Innovative Acrylic(PMMA- Polymethyl methacrylate) Recycling Technology Complying with Regulations

Project Information

P2L

Grant agreement ID: 856103

DOI

10.3030/856103

Project closed

EC signature date 28 January 2019

Start date 1 February 2019

End date 31 July 2019

Funded under

• INDUSTRIAL LEADERSHIP - Innovation In SMEs

Total cost

€ 71 429,00

EU contribution

€ 50 000,00

Coordinated by

M-D2 MUHENDISLIK DANISMANLIK INSAAT TAAHHUT IC VE DIS TICARET LIMITED SIRKETI
Türkiye

Periodic Reporting for period 1 - P2L (Innovative Acrylic(PMMA- Polymethyl methacrylate) Recycling Technology Complying with Regulations)

Reporting period: 2019-02-01 to 2019-07-31

Summary of the context and overall objectives of the project

Problem:

The global consumption of MMA is around 4.2 M tonne/year. Global waste PMMA production is expected to be 800,000-1,000,000 tonne/year (20-25% MMA consumption). It is increasing in parallel to the PMMA production. MMA consumption in Europe is around 1 M tonne/year. 200,000 tonne/year waste can be recovered in a mid to long term by creating an economy of 1400 M€ and 1700 new jobs. P2L generates solutions for both economic and social problems by decreasing waste accumulation in developed countries.

PMMA is used in TV screens to LED lights, automobile backlights to aeroplane windows, mobile phone screens to laptop/tablet screens and many more in optical or surface/coating solutions. The increasing PMMA consumption (forecasts project 100% increase till 2030) and its wide usage(~3.36 M tons annually), may result in a catastrophic waste problem globally since China decided to stop importing waste plastics in 2017. China started this waste ban in 01.01.2018 and this situation hit especially the developed countries and waste crises became catastrophic. Therefore developing a safe, economical and environmentally friendly recycling method becomes more urgent and more important each day.

Recycling PMMA in developed countries like European Countries, USA and Japan are very limited due to the occupational safety and health regulations with environmental concerns. Conventional PMMA recovery includes molten lead baths that create serious health threats and environmental pollution. Because of the drastic consequences on workers’ safety and environmental, this method is not applicable in Europe and developed countries for many years. Like most of the other plastic wastes, PMMA wastes were being collected and sent to China until 2018. Today the world needs a new plan for recycling waste PMMA.

Solution:

P2L technology is not only a MMA production plant with high purity by recycling PMMA wastes, but also it is the safest, most eco-friendly, and lowest power consuming one.

Commercialization of P2L; energy-efficient, safe and eco-friendly PMMA recycling plants will be built worldwide and waste PMMA will be converted to higher value R-MMA product in Europe. This innovative recycling technology will also be adapted for other waste plastics in the near future.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

M-D2 focused on the following specific objectives for the feasibility study:
1) Market analysis to determine the dynamics of the market and decide the target markets.
2) Benchmarking to take place in the target markets among competitors.

MMA prototype was produced. Samples prepared from this product were sent to Birleşik Akrilik and Akrifen Akrilik. These companies are important customers of MMA in Turkey has approved the products. Customers have stated that they do not see such a quality recycling product in the sector and they want to buy it in high amounts. In addition, this product has been mentioned to Arkema company, Arkema company has requested us to collaborate on this product.

3) Legal Search for regulations and barriers.

We are aware of the legal regulations and barriers in Turkey. We agreed with Dr. Paolo Arcelli to learn about the legal requirements in the EU, Italy, and Germany. He is a director of Business Insight Division Plastic Consult S.r.l. He will send us a detailed report about it.

4) Determining the risks and opportunities.
5) Prepare a sustainable commercialization plan with feasible market entry strategy.

Coaching Plan
Interviews with investors and investor presentations
Purchase of MMA Market report

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

P2L was selected amongst the top Seal-of-Excellence European startups to be presented at the Innovative Enterprise in Bucharest. As a result of this activity, 3 investors have contacted us. They are presented with terms and conditions of cooperation and are expected to return.
MMA waste is a global problem. To solve this problem, 13 companies have formed a joint consortium. The R&D activities will be carried out until 2023, and this consortium has allocated a budget of € 6.6M for these activities (www.mmatwo.eu). We have completed the R & D activities with a much less budget with our pilot facility. We received this confirmation from the customers to whom we sent prototype products.

P2L is a superior PMMA pyrolysis technology and game-changing invention that promises a very high return on investment. As seen in the comparison table there is no better alternative neither in technology nor in commercialization in the market. On top of it, the output product of P2L does not contain any traces of heavy metal, unlike the conventional Attempts to find such an eco-friendly recycling method has continued for many years. These methods have not been commercialized due to their poor end product qualities, operational difficulties, and high energy consumption.
Inductively Heated Pyrolysis Method - P2L
The inductively heated reactor is a cylindrical non-magnetic body wrapped with induction coils around. A ribbon mixer along with the reactor mix continuously the metal direct heater particles with PMMA chips. PMMA particles are heated up fast and precisely for the optimum pyrolysis. The mixer provides uniform distribution.
The unique method of P2L, direct heating of magnetic particles via induction field increases energy efficiency up to 85%(Typical efficiency value for induction systems) with high purity. The process is energy efficient and clean by inductive heating of particles that eliminates the circulation of hot inert gas. P2L produces a monomer yield ranging between %87-%93 (Pure monomer recycled from acrylic waste). The rest is obtained as a mixture of various chemicals and carbon black. This mixture is also used in the plant as a heat source. So the system is defined as lossless.
Why now?: The China ban beginning in 2018, upcoming trade wars, developing environment regulations as a result of climate change and the technological evolution are the reasons for commercialization of P2L right now. M-D2 started R&D of technology-based in P2L in the beginning of 2017. Past and future developments & milestones can be seen in the Table 2 till the end of 2020. The prototype is validated in the lab at the beginning of 2018.

In this picture we show the prototype distilation unit used in our project.

PMMA polymerise from the prototype product

In this picture we show the laboratory distilation unit used in our project.

In this picture we show the pyrolysis unit prototype used in our project.