Plastic process scrap recycling
Currently most plastic recycling in the UK is of 'process scrap' from industry, i.e. polymers left over from the production of plastics. This is relatively simple and economical to recycle, as there is a regular and reliable source and the material is relatively uncontaminated. Process scrap represents some 250,000 tonnes of the plastic waste arisings in the UK and approximately 95% of this is recycled. This is usually described as reprocessing rather than recycling.
Post-use plastic recycling
Post-use plastic can be described as plastic material arising from products that have undergone a first full service life prior to being recovered. Households are the biggest source of plastic waste, but recycling household plastics presents a number of challenges. One of these relates to collection. With over 20 million UK households, kerbside recycling systems are required to regularly collect relatively small quantities of mixed plastics from a large number of sources. Currently, just over half of local authorities offer some form of plastic bottle collection service, and only an estimated 15% of UK households are served by kerbside collections that include plastic bottles. The densest network of plastic bottle collection schemes is found in the South and East of England and the Midlands. East Anglia, Wales, Scotland and Northern Ireland have the least coverage. There are approximately 4,000 plastic bottle collection banks in the UK.
RECOUP (RECycling Of Used Plastics Limited) undertakes an annual survey of plastic bottle recycling activity in the UK. Results of the most recent survey indicate that an estimated 24,000 tonnes of plastic bottles were collected in 2003. However, this still only amounts to approximately 5.5% of all plastic bottles sold.
Mechanical recycling
Mechanical recycling of plastics refers to processes which involve the melting, shredding or granulation of waste plastics. Plastics must be sorted prior to mechanical recycling. At the moment in the UK most sorting for mechanical recycling is done by trained staff who manually sort the plastics into polymer type and/or colour. Technology is being introduced to sort plastics automatically, using various techniques such as X-ray fluorescence, infrared and near infrared spectroscopy, electrostatics and flotation. Following sorting, the plastic is either melted down directly and moulded into a new shape, or melted down after being shredded into flakes and than processed into granules called regranulate.
Chemical or feedstock recycling
Feedstock recycling describes a range of plastic recovery techniques to make plastics, which break down polymers into their constituent monomers, which in turn can be used again in refineries, or petrochemical and chemical production. A range of feedstock recycling technologies is currently being explored. These include: pyrolysis, hydrogenation, gasification and thermal cracking. Feedstock recycling has a greater flexibility over composition and is more tolerant to impurities than mechanical recycling, although it is capital intensive and requires very large quantities of used plastic for reprocessing to be economically viable (e.g. 50,000 tonnes per year).
Plastics recycling in the UK
In 1998, a pilot feedstock recycling plant went operational at BP's Grangemouth site in Scotland, with a capacity to process 400 tonnes of mixed plastic waste per annum. A feasibility study into its viability concluded that a 25,000 tonnes per annum plant could be supported from the area's municipal waste sources alone.
In 1991, LINPAC Plastics Recycling opened a unique plant with the ability to recycle post-consumer polystyrene products. The plant, based in Allerton Bywater, West Yorkshire, has a capacity of over 14,000 tones per year, which is set to increase to 25,000 tonnes per year by 2005. The plant is able to process fast food boxes, meat trays, egg cartons, yoghurt pots, vending cups, and a range of other polystyrene products. In addition, the plant processes a range of polyethylene and polypropylene goods, such as bottles, crates, sheets, caps, pipes and fibres.