The Best Practice on the
Reduction of Plastic Waste
Development of New Recycling System
for Used Plastics
Kazuyuki Hirabayashi
Showa Denko K.K. (Japan)
About Showa Denko K.K.
Showa Denko Group (at December 2005)
• Number of Group Companies 155
• Net Sales (Consolidated) 740.7 billions of yen
• Operating Income (Consolidated) 52.1 billions of yen
• Net Income (Consolidated) 7.6 billions of yen
• Number of Employees (Consolidated) 11,166
• Major products
Petrochemicals Sector (Olefins, Organic chemicals, Polyolefins, Plastic
products)
Chemicals Sector (Chemicals, Gases and Specialty chemicals, Specialty
resins)
Electronics Sector (Hard disks, Compound semiconductors, Rare earth
magnetic alloys, Specialty gases for semiconductor processing,
Electroceramic materials, Fine carbons and other electronic materials)
Inorganic Materials Sector (Ceramics and Carbons)
Aluminum Sector (Aluminum metal, Sheets, Extruded products, Fabricated
products, building materials, engineering and others)
About Showa Denko K.K.
Domestic Facilities
Omachi Plant
Hikone Plant
Kitakata Plant
Shiojiri Plant
Higashinagahara Plant
Tokuyama Plant
Oita Complex
Oyama Plant
Chiba Plant
Chichibu Plant
Sakai Plant Yokohma Plant
Kawasaki Plant
About Showa Denko K.K.
Global Subsidiaries
Overseas Production Companies
P.T. Showa Esterindo Indonesia
Taiwan Showa Chemicals Manufacturing Co., Ltd
Showa Denko Carbon, Inc.
Lianyungang Zaoling Abrasives Co.Ltd.
SHOTIC Europa -Industria de Aluminio Lda.
SHOTIC (Singapore) Pte. Ltd.
Showa Aluminum Corporation of America
Showa Aluminium Czech s.r.o.
Showa Aluminum (Thailand) Co., Ltd.
P.T. Showa Aluminum Indonesia
Showa Aluminum Manufacturing Philippines Corporation
Baotou Showa Rare Earth Hi-tech New Material Co., Ltd.
Showa Denko (Dalian) Co., Ltd.
Showa Denko HD (Malaysia) Sdn. Bhd.
Showa Denko HD (Singapore) Sdn. Bhd.
Activity Guidelines regarding
Responsible Care (Showa Denko, 1995)
(1) In the total life cycle of chemical substances, we should make our best effort to review
and improve the business activities from the viewpoint of ensuring safety / health and
protecting the environment.
(2) In the manufacturing activities, we should make best efforts to reduce the burden on
the global environment not only by conventional approaches to environmental
protection but also by promotion of raw material switching, energy conservation,
wastes reduction and recycling, and reduction in the release of chemical substances.
(3) In new product development, new business development and establishment /
increase / renewal of facilities, we should make our best effort to ensure safety /
health and protect the environment.
(4) We should promote R & D and technology development which will contribute to the
improvement of safety / health and protection of the environment. We should also
promote marketing of alternative or new products.
(5) We should investigate the influences of the products and materials we handle on
Safety / Health / Environment, and encourage our employees to have deep
knowledge related to safe use and handling, and also provide our customers with
such information.
(6) In overseas business activities, technology transfer and international trading of
chemical products, we should give full consideration to ensuring safety / health and
protecting the environment.
(7) We should comply with the international rules and domestic laws and regulations and
make our best effort to cooperate with the relevant international organizations and
foreign / domestic administrative agencies.
(8) We should positively participate in various activities related to environmental
protection and make our best effort to communicate with society and communities
for better understanding and trust.
Showa Denko Kawasaki Plant
P roducts flow in the Kaw asaki
P lant
Trichloroethylene/Tetrachloroethylene
H ydrogen Fluoride
Special gases
ＨＦＣ-１３４a・H FC -125
H ydrogen
com m on salt
C hlorine
Epitaxial w afer
※ ＊
Fluorine
ＦＣー１４・ＦＣ－１１6
H ydrochloric aide
H igh purity gas for sem i-conductor processing
Special clean gas
Sodium hypochlorite
C austic Soda
H igh purity N H 3　C H 2　H br and B C L3　gas and clean cylinders for them
※
Sodium bisulfite
N itrogen
V apor G row n C arbon
Fiber
＊
A ir
O xygen
Liquefied sulfurous acid
A rgon
A m m onium thiosulfate
C lean S
Surface treatm ent
P ollution preventive
cylinders/devices
A bsorption decom position and recycling
C ivil Engineering
M aterials
APS
C osm etics and w hitening agent
N itrous oxide
W aste plastic
H ospitane C
Fodder addotoves
DM OD
P hotographic chem icals
A ir
A lanine
Food additive/V B m aterials
Liquid A m m onia
D ecom posed gas
Tow n gas
A m m onia
N aphtha
C arbon dioxide
ELA SLEN
W ire coating/P V C R ubber m odifier
＊
＊
P ropylene
SH O P R EN E
C hloroprene rubber
A crylonitrile
G lycine
Food additive
D erivative
m aterials
by products
ED TA
C helating agent
G LD A
B iodegradable chelating agent
isophthalonitrile
A grichem ical m aterials/D aconyl
PAS
Terephthalonitrile
C ataplasm
R aw m aterials for agricultural chem icals
Independent pow er produce
＊
＊
＊
＊
Keihin Industrial C om plex
APM
C osm etics and w hitening agent
D /L C ystine
C osm etics and high grade perm anent w ave
H YD
Food additives and A spartam e
BHD
P hotographic chem icals
B EH
P hotographic chem icals
SH O D EX
C olum n for high-speed liquid
chrom atography
Chemical Recycling
of Waste Plastic
for Ammonia Production
Waste Plastics recycling and disposal in Japan
Material recycling(15％)
<Showa Denko Planｔ>
Chemical recycling(3％)
Recycling
(55％）
Perfect
Gasification
Chemical recycling
Liquefaction
Blast furnace feed
Waste
Plastics
(10mil
ton/year)
Coke oven feed
Thermal recycling(37％)
Disposal
(45％)
Incineration without
power generation(18％)
Landfill(28％)
Recycling as chemical
raw materials
（H2,CO,CO2,Cl,S, etc.）
Location
凡 例
Pre-treatment
gasification
計画地
Ammonia plant
Kawasaki
plant
Ｎ
SHOWA DENKO PLANT
(1) Scale
・Waste plastics
195T/D
・Ammonia
175T/D
・Hydrogen
346,000Nm3/D
(2) Plant plot
(1)Pre-treatment plant
Showa Denko K.K. kawasaki plant
Area ； ６,５９０ｍ２
(2)Gasification plant
Showa Denko K.K. kawasaki plant
Area ； ７,４００ｍ２
Waste Plastics treatment process flow
Pre-treatment plant
Gasification plant
Waste
Plastics
Storage
Lawtemperature
gasifier
Crusher
Hightemperature
gasifier
Separator
Metal
Recovered
Metal
Metal
Feeder
Extruder
Scrubber
Slag
treatment
Slag
Construction
materials
CO shift
Neutralization
NaCl
Caustic soda
raw materials
De-sulfur
S
Sodium sulfite
(NaHSO3)
Gas
Compressor
CO2
Dry ice
Liquefied CO2
H2
Ammonia
RPF
RPF ( Recycle Plastic Fuel )
H2 business
Process Flow to produce Ammonia Gas from
Waste Plastic
Waste
Plastics
Pre-treatment
plant
Component of Waste Plastics (Example)
195T/D
C
H
O
N
wt% 74.2 10.7 6.3 0.4
T/D 144.7 20.9 12.3 0.8
Gasification
Scrubber
Cl
2.5
4.9
Boiler
S Metal Slag Total
0.1 2.9 2.9 100
0.2 5.6 5.6 195
CO shift
De-sulfur
Gas
Compressor
Law-temperature
High-temperature
Slag
treatment
Metal
Recovered
Metal
5.8 T/D
Slag
Construction
NaOH
S
NaCl
materials
Caustic
Soda
Sodium sulfite
(NaHSO3)
5.8 T/D
8.2 T/D
0.65 T/D
Dry ice
Liquefied CO2
430T/D
CO2
H2 business
H2
Ammonia
175T/D
Japanese Containers and
Packaging Recycling System
Flow of Containers and Packaging Recycling
Ｓｅｌｅｃｔｉｖｅ ｄｉｓｃａｒｄ
Selling container or packaging
Selective
collection
Consumers
Payment of fees
for recycling
Payment of recycling fee
Ｍｕｎｉｃｉｐａｐａｌｉｔｉｅｓ
(pressing
and stock)
8%
The Japan Containers
and Packaging
Recycling Association
Payment for
recycle fee
Bidding
Showa Denko
Transport
Recycler
Specified business
entities
Manufacturing or
92% selling companies
Plastic containers
Pre-Treatment process
Ｗａｓｔｅ Ｐｌａｓｔｉｃ
Crasher
Extruder
RPF (Recycle Plastic Fuel for Gasification)
Gasification Plant
Gasification Plant
Gasification plant outline
Law-temperature gasifier
(fluidized-bed type)
High-temperature gasifier
(swirling type)
Silo
O2 +
Steam
RPF
From Pre-treatment plant
Scrubber
CO shift
De-sulfur
O2 +
Steam
Caustic soda
raw material
Quench
H2
CO2
Sodium sulfite
raw material
Metal
Slag
Perfect Chemical Recycling (zero-emission)
Thank You