LIFE
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<strong>LIFE</strong> ENVIRONMENT |<br />
<strong>LIFE</strong> and the circular economy<br />
Recycling airbags<br />
Airbags are made from composite<br />
materials that are difficult to recycle.<br />
As a result, 9 000 tonnes/yr of waste<br />
generated by the European airbag industry<br />
currently goes to landfill. The<br />
Move4earth project (<strong>LIFE</strong>11 ENV/<br />
FR/000748) was set up to take advantage<br />
of growing demand for the<br />
polyamides used in airbags. It is demonstrating<br />
a novel process for recycling<br />
and reusing polyamides from siliconecoated<br />
airbag cushions, to deliver a<br />
new high-grade material (PA 6.6) with<br />
comparable properties to nylon (polyamides<br />
in the marketplace).<br />
“The purpose of our innovation is to<br />
find a technical solution to separate<br />
the two different components of the<br />
fabric: the main fibre component and<br />
the coating,” says project director<br />
Richard Bourdon. “The aim is to bring<br />
something new to the industry by being<br />
able to achieve such a separation.”<br />
The technology combines mechanical<br />
and chemical processes, including fine<br />
grinding followed by a chemical activation<br />
stage. “Chemical activation is the<br />
use of a chemical to cut the adhesive<br />
between the fibres and the coating, so<br />
that they can be completely separated<br />
by centrifugal washing. This is very<br />
new, and there is a patent registered<br />
for the process,” he says.<br />
A pilot plant has been built at project<br />
beneficiary Solvay’s facility in Gorzów<br />
(Poland), which will be operational by<br />
late 2016. According to Mr Bourdon,<br />
after demonstrating the process with<br />
airbags, Solvay plans to apply it to other<br />
post-consumer textile wastes (e.g.<br />
polyamide/elastane fabrics).<br />
Economic viability will depend on several<br />
factors. “Post-industrial waste already<br />
has a commercial value and you<br />
pay more, but post-consumer waste<br />
represents an added-value to industry<br />
or society,” explains Mr Bourdon. “In<br />
general, beside this aspect, you have<br />
several key drivers. The first one is<br />
capital investment. Move4earth would<br />
not have been possible without <strong>LIFE</strong><br />
funding because it is the first pilot project<br />
and the technology is not yet optimised,<br />
and it would have to be much<br />
bigger to be commercially viable. Then<br />
a second very important driver is the<br />
cost to collect and prepare the waste<br />
before it can be recycled for such a<br />
process.”<br />
Major environmental benefits could<br />
result from the recycling of polyamides.<br />
Provisional data from Solvay’s<br />
experts (yet to be independently certified)<br />
suggest that for the production<br />
of one tonne of PA 6.6, the carbon<br />
footprint is reduced (26%), and less<br />
energy (47%) and water (69%) are<br />
consumed, due to the waste being diverted<br />
from incineration and landfill.<br />
PA 6.6 is an environmentally-friendly<br />
alternative to nylon made from virgin<br />
materials. “We are looking at all<br />
markets selling nylon compounds,”<br />
says Mr Bourdon, “The biggest one is<br />
the automotive market, then you have<br />
electrical and electronic devices, and<br />
many consumer goods, because nylon<br />
can be a good material with very high<br />
flame-retardant properties.”<br />
Waste management<br />
The impact of <strong>LIFE</strong><br />
The <strong>LIFE</strong> pÒrogramme has funded around 100<br />
projects addressing waste recycling for different<br />
waste streams, such as glass, plastic,<br />
packaging, textiles, construction and demolition<br />
waste (CDW), municipal solid waste<br />
(MSW) and organic waste. A number of recent<br />
projects have developed technologies that not<br />
only recycle but also upcycle (improving the<br />
properties of the recycled material), thus ensuring<br />
a high-quality end product. In combination<br />
with product design that facilitates recovery<br />
and separation, this will help increase the amount<br />
of recycled material used in production (closing<br />
material loops).<br />
Projects have developed technologies to produce<br />
new high-value products from a range of waste<br />
materials, including specialist textiles, wood and<br />
rubber, household plastics and hazardous waste.<br />
The Move4earth project has demonstrated a solution<br />
for separating composite materials, which is a<br />
particular challenge (see box).<br />
Another innovative <strong>LIFE</strong> project carried out the<br />
first European demonstration of the use of plastic<br />
polymer waste in asphalt mixes for roads. POLYMIX<br />
(<strong>LIFE</strong>10 ENV/ES/000516) designed and validated<br />
four asphalt mixes, incorporating polyethylene (PE),<br />
polypropylene (PP), polystyrene (PS) and end-oflife<br />
tyres (ELT). These were used to construct sections<br />
of a demonstration stretch of heavily-used<br />
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