PROJECT DESCRIPTION
BACKGROUND
The EU Waste Framework Directive (2008/98/EC) and the Packaging and Packaging Waste Directive (94/62/EC) (amended by Directive (EU) 2018/852) place emphasis on reuse and recycling of plastic waste. It is calculated that in the EU27 in 2008, 25 million tonnes of plastic waste were produced, including 12.1 million tonnes (48.7%) of stored waste. While the target was to recover 12.8 million tonnes (51.3%), just 5.3 million tonnes (21.3%) were recycled. According to estimates for 2015, the level of mechanical recycling will increase to 30% (from 5.3 million to 6.9 million tonnes). But waste storage and incineration with energy recovery will remain the dominant method of waste management. In Poland in 2012, only 25% of plastic waste was recycled, 17% was used for energy recovery and 58% of plastic waste was deposited in landfills. The growth of plastics production is proportional to gross domestic product, and as a result the general growth of plastic waste production in 2008-2015 is expected to reach 5.7 million tonnes (23%). This increase is mainly due to a 24% increase in the size of the packaging sector and is consistent with an overall Europe-wide increase in this waste. With no improved methods of product design and better waste management, the amount will continue to increase in the EU along with production.
OBJECTIVES
The overall objective of the LIFE EMU-NEW project was to develop innovative technology for producing bitumen emulsion modified with recycled polymer and mineral nanofibers, which can be used in the production of asphalt. The technology had previously been studied and verified by the beneficiary at laboratory scale, and key process parameters had been established. The aim was to test this technology in a pilot plant consisting of four phases: 1. modified asphalt production station; 2. nanofibres production station; 3. waste polymer liquefying, purifying and modification station; and 4. emulsion production station. In addition, the project aimed to improve the eco-efficiency indicator by lowering the material-consumption rate of the production process. The plant was expected to require less asphalt for the production of asphalt emulsions, because these nanoemulsions achieve additional durability by being reinforced with nanofibres from selected polymer waste and mineral nanofibers.
RESULTS
The LIFE EMU-NEW project developed a prototype installation for producing bitumen emulsion modified with waste polymers and mineral nanofibres that can be used in the production of asphalt for road construction or repair.
Technological changes were made to the production process for asphalt, to enable waste polymers to be utilised, along with the design and construction of new process control apparatus. The innovative technology consisted of four lines: i) a processing line for modified asphalt; ii) a unit for melting, cleaning and modifying waste polymers; iii) a unit for nanofibres production; and iv) a unit for asphalt emulsion production modified with nanofibres.
The beneficiary assembled the prototype installation, and validated its operation through a series of tests. The tanks of the prototype were filled with bitumen, where they were mixed with the modified waste polymers, to produce the modified asphalt and modified asphalt emulsions.
Testing of the installation showed that the prototype achieved a production of modified asphalt of 0.35 m3/h. The beneficiary concluded from the initial tests that the use of nanofibres in the production of modified bitumen was unprofitable. Therefore, testing and development continued only for bitumen emulsion modified with waste polymers.
Bitumen modified with waste polymers produced in the prototype installation was used to build a 5 km section of local road. This allowed testing of the new products under real conditions. Testing showed that the properties of the modified asphalt and asphalt emulsions meet the requirements of materials used in road construction. These results were confirmed by the National Road and Bridge Research Institute - the state laboratory certifying materials that can be used for road construction. This opened the possibility of the commercial use of asphalt and asphalt emulsions produced in the prototype installation.
Long-term environmental benefits will depend on the launch of this technology at full industrial scale. In this case, the amount of plastic waste re-used will increase to around 1 190 000 kg/year. This will reduce the consumption of crude oil used for bitumen production, by replacing about 9% of this raw material with plastic waste. It should also reduce the greenhouse gas emissions connected to bitumen production.
The construction of the prototype created 16 jobs, and its testing and operation in the coming years should create an additional 5 jobs. The beneficiary will continue testing, with the goal of achieving the optimal amount and type of plastic waste to produce modified bitumen to make asphalt for roads. The fine-tuning of the technology should also reduce production costs for modified bitumens, thus ensuring economic competitiveness on the market for this type of product.
Implementing the project’s technology will increase the use of waste plastic. This may help improve the functioning of companies operating in this sector (collection and re-using of plastic waste), and also reduce the cost of waste management. As the technology is replicated to build roads, new asphalt emulsions will be more durable and resistant to meteorological conditions. This will reduce the cost of road maintenance.
