet Economics of the recycling process are promising Next step: Commercial scale testing
Slide 26 - Axion Consulting Tudor House Meadway Bramhall SK2 2DG 0161 426 7731 info@axionconsulting.co.uk