FIRST BRAZILIAN PVC CONGRESS

2. FIRST BRAZILIAN PVC CONGRESS Sao Paulo, June 6-8, 2005 Helmuth Leitner

3. NEW TECHNOLOGIES • Vinyloop® • Stigsnaes feedstock • Sumitomo feedstock • Clean inceration Neutrec® - Resolest® • Ecoefficiency

4. THE PROCESS OF VINYLOOP

6. VINYLOOP FERRARA • Production in 2003 was 2199 to • Plan for 2004 was 7500 to • But there were many technical problems • And the unit was used as a pilot for new material streams • We didn’t reach this target • But the production reached 10-13 batches/day (nominal = 14) • The monthly production reached 460 to of treated material

7. VINYLOOP FERRARA • There were very specific problems: • The quality of the industrial water • The quality of the raw material (waste) with its low PVC content • The variation of the quality of the waste • The high amount of rubber • The extraction of parts of rubber by the solvent • And more problems with the filter

8. THE REALITY TODAY (MARCH 2005) • % PVC content > 75 • Input/batch 3,75 to • Batch/day 8,5 • Stream factor 90 % • CAPACITY 10500 to/y

9. VINYLOOP FERRARA • Markets: Through our contacts, we see a potential market for Ferrara in the range of 1900 to R-PVC/month

10. PRODUCTS One major application: FOILS

11. CABLES AND HOSES

12. VINYLOOP FERRARA • The lead stabiliser was a major point of discussions with our clients • Most cable producer refuse a lead containing compound (even if it’s THEIR LEAD !) (Europacable!)

13. VINYLOOP FERRARA • The technology is now under control • The final investment is above 14 M € to be compared to the 8.5 M € • As much as economically feasible, the Ferrara plant was used to test the new residues streams and the next ideas to improve the process • Tests have been successfully performed on roofing and flooring residues • The next projects will benefit from the lessons learned in Ferrara

14. VINYLOOPOTHER PROJECTS • Vinyloop Bernburg project cancelled  economically not feasible • Replaced by Vinyloop Dreux: high public funding was the reason; but was only a promise and reduced finally to less of 50 % initially promised • The most promising economic situation for Vinyloop is at the moment  Japan

15. SCOPE OF JAPAN PROJECT • Scope of the revised project – start up 2006 • One line de 18 kt using the 2nd generation process cables, noubi (agricultural) et wallpaper • Investment of a pre-treatment in 2 phases • Budget for a filtration 3rd generation integrated in the business plan (2008)

16. STIGNAES FEEDSTOCK

17. PRE-TREATMENT OF PVC-WASTE AND MIXING OF FEED TO REACTOR • Shredding • Washing, sorting and • granulation • Plast-Sep sorting plant specially designated to sort cable waste or other metal-containing PVC waste • PVC-granulates is mixed with lye and softened water in mixing tank

18. KEEP THE EARTH GREEN !

19. DE-CHLORINATION BY HYDROLYSIS • Waste from mixing-tanks is charged via heat exchanger system • Reaction start temperature 225°C • Exothermic reaction gives temperatur rise to 260°C • Chlorine level input 30%, output < 100 ppm • Outlet via heat exchanger system

20. AFTER-TREATMENT • Salt water from hydrolysis plant is adjusted to pH 7 • Solids are sent to post heating • Brine is nano filtrated • Salt brine is crystalized under vacuum • Pure, dry salt!! Model photo

21. POST HEATING • De-chlorinated solids from hydrolysis are dried • The material is heated up to 600°C and carbonhydrates evaporates • Solid residue with coke and minerals • Oil product: 1 ppm chlorine

22. THE PVC PROCESS

23. SYNERGIES BETWEEN THE CARBOGRIT- AND PVC PROCESS

24. SUMITOMO FEEDSTOCK • Process on industrial scale in Japan • Working at 1400 ° • Gives high output of Syngas and HCl • The only problem: it needs a high gate fee

25. END OF LIFE • Clean Incineration : NEUTREC® + Resolest® but • also MVR (Hamburg) which produces HCl as a product

26. RESOLEST® PLANT IN ROSIERES-AUX-SALINES« REFIOM » VALORISATION • Located in France close to SOLVAY soda ash plant • Capacity of 50 000 tons residues per year : neutralisation residue coming from municipal solid waste incineration plants using sodium bicarbonate • Combination of 2 processes : • SOLATECH® (WATCO - REVATECH) • NEUTREC ® (« brine ») • Solidified residues are landfilled in « class 1 » landfill • Purified brine is sent by pipe-line to SOLVAY soda ash plant of Dombasle

27. OVERVIEW

28. CONCLUSIONS • NEUTREC® process offers the possibility to recycle the sodium residuals, for example in : • the SOLVAL unit in Rosignano (Italy), since 1998 • the RESOLEST unit in France in 2002 • Residual Sodium Chemicals are purified and recycled in a SOLVAY soda ash plant, as a substitute for a raw material used for the soda ash production

29. CONCLUSIONS • As opposed to lime processes, which produce high quantities of calcium salts which are difficult to recycle, Neutrec strongly reduces the quantity of ultimate solid residues. • NEUTREC® process is therefore completely integrated with Sustainable Development, thanks to its efficiency and to the valorisation

30. ECO EFFICIENCY

31. ENVIRONMENTAL ASSESSMENT • The study focuses on the following environmental criteria: • Primary energy consumption (non renewable resources) • Global Warming Potential (GWP 100 years) • Acidification Potential (AP) • Characteristic emissions on inventory level, e.g. dioxins (PCDD), lead (Pb) • Hazardous waste, municipal and inert waste, wastewater.

32. NET RECOVERY

33. ECO EFFICIENCY

34. ECO EFFICIENCY

35. « PVC » ELEPHANT Big Animal » Big Market Old Species » sustainable High Value Not very fast but powerful Ecoefficient Specific Abilities Attacked by people who want to get the value public

36. Thank you for your attention !