Move 4earth® project

OBJECTIVES OF THE PROJECT

Move4earth LogoClick to enlarge

The demand for recycled plastics is growing in all European markets:

  • Good environmental performances 
  • Lower dependency to fossil resources which prices are rather volatile and constantly increasing.

Regulations are pushing for more recycling and less landfilling in Europe. The directive 2000/53/EC sets a 85% target by 2015 for reuse and recycling of post consumer cars, but no sustainable solutions exist for airbags.

Industrial objectives

1. Reach target throughput under stable processing conditions

  • Validation of elementary operations
  • Validation of entire continous process at nominal throughput

2. Produce a high quality recycled polymer

  • Purified
  • Stable properties near to traditional Technyl® polymer


Environmental objectives

1. Prove environmental efficiency through Life Cycle Analysis

  • Minimize energy and water consumption

2. Validate value-creation option for the by-product (Silicon)

  • Up to 15% of the flow

INDUSTRIAL PROCESS

move4earth-fabrics 

PROJECT FIGURES & STEPS

  • More than 70% of car airbags are made of silicon-coated polyamide in Europe
  • More than 125,000 tons of end-of-life wastes deposit worldwide
  • Up to 10,000 tons of post-industrial airbag wastes per year in Europe

- September 2012: Project launching
- 2013-2014: Process engineering and validation
- 2015: Demonstrator construction
2016: Industrial demonstration of the recycling process completed and Move 4earth® Unit Grand Opening
- 2017-2018: Ramp-up and optimization of the recycling process

MAIN ACTIONS

The main actions of the project can be summarized as follows:


Design and build the demonstrator

  • COMPLETED

Move 4earth process

Validate and optimize the recycling process

  • COMPLETED — Process validation   
  • COMPLETED AND SUCCESSFULL — Ramp-up and optimization  
  • Production running according to design capacity 
  • A new range of product has been created for commercial applications in automotive, building and construction, and consumer appliances — CLICK HERE & HERE

Demonstrate valorization streams for By Products (i.e. silicone coating residuals)

  • COMPLETED
  • Energy valorization stream demonstrated and implemented
  • Alternative material recovery solutions demonstrated and implementation started. The silicone residue can be used to produce booster additives for polyolefins
  • Other material recovery streams can be explored — INTERESTED? ASK YOUR SAMPLE HERE!

Assess the environmental impacts of the process and the benefits of the newly created recycling stream based on a Life Cycle Analysis methodology

  • COMPLETED
  • A "cradle to gate" Life Cycle Analysis performed by Solvay shows that TECHNYL® 4EARTH compounds using recycled PA66 polymer from the Move4earth technology offer very significant reductions of environmental impacts compared to equivalent virgin materials
  • Summary LCA REPORT available for download — CLICK HERE

Confirm the potential use of the Move 4earth®technology to recycle various types of technical textile wastes

  • COMPLETED — Beside post-industrial silicone coated fabrics, the project has been focusing on post-consumer airbag cushions and PA/elastane fabrics

    • Several tons of post-consumer airbags have been processed with no difficulties. The technology is ready for this type of waste, however challenges remain in order to organize large scale collection networks and also secure a proper decontamination of the fabrics after explosion of the airbag module.

Move 4earth Airbags Waste



    • Trials done with PA/Elastane fabrics have failed. The technology is not suitable for this type of waste.


Move 4earth Elastane Fabrics


Future perspectives

  • Scale-up projects and collaboration with key players of the automotive value chain to explore future post-consumer airbag collection and recycling streams. Possible closed loop business models
  • Design for recycling projects aiming at redesigning some technical textiles (currently not recycled) with PA66/silicone fabrics in order to make them recyclable with the Move4earth technology

INTERESTED? — CONTACT US HERE



MOVE 4EARTH® IN A NUTSHELL

logo-life  Move4Earth® is supported by European Commission Life+ programme