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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 />

49

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