The document discusses the collaboration between MBA Polymers and EMR to develop a supply cycle for recycling car plastics, focusing on producing high-quality green plastics from automotive shredder residue (ASR). Key processes include pre-processing to separate plastics from contaminants, and advanced manufacturing techniques to ensure the final products have virgin-like quality. MBA Polymers aims to address global OEM demands for consistent, high-quality plastics while promoting environmental sustainability.

1. Car-Plastics meets its Re-Maker
Developing a Supply Cycle for Car Plastic
Chris Slijkhuis

2. Creating a Global Footprint to produce Green Plastics
UK
California Austria
Guangzhou

3. Announcement of new MBA Polymers Plant in the UK
MBA Polymers strengths
European Metal Recycling strengths
Non- Remove Global
Shredding Remove Plastics
Item collection and Decon- ferrous remaining Grade Com- sales,
and ferrous remaining type
aggregation tamination concen- non-target sorting pounding marketing
recovery metals sorting
tration materials & support
one Key element MBA Polymers
is Pre-processing
EMR and MBA Polymers decided to create teamwork to Close the Loop for Plastics

4. Teaming up to get from Supply Chain to Supply Cycle……..
Design For the Environment
Manufacturing Delivery
Operations
Procurement
Integrated Customer
C
Supply
Chain
Use / Service
Recycling
Take-back
Take back
De-pollution
Waste Minimisation

5. Pre-processing ASR is key to liberate the plastics
De-Pollution
Shredder Ferrous-Metals
Non-FE Size reduction,
Non-Ferrous-Metals liberation and
Separations
separation
Pre-Processing ASR to further Separate Plastic/non-Plastic
Mixed Plastic Rich Materials

6. View on the ASR Raw Material
Feed stock
Feed-stock for plastic material pre-processing
pre processing

7. The key challenges with ASR plastics
Low quantity and composition of t g t plastics
L tit d iti f target l ti
• Most ASR contains less than 30% plastics
• Much of which small amounts of many specialty plastics
• Upgrading is required to eliminate most non-plastics
Removal of non-thermoplastic contaminants
non thermoplastic
• Rubber
• Wood
• Fabric, foam & other “fluff”
• Dirt, glass & stones
Large variety of many different plastics
Painted/coated plastics
And other surface contamination like dirt, fluids, etc.
IARC

8. Composition of a typical ASR fraction
Plastics and
Rubber
R bb Fines
Fibers, foam,
stones,
rubber etc.

9. What is necessary to produce 1 ton of plastics?
approx. 900 liter crude oil
Approx. 9 tons ASR
approx. 14.000 kWh
approx. 950 kWh
pp
OR
<10% of the water consumption
<10% of the energy consumption
gy p
2-3 kg reduction of CO2 emissions per kg of recycled plastic

10. So there is a good incentive to recycle plastics
Plastics and
Rubber
Fines
Fi
Fibers, foam,
, ,
stones,
rubber etc.

11. Pre-processing principles
Sourcing & Goods In
Goods-In
• Material Handling / Logistics
• Assaying / Material Analysis
Pre-Processing
• Cleaning material of minerals
• Glass, stones, dust
• Eliminating organic fractions
• such as wood, rubber, foam, textiles
, , ,
Size reduction to a standard particle size
Concentrating target plastics to some 80% by weight
l b h

12. View on Pre-processed Plastic Rich Material
From feed stock to pre processed plastics
feed-stock pre-processed

13. View on Pre-Processing non-plastic byproducts
Foam Rubber and wood
concentrate
Dirt and other fluff Example of
metals recovered
from SR
Potential feed-stock for Recycling & Thermal Recovery

14. Some 80 % Target Plastics after pre-processing
Other non-plastics,Fines & Dust, 0.2%
5.7%
Wires/Electronics, 0 %
i l Wood, 0.7%
i 0.7%
Foam/Fluff, 1.3% PP, 16.2%
Rubber, 7.0%
un-ID'd plastics, 0.8%
trace plastics, 2.8%
POM, 1.4%
PPO-filled, 1.6%
PPO-filled 1 6%
PC-PBT, 1.9%
ABS, 15.8%
PA-filled, 1.9%
PC ABS,
PC-ABS, 2.0%
PPO, 2.1%
PVC, 2.6%
ABS-FR, 3.3%
PA-filled, 5.0% PP-filled, 14.0%
HIPS, 6.5%
PE, 6.5%

15. High Tech Separations of the Plastics
Cleaning plastics
• Closed circuit water treatment
• A wide variety of separations
• Stringent Quality & Process Control
High-Tech Seperations
• Obtaining PP,
Obt i i PP ABS & (HI)PS flakes
fl k
• In several grades
Resulting in pure flakes of PP, HIPS and ABS
• The flakes are the raw material for quality plastics

16. View on purified filled PP Flakes

17. View on purified ABS flakes

18. View on purified HIPS Flakes

19. Blending, Extrusion and Compounding
Blending the flakes
• Creating homogenous products
g g p
Extruding into pellets
• High tech compounding lines
• To create purified resins (virgin like properties)
Final products Quality Control
• Stringent quality control as practiced in other MBA Polymers plants
• MFI (Melt Flow Index) – viscosity at given temperature and shear
rate
• Izod (Impact Strength Measurement)
• Tensile Strength

20. PP products made from ASR in comparison
MBA MBA OEM B OEM B
Property OEM A
PP-A PP-B PP-A * PP-B *
Melt flow rate (g/10 min)
2.2 3.7 ------ >7.0 >7.0
@ 230/2 16
230/2.16
Tensile strength at yield (MPa) 19.3 20.5 >21 >14.0 >14.0
Tensile modulus (MPa) 741 1040 ------ ------ ------
Tensile l
T il elongation at b k (%)
ti t break 43.4
43 4 35.0
35 0 ------ >50
50 >35
35
Flexural strength (MPa) ------ ------ ------ >8.8 >16.7
Flexural modulus (MPa) ------ ------ >870 400-600 500-700
Notched izod impact (J/m) 465 190 >100 >400 >300
0.89-
Specific gravity 0.935 0.954 <0.95 <0.95
0.92
* Properties were measured using comparable ISO standards. Results have been converted to
ASTM units where appropriate (e.g. notched izod impact), and should be nearly identical with
ASTM test results.

21. Why a High-Tech Global Footprint.......
Electronics & Automotive OEM’s are Global and
they demand:
• Global Supply of Plastics
• Virgin-like quality of the tech plastics they use
• Large dependable and consistent volumes
Large,
• Consistent technical specifications
• A global answer to their Waste Plastics
• Reliable service levels
for new products
to become designed in
in........

22. Products – ABS, PS, PP as pellets & compounds

23. Consistent Properties with MBA Polymers’ Resins
10,0
MF (200°C/5k in [g/10min]
9,0
90 MFR Analysis Type MBA PS 3 30
a ys s ype S 3130
8,0
kg)
7,0
6,0
FR
5,0
4,0
40
0 20 40 60 80 100 120 140 160
Samples

24. MBA Polymers’ Resin Advantages
High quality resin with stable properties
• ISO 9001:2000
• RoHS certification
Custom properties for custom applications
p p pp
100% Post-Consumer Recycled Content
Green “Cl
G “Cleantech” image and responsibility
h” i d ibili
Saving large amounts of energy
Low CO2 Emissions
Resins with Environmental Awareness

25. The World Economic Forum recognized MBA Polymers
Technology Pioneer 2006
The criteria for becoming this
WEF recognition as Tech Pioneer are:
Innovation
Potential Impact
Proof of Concept
Growth and Sustainability
Leadership
L d hi
Status

26. Our president and founder puts his teeth into ASR plastics....

27. and is determined not to loose them...
Thank you very much for your attention