EUU, Alm.del - 2022-23 (2. samling) - Supplerende svar på spørgsmål 49: Spm. om, hvilke interessenter, virksomheder mv. ministeriet har været i dialog med i forbindelse med ønsket om at indføre et forbud imod anvendelsen af PFAS, til miljøministeren, kopi til udenrigsministeren

Europaudvalget 2022-23 (2. samling)
EUU Alm.del
Offentligt

Final Report

Fluoropolymer waste in Europe 2020

–

End-of-life

(EOL) analysis of fluoropolymer applications, products and associated waste streams

Elaborated for

July 2022

EUU, Alm.del - 2022-23 (2. samling) - Supplerende svar på spørgsmål 49: Spm. om, hvilke interessenter, virksomheder mv. ministeriet har været i dialog med i forbindelse med ønsket om at indføre et forbud imod anvendelsen af PFAS, til miljøministeren, kopi til udenrigsministeren

Main objective and conclusion

Main objective

The report ‘Fluoropolymer

waste

in Europe 2020‘

was initiated to provide detailed

information about the end-of-life fate of fluoropolymer applications, products and

associated waste streams. The report has qualitative and quantitative character.

Conclusion

▪

In 2020, around 40 kt of fluoropolymer materials were sold to EU

fluoropolymer product manufacturers. 23.5 kt of fluoropolymer waste were

collected, either in commingled waste streams or partly in source separated

waste fractions.

Almost 84% of all fluoropolymer applications were incinerated at the end of

their life in energy recovery (MSWI ~72%) or thermal destruction (metal

recycling ~12%) processes. 13% of the collected fluoropolymer waste was

landfilled and around 3% was recycled.

This report delivers an in-depth description on how and where fluoropolymer

containing products and corresponding wastes are generated and what happens to

the collected fractions at the end of their life. Quantities of fluoropolymer waste are

included as far as possible based on an end-of-life fluoropolymer (and relevant

fluoropolymer containing products) lifetime assessment model.

A correlation matrix between fluoropolymer applications and the penetration of

relevant waste streams (by mass in kt and %) was developed and the waste

treatment route (recycling, energy recovery and landfill) is shown.

▪

Identification where fluoropolymer applications and products end up at the end

of their life including re-use of processing scrap and recycling of either pre- or

post-consumer fluoropolymer waste (either mechanical, e.g., conversion into

PTFE micro powders or chemical) in the EU.

Identification of major waste streams in which the fluoropolymer applications

and products end up incl. total volumes in kt as well as the penetration of

fluoropolymers (in kt and %) in the EU.

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Fluoropolymer waste in Europe 2020

▪

End-of-life fluoropolymer production and processing equipment used for

different industrial segments, such as Chemical, Energy, Food & beverage,

Pharma and Semiconductor accounted for the major share of the total

fluoropolymer waste quantity collected (~13 kt).

The overall fluoropolymer penetration in all waste streams was less than

0.01% by weight. In comparison, plastics in total accounted for about 4.8% of

the total waste collection volume (excl. mineral fractions).

Chemical recycling of fluoropolymer waste offers the opportunity to produce

virgin-like fluoropolymer raw materials for the production of goods and

products without quality limitations. However, building robust supply chains for

large-scale and economical feasible recycling processes is one of the most

important issues to be addressed in the coming years.

▪

Conversio Market & Strategy GmbH

About Conversio

Conversio employees specialize in b2b research and consultancy and work in the field of plastics production, processing and waste management more

than 25 years. In 2018 Conversio conducted a fluoropolymer analysis focusing on potential recycling opportunities on behalf of the PlasticsEurope

Fluoropolymer project group.

In March 2022, Conversio was commissioned to conduct a new report with focus on the end-of-life scenario of fluoropolymer products and applications

by the industry association Pro-K.

Christoph Lindner

+49 (0) 6021 / 9219991

[email protected]

Hendrik Beylage

+49 (0) 6021 / 9219996

[email protected]

Julia Hein

+49 (0) 6021 / 9219997

[email protected]

Conversio Market & Strategy GmbH

Am Glockenturm 6

63814 Mainaschaff

Germany

+49 (0) 6021 1506 700

[email protected]

www.conversio-gmbh.com

2022-07-19

Fluoropolymer waste in Europe 2020

Agenda

Introduction and project frame

Management Summary

Fluoropolymer products & applications

Fluoropolymer waste

In-depth waste analysis

Circular economy approach

Appendix

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Fluoropolymer waste in Europe 2020

List of abbreviations

ABS

AFRA

ASR

B&C

C&I

CAPA

CCL

CPI

ELV

EOL

ETFE

FEP

FKM

HVACR

LCA

Acrylonitrile butadiene-styrene copolymer

Aircraft fleet recycling association

Auto shredder residue

Building & construction

Commercial & industrial

Centre for aviation

Copper cladded laminates

Chemical, process & industrial

End-of-life vehicle

End-of-life

Ethylene tetrafluoroethylene

abbreviated for EU27 + Norway, Switzerland, UK

Electric vehicle

Fluorinated ethylene propylene

Fluor-rubber/caoutchouc

Fluoropolymers

Heating, ventilation, air conditioning, refrigeration

kilo tonnes

Life cycle analysis

LCV

MSW

MSWI

PCB

PCTFE

PE-HD

PFA

PTFE

PVC

PVDF

PVF

RDF

SLF

SRF

WEEE

Light commercial vehicle

Municipal solid waste

Municipal solid waste incineration

Printed circuit boards

Polychlorotrifluoro ethylene

High-density polyethylene

Perfluoroalkoxy

Polypropylene

Polystyrene

Polytetrafluorethylene

Photovoltaic

Polyvinyl chloride

Polyvinylidene fluoride

Polyvinyl fluoride

Refuse derived fuel

Shredder-light fraction

Solid recovered fuel

tonnes (metric)

Waste from electrical and electronic equipment

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Fluoropolymer waste in Europe 2020

Initial situation, frame and target

Fluoropolymers are high-tech polymers with fluorine atoms directly attached to their carbon backbone. They are plastics which are virtually chemically

inert, non-wetting, non-stick, and highly resistant to temperature, fire and weather. These polymers are used various applications and different industries,

e.g., transportation, chemical process industry, (consumer-)electronics, pharmaceutical industry.

Since the discovery of PTFE in 1938, fluoropolymers have become critical components in numerous technologies, industrial processes and everyday

applications. Their use is widespread what makes it a challenge to evaluate the full range of applications and shares (by weight) in associated waste

streams.

Compared to other plastics, fluoropolymers are usually used as part of other applications and represent around 0.1% of the total plastics processing

demand of the EU countries.

Nevertheless, these plastics, with their unique properties, are high-quality materials where other materials are either inferior or simply do not offer

adequate substitutes.

The data and information presented in this report reflect the willingness of the fluoropolymer industry to provide additional end-of-life information on

fluoropolymer applications and products in response to requests from EU legislators.

2022-07-19

Fluoropolymer waste in Europe 2020

Project frame

–

Regional focus

EU27+3 countries (abbreviated by the term “EU” in this report)

Analyzed types of fluoropolymers within this study

▪

Non-melt processible fluoroplastics, such as PTFE, represent the main focus of the study*

Thermoplastics such as PVDF

Other ETFE

PFA

PCTFE

FEP

▪

Elastomers (vulcanized, rubbers) such as FKM

The distribution of FP types shown in the graph on the right is

unique for the EU market and differs with regard to individual

FP shares in other regions such as North America.

The share of FEP materials used for Local Area network (LAN)

cabling (fire resistance) for housing applications in the US is for

example significantly higher compared to the EU market.

PTFE

56%

Total 40 kt

of fluoropolymers

converted into

products by EU

converters

12%

PVDF

FKM

* almost 90% of all fluoropolymer (and elastomer) processors process PTFE materials for the manufacturing of their products

2022-07-19

Fluoropolymer waste in Europe 2020

Project frame

–

Important applications and origin of fluoropolymers waste

Fluoropolymers provide specific physical and chemical characteristics for wide range of different processes, components and final product applications.

The widespread use of fluoropolymers in various applications and industry segments makes it a challenge to evaluate the full extent of fluoropolymer

waste origins and corresponding penetration of major waste streams.

This study will focus on six major industries where the use and waste generation of fluoropolymers is considered to be particularly significant.

Within each of the key sector, the specific uses (“applications / products”) of fluoropolymers will be identified. For each key

sector (based on the

corresponding relevant products and applications), this report shows the quantity of fluoropolymers put on the market, different lifetime scenarios and

end-of-life treatment of fluoropolymer waste.

The study will cover the following industry segments:

Automotive

Aerospace

Electronics & semiconductors

Chemicals (CPI)

Medical & pharma

Other (e.g., cookware)

2022-07-19

Fluoropolymer waste in Europe 2020

Project frame

–

Fluoropolymer products and applications in different industry segments

–

Automotive, Aerospace, Electronics and semiconductors

Major fluoropolymer applications and product illustrations I

Industry segment

Automotive

Major applications

Excl. vehicles >3.5 tonnes and other transport segments such as

trains and ships

▪

Battery binder, e.g., PTFE and PVDF in EVs

▪

Oxygen sensor parts (wire insulation, grommet and sleeve)

▪

Seals & bearings; fuel and brake system components

▪

Ventilation of electronic housings, gear boxes, lamp housings and

batteries using porous PTFE.

Large and small commercial and private aircrafts, aerospace

communication technology and associated aerospace periphery

▪

Cable insulation (tape winding)

▪

PTFE tubing for fuel system & hydraulics

▪

Spring reinforced seals for hydraulic systems

▪

Bearings

Electronic devices of any kind incl. semiconductor manufacturing,

communication technology, HVACR, consumer electronics

▪

PCB (printed circuit boards), CCL (copper cladded laminates)

▪

Associated products such as smartphones, tablets, notebooks

▪

Cable insulation, containers, pumps and other (ultra-pure) liquid

handling equipment, e.g., in chip manufacturing plants

▪

Seals, valves, tapes used in various HVACR applications

Fluoropolymer product illustrations

Aerospace

Electronics &

semiconductors

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Fluoropolymer waste in Europe 2020

Project frame

–

Fluoropolymer products and applications in different industry segments

–

Automotive, Aerospace, Electronics and semiconductors

Major fluoropolymer applications and product illustrations II

Industry segment

Chemicals (CPI)

Major applications

Industry segments chemical, process & industrial incl. petrochemical

and energy applications

▪

Pipe liners (e.g., PTFE); lining of valves, pumps (e.g., PFA)

▪

Bellows (flexible vessels), lining of distillation columns, containers

for storage and transportation

▪

Hoses, seals, films etc. used for renewable energy applications

▪

Gaskets, filters, membranes, flue gas coolers, etc.

Medical applications and equipment of any kind, pharmaceutical

processing equipment

▪

Tubing (e.g., PTFE)

▪

Components for syringes & diaphragms

▪

Components and products for microinvasive surgery

▪

Implants, stents

Fluoropolymer product illustrations

Medical & pharma

Other (e.g., cookware)

Coated consumer & professional cookware, coated sheer metal

applications such as building cladding, industrial food & beverage

processing equipment, lubricants, architectural and wearable textiles,

defence & military applications, renewables like PV and wind power

▪

Coating of pans, pots and trays, sheet metal building cladding

▪

Textiles (wearable) and coated (glass) fabrics (architectural)

▪

Applications not listed in the other industry segments

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Fluoropolymer waste in Europe 2020

Project frame

–

Fluoropolymer waste in major waste streams

–

residential, electronics and automotive

Corresponding waste streams I

Waste stream

Residential household waste and

municipal waste generated by

commercial activities

Definition

Residential waste collected by or on behalf of municipalities (household

waste, excluding all waste fractions which are collected separately) as

well as municipal waste generated by commercial activities and other

sources, whose activities and waste are similar to those of households

(commerce, trade, small business, institutions and municipal services),

collected by or on behalf of municipalities

Waste from electrical and electronic equipment (commonly referred to

as WEEE) from households and commercial and industrial (professional

WEEE) activities; collected on behalf of municipalities, retailers and

private organizations

Plastic waste through dismantling of end-of-life vehicles (ELVs) and

plastic residual fractions as part of metal shredding processes in auto-

shredder residue respectively shredder-light-fraction

Fluoropolymer end-of-life applications

▪

Other (e.g., cookware)

Electronics (usually smaller end-of-life

consumer electronics)

Electronic waste collection (WEEE)

▪

Electronics & semiconductors

ELV incl. auto-shredder residue (ASR)

▪

Automotive

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Fluoropolymer waste in Europe 2020

Project frame

–

Fluoropolymer waste in major waste streams

–

commercial and industrial

Corresponding waste streams II

Waste stream

Commercial & industrial

Various waste streams collected (mostly)

on behalf of private waste management

companies respectively dedicated waste

services for specific industries.

▪

Description of relevant fluoropolymer waste

streams as far as possible (e.g., extraction

of fluoropolymer pipe liners from chemical

process equipment)

Definition

Commercial & industrial waste generated, collected, sorted, treated and

disposed of by private waste management companies, e.g., waste

services for chemical and pharmaceutical industries, energy sector

(power plants), food and beverage industry, building and construction

applications, medical applications, aerospace applications, car repair

shops, as well as all remainder products and applications not collected

in residential household waste and municipal waste generated by

commercial activities, WEEE and ELV waste streams

Fluoropolymer end-of-life applications

▪

Automotive

Aerospace

Electronics & semiconductors

Chemicals (CPI)

Medical & pharma

Other (e.g., professional cookware)

2022-07-19

Fluoropolymer waste in Europe 2020

Project frame

–

Waste treatment

Recycling, Energy Recovery, Landfill

Waste treatment

Recycling

Definition

▪

Physical material processing of fluoropolymers waste into regrind and recycled granules and compound materials

Recycling of pre- and post-consumer fluoropolymer waste. Thermoplastic fluoropolymer supply for recycling primarily from industrial

applications such as semiconductor process equipment or from chemical and pharmaceutical end-of-life applications.

As most fluoropolymers (and elastomers) are not melt-processable such as thermoplastics, the term recycling in this report includes mechanical

recycling and other recycling technologies such as regrind and sintering as well as chemical recycling.

Waste incineration for energy recovery purposes in MSWI plants (municipal solid waste incineration), SRF / RDF (solid recovered fuel / refuse

derived fuel) power plants or cement kilns (e.g., rotary kilns) and hazardous waste incineration plants (e.g., for hospital waste).

The average calorific value of some FP waste fractions such as PTFE is typically lower compared to other plastics such polyolefins. However,

the usually small shares of fluoropolymers within a mixed waste fractions send to MSWI plants have no significant effect on the overall waste-

to-energy performance.

Please note, that this report does not provide detailed information about average operative incineration temperature levels. A further analysis of

existing exhaust gas treatment systems is also not part of this report.

Waste treatment on a landfill sites for the disposal of waste fractions

The EU landfill directive defines the different categories of waste (municipal waste, hazardous waste, non-hazardous waste and inert waste)

and applies to all landfills, defined as waste disposal sites for the deposit of waste onto or into land.

Typically, fluoropolymer waste is chemically inert.

▪

Incineration for heat /

electricity utilization

(Energy recovery)

▪

Landfill

▪

2022-07-19

Fluoropolymer waste in Europe 2020

Project frame

–

Target companies

End-of-life fluoropolymer applications and relevant players along the waste chain

Large shredder WEEE

facilities

dismantlers

Waste

management

companies

Metal recyclers

Industrial

service

companies

Hospitals

Aircraft

dismantlers

Municipal

Internal service

waste services / maintenance

Automotive

Aerospace

Electronics &

semiconductors

Chemicals (CPI)

Medical &

pharma

Other (e.g.,

cookware)

✓

(✓)

✓

(✓)

✓

(✓)

✓

(✓)

✓

(✓)

✓

2022-07-19

Fluoropolymer waste in Europe 2020

Main objective, key questions and targets

–

The main objective of the project was to further determine and define the main applications and products, where fluoropolymers are used and to

understand what happens to those applications at the end of their life. A correlation matrix between fluoropolymer applications and the penetration of

relevant waste streams (by mass in kt and %) was developed and the waste treatment route (recycling, energy recovery and landfill) is shown.

This report delivers an in-depth description on how and where fluoropolymer containing products and corresponding wastes are generated and what

happens to the collected fractions at the end of their life. Quantities of fluoropolymer waste are included as far as possible based on an end-of-life

fluoropolymer (and relevant fluoropolymer containing products) lifetime assessment model. This report has qualitative and quantitative character.

The main scope of the report can be summarized as follows:

▪

Identification where fluoropolymer applications and products end up at the end of their life including re-use of processing scrap and recycling of

either pre- or post-consumer fluoropolymer waste (either mechanical, e.g., conversion into PTFE micro powders or chemical) in the EU.

▪

Identification of major waste streams in which the fluoropolymer applications and products end up incl. total volumes in kt as well as the penetration

of fluoropolymers (in kt and %) in the EU.

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Fluoropolymer waste in Europe 2020

Main objective, key questions and targets

–

The report has a semi-quantitative character with additional supplemental qualitative case studies for specific waste streams and applications providing

further information about the fate of fluoropolymer-relevant applications at their end-of-life.

This report provides…

▪

information on where the fluoropolymer applications end up at the end of their life and in which waste streams,

data about the quantities of different waste streams with a model-based estimation about the expected fluoropolymer penetration,

a general overview for the treatment of relevant waste streams and where included end-of-life fluoropolymers applications end up or are co-

treated as part of commingled fractions (e.g., metal recycling, waste incineration, landfill, etc.),

information about collection and treatment opportunities of fluoropolymer associated products in terms of circularity,

additional knowledge on the treatment of pre-consumer fluoropolymer processing waste of fluoropolymer product manufacturers.

Analysis of end-of-life

fate of fluoropolymers within…

▪

different applications

▪

different products

▪

corresponding waste streams

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Fluoropolymer waste in Europe 2020

Methodology and data model

–

Structure of the fluoropolymer flow analysis

▪

Identification and assessment of pre-defined fluoropolymer applications and corresponding products within the applications Automotive, Aerospace,

Electronics & semiconductors, Chemicals (CPI), Medical & pharma and Other (e.g., cookware)

▪

Description and assessment of the end-of-life fate of different fluoropolymer associated applications and products

▪

Model calculation of corresponding waste streams and their treatment, including fluoropolymer shares

Data model approach

▪

Identification of major fluoropolymer-relevant products and applications in different industry segments

▪

End-of-life analysis of fluoropolymer products based on individual EOL scenarios, e.g., by average lifetimes of fluoropolymer products and

applications

▪

Modeling of fluoropolymer waste collection data for the main industry segments and applications considering the dated back FP market volumes for

a calculation of the total EU fluoropolymer waste in 2020 incl. continuous plausibility checks

▪

Identification of relevant waste streams and the different waste treatment routes (recycling, incineration, landfill)

▪

Estimation of the fluoropolymer penetration and (co-)treatment routes within the different waste streams

▪

Discussion of preliminary results with the Fluoropolymer project group and preparation of a final model calculation and reporting

2022-07-19

Fluoropolymer waste in Europe 2020

Methodology and data model

–

Multimethodological approach

Secondary research

Comprehensive analysis of information and data

from

external databases and secondary

research sources

Conversio own databases

Analysis of existing knowledge

including data

transfer, validation and reframing from previous

reports, e.g., EU Circular Economy 2020 report or

Post-consumer fluoropolymer report 2019

Incl. reports from environmental agencies, official

Incl. analysis of existing model calculations in with

statistics and databases, fluoropolymer

regard to individual lifetime and waste collection

manufacturer datasheets, academic journals,

scenario incl. validation and reframing of existing

information from associations, etc.

knowledge together with new insights.

Analysis of data from

different information

sources, elaboration of a

□

The project methodology is based on a

semi-quantitative,

data model, validation

multi-methodological approach.

and reporting

Primary research

Interviews

with quantitative and qualitative

questions in Europe with fluoropolymer

product manufacturers, waste generators,

waste management companies, shredder

facilities, WEEE dismantlers, etc.

2022-07-19

Fluoropolymer waste in Europe 2020

□

Generally, for application and industry segment shares, average

lifetimes and fluoropolymer waste collected in different waste

streams, information from

several information sources

has

been used such as data and information from official production

and waste statistics, Conversio own reports and databases,

interviews with industry experts along the fluoropolymer value

chain as well as further secondary research sources.

Methodology and data model

–

Data model

Where a calculation on individual fluoropolymer EOL product scenarios was insufficient, a data extrapolation was performed, e.g., for the large number of different

commercial & industrial applications.



FP products & applications



LCA model for individual FP products

EOL analysis of major FP products in different

industry segments



FP waste analysis

Alignment of dated back FP market volumes, LCA

assumptions and interview results

Topic

Interviews with fluoropolymer product manufacturers

and harmonization with existing data and calculations

Result

FP put on the EU market in 2020

FP market volumes per industry segment and

application; estimation market shares by FP types

Lifetime model for FP applications

EOL FP data model by average lifetime in years incl.

dated back FP market volumes per application

EU FP waste in 2020

FP waste volumes per waste stream and industry

segment incl. waste treatment routes

Secondary research + Primary research + Plausibility checks

2022-07-19

Fluoropolymer waste in Europe 2020

Agenda

Introduction and project frame

Management Summary

Fluoropolymer products & applications

Fluoropolymer waste

In-depth waste analysis

Circular economy approach

Appendix

2022-07-19

Fluoropolymer waste in Europe 2020

Management Summary I

▪

In 2020 about 40 kt of FP materials were sold to European FP product manufacturers. The

largest share accounted for PTFE materials (~56%) followed by PVDF (~12%), FKM (~8%) and

FEP (~8%).

By view of FP product manufacturers, tubes & pipes (~15%) followed by liners (~13%), coatings

(~12%) and Seals (~11%) were the most relevant FP applications.

The most relevant industry segments were Chemicals (~29% incl. Energy), Automotive (~31%)

and Others (~21% incl. coated metals, cookware, lubricants, textiles, Food & beverage etc.).

Fluoropolymer market by industry

segments & products / applications 2020

Shares based on quantity in kt

▪

The data for FP materials used by manufacturers (i.e., FP materials sold) in the European

market was aligned with the report* by the Wood Group on behalf of PlasticsEurope in 2022.

Based on the Wood Group report, the quantity of FP materials sold in Europe declined by

around 23% from 52 kt in 2015 to 40 kt in 2020 due to lower import volumes, the pandemic

situation, raw material price increases and data model adaptions.

In total, about 49 kt of FP raw materials were produced in the EU in 2020, making the EU a net

exporter of FP raw materials (export surplus).

▪

2022-07-19

Fluoropolymer waste in Europe 2020

* Update of market data for the socio-economic analysis (SEA) of the European fluoropolymer industry (Wood Group UK Limited; May 2022)

Management Summary II

▪

In 2020, around 23.5 kt of FP waste were collected* via different residential as well as commercial and industrial waste streams.

Applications with typically longer lifetimes accounted for the larges share of FP materials used. Accordingly, the backdated FP volumes which were, for example, used

in a passenger car or aircraft 20 years ago were significantly lower which results in a gap between FP manufacturing and waste quantities in the same year.

In total almost 60% of

the FP manufacturing

quantities in 2020 were

collected as FP waste

in the same year.

▪

Additional reasons for a gap between FP manufacturing quantities and collected waste

are statistical gaps of reported end-of-life vehicle figures in Europe. According to the

Heinrich Böll

Foundation’s European Mobility Atlas 2021, around 12 million cars leave

European roads, but only about half of these are handled in authorised recycling facilities

respectively are recorded by official statistics.

In addition, the EU is a net exporter of many FP based products, incl. industrial

production and processing equipment, passenger cars, aircrafts or medical and pharma

applications. The export surplus resulted in lower quantities of FP products and

applications being put on the market compared to FP products and applications being

manufactured.

Compared to the 2017 figures, where about 22.9 kt of FP waste were generated and 19.7

kt were officially collected, the amount of FP waste collected in 2020 slightly increased.

For the calculation of FP waste collected in 2020, additional new insights and an

extended research scope (e.g., through maintenance measures of transport applications)

were taken into account.

Pre-consumer process losses of FP product manufacturers accounted for around 20% or

~8 kt in 2020.

▪

2022-07-19

Fluoropolymer waste in Europe 2020

* Waste generation and waste collection often slightly differ. For example if an EU end-of-life aircraft or ship is dismantled in extra-EU countries.

Management Summary III

▪

The most relevant waste streams for the collection of end-of-life FP applications are commercial and industrial waste streams, which are usually collected by private

waste management or industrial service companies.

Only a small proportion of FP waste is collected in residential or private waste streams, such as mixed residential waste, which is often collected on behalf of

municipal waste collection services.

▪

Commercial and industrial waste streams

mainly cover end-of-life FP production and

processing equipment from (petro-)chemical

and pharmaceutical companies, food &

beverage producers, the semiconductor

industry or the energy sector.

Significant volumes of FP waste are also

collected in electronic waste (WEEE) or ELV

waste.

Large shredder facilities often process ELV

wrecks and larger end-of-life appliances within

the same waste stream and lighter materials

such as plastics (incl. FP) are sorted out in a

shredder-light fraction.

▪

2022-07-19

Fluoropolymer waste in Europe 2020

Management Summary IV

▪

In total, about 23.5 kt of FP waste were collected in 2020, which is less than 0.01% of the total waste collection (615,000 kt).

In comparison, around 29,450 kt of plastics were collected in 2020 (<5% of the total waste collection excl. mineral fractions).

Almost 84% (or 20.4 kt) of the total FP waste collected in Europe in 2020 is either (co-)incinerated or thermally destructed.

Around 3.1 kt or slightly over 13% of the total FP waste collected were sent to landfill sites.

Slightly more than 0.8 kt were collected separately for recycling and a significant proportion of this was exported for recycling, e.g. to Asian countries.

Potential circular

economy approach

for FP waste

2022-07-19

Fluoropolymer waste in Europe 2020

At a glance

►

In 2020, around 40 kt of fluoropolymer materials were sold to EU fluoropolymer product manufacturers.

23.5 kt of fluoropolymer waste were collected, either in commingled waste streams or partly in source separated waste fractions.

►

Almost 84% of all fluoropolymer applications were incinerated at the end of their life in energy recovery (MSWI ~72%) or thermal destruction (metal

recycling ~12%) processes. 13% of the collected fluoropolymer waste was landfilled and around 3% was recycled.

►

End-of-life fluoropolymer production and processing equipment used

for different industrial segments, such as Chemical, Energy, Food &

beverage, Pharma and Semiconductor accounted for the major share

of the total fluoropolymer waste quantity collected (~13 kt).

►

The overall fluoropolymer penetration in all waste streams

was less than 0.01% by weight. In comparison, plastics in total

accounted for about 4.8% of the total waste collection volume

(excl. mineral fractions).

►

Chemical recycling of fluoropolymer waste offers the opportunity to

produce virgin-like fluoropolymer raw materials for the production of

goods and products without quality limitations. However, building robust

supply chains for large-scale and economical feasible recycling processes is one of the most important issues to be addressed in the coming years.

2022-07-19

Fluoropolymer waste in Europe 2020

Agenda

Introduction and project frame

Management Summary

Fluoropolymer products & applications

Fluoropolymer waste

In-depth waste analysis

Circular economy approach

Appendix

2022-07-19

Fluoropolymer waste in Europe 2020

Converting of fluoropolymer materials in EU in 2020

–

by industry segments

Fluoropolymer market by industry segments 2020

Shares based on quantity in kt

Aerospace

31%

▪

Electronics &

semiconductors

10%

▪

Chemicals (CPI)

29%

Total 40 kt

of fluoropolymers

converted into

products by EU

converters

21%

Automotive

▪

Medical & pharma

Other

▪

Around 12 - 13 kt of FP materials were used for the production of automobiles

and associated spare parts. Modern cars use around 0.6 up to 0.8 kg of FP

materials to cope with the tighter emission regulations and the growing

importance of sensor, communication, safety and comfort systems.

In addition, EVs use PVDF electrode binders and separator coatings in their

battery systems improving the overall battery performance and long-term

reliability of the battery system.

The chemical industry together with the petrochemical and energy industry

(incl. renewables) accounted for almost 30% of all FP products and

applications manufactured in the EU. Relevant applications are for example

liners for pipes, pumps and vessels or FP gaskets, tubing, bellows, flue gas

treatment / cooling systems and various other products.

Medical applications, such as syringes, tubing, pipes, milled & drilled lab

equipment, diaphragms or microinvasive surgery applications, such as stents,

account for around 2 - 3 kt of FP materials used for manufacturing.

Electronics & semiconductors also include electronic devices such as

smartphones, tables and notebooks incl. the associated infrastructure for long

distance communication such as antennas.

Other applications account for around 7 - 8 kt of FP materials used in 2020,

incl. ~5 kt for coated metals incl. consumer cookware (>2 kt).

2022-07-19

Fluoropolymer waste in Europe 2020

Converting of fluoropolymer materials in EU in 2020

–

by products & applications

Fluoropolymer market by products & applications 2020

Shares based on quantity in kt

Pumps Wire conduits & cables

Seals (O rings, gaskets)

Electrolysis cells / Batteries

11%

Bearings

Other

Hoses

(incl. Fluoroelastomers)

▪

The split into different FP products & applications was based on survey results

with more than 20 different FP product manufacturers in the EU.

The three FP application and product categories Tubes & pipes (100% FP

materials), liners (e.g., for corrosion prevention of steel pipes) and seals (incl.

O rings and gaskets accounted for around 40% (or 15 - 16 kt) of the total FP

materials processed in the EU in 2020. Coatings for coils / sheet metal, pans,

pots, etc. account for about 5 kt.

The category textiles & fabrics includes wearable FP (membrane) materials for

outdoor clothing as well as protective clothing for professional tasks such as

firefighter coats. This category also includes glass coated fabrics used for

architectural and industrial applications.

The category Other includes, for example, other additives, compounding with

engineering polymers, as well as various other smaller applications such as

bellows, membranes, etc.

Tubes & pipes

15%

(100% plastic)

Total 40 kt

of fluoropolymers

converted into

products by EU

converters

Lubricants & greases

▪

12%

Coatings

▪

13%

Liners

Milled & drilled parts

▪

Films & tapes

Textiles & fabrics

Lubricants & greases include dry FLP lubricants or FP additives for lubricants /

greases.

2022-07-19

Fluoropolymer waste in Europe 2020

Converting of fluoropolymer materials in EU in 2020

–

by FP types

Fluoropolymer market by polymer & elastomer types 2020

Shares based on quantity in kt

▪

Other

ETFE

PFA

PCTFE

Around 50 - 60% of the EU 2020 FP market accounted for PTFE based

products & applications for different industry segments.

▪

PTFE

56%

Total 40 kt

of fluoropolymers

converted into

products by EU

converters

FEP

▪

12%

PVDF

▪

PTFE is a not melt-processable thermoplastic resin with duroplast

characteristics and therefore not suitable for mechanical recycling processes,

which are usually used for thermoplastic materials such as for example

polyolefins. Fluoroelastomers, such as FKM, are also not suitable for

mechanical plastic recycling processes.

Chemical recycling provides an opportunity to recycle pre- and post-consumer

PTFE materials into a virgin material qualities.

Opened in 2015, a chemical pilot recycling plant located in Burgkirchen

(Germany) by 3M (former Dyneon) shows that the recycling of non-melt-

processable FP is possible. The existing plant is capable of recycling up to

500 t of FP materials per year.

In addition, pre- and post-consumer PTFE is for example thermo-mechanically

recycled into micro-powders.

FP materials, such as PVDF or PFA, are technically suitable for conventional

mechanical recycling processes.

FKM

▪

2022-07-19

Fluoropolymer waste in Europe 2020

Fluoropolymers quantities by industry segment in the EU in 2020

–

long lifetimes, export surplus and

export of used cars and electronics

12.5 kt

Export surplus of new cars

and associated

parts. In general low service requirements of FP

affiliated parts. Typical age of an ELV around 12

years + approx. 60 g of FP materials replaced

via maintenance.

Export surplus of used and

deregistered cars

to countries outside the EU.

0.8 kt

Automotive

Aerospace

Electronics &

semiconductors

FP products manufactured by EU companies are mainly used for

applications that have longer lifetimes and often for products that

have high export surplus rates.

Compared to other materials such as polyolefins or PET, which

are aften used in short-life (<1 year) packaging applications, FP

materials are predominantly used for technical applications.

Export surplus of new aircrafts

and associated parts. D-check maintenance of commercial

aircrafts in use every 12 years incl. exchange of (at least partly) FP fuel and hydraulic system parts.

4 kt

Usually

lifetimes of 10 - 20 years

for processing equipment. Lifetimes of consumer

electronics between 3 - 10 years.

Export surplus of used electronics

outside the EU.

Average

lifetimes

of liners and other affiliated FP products used for

chemical production processes between

10 - 20 years.

Range from

1 year, e.g., for high-purity applications and very aggressive

substances and demanding production environments

up to 50

years

for tubes and pipes used for less aggressive substances and

less demanding production environments.

Possibility to improve

recycling,

e.g., of liners previously used for corrosion prevention.

Chemicals (CPI)

11.5 kt

Medical & pharma

Other

2.8 kt

Lifetimes of ,e.g., PTFE coated pots and pans on average

4 - 5 years other transport applications 15 - 25 years,

architectural fabrics up to 20 years, processing equipment in

the food and beverage industry 5 - 15 years, etc.

40 kt of FP products & applications

manufactured in the EU in 2020

2022-07-19

Fluoropolymer waste in Europe 2020

8.4 kt

Average

lifetimes

of FP pharma processing

equipment of around

5 - 15 years.

Medical

FP applications range from short life single-

use products, e.g., sterile syringe filters up to

several decades for PTFE covered stents.

Fluoropolymers quantities 2015 vs. 2020

FP raw materials sold to the EU FP product manufacturers

–

export and import adjusted

Sector

Chemical & Power

Food & Pharma

Electronics

2020 FP quantity

sold in the EU in kt

10 - 12

3.5

2015 FP quantity

sold in the EU in kt

16.5

3.5

▪

The data for the FP materials used by manufacturers (i.e., FP materials sold)

in the EU market was aligned with the Wood Group report “Update of market

data for the socio-economic analysis (SEA) of the European fluoropolymer

industry” on behalf of

PlasticsEurope in 2022.

▪

Transport

Renewable energy

Cookware

Medical

Textiles & architecture

Other

Total

2022-07-19

15.5

0.5

1.5

Fluoropolymer waste in Europe 2020

18.5

0.5

3.5

1.5

▪

The authors noted that the data presented in their latest report covers a high

market share (i.e., higher number of participants) and was not extrapolated

compared to 2015 data, which was extrapolated.

According to the report the major reasons for the decline from 52 kt of FP

materials sold in 2015 compared to 40 kt in 2020 were a result of lower import

quantities and the overall production drop in various industries due to the

pandemic situation. The increase of FP raw material prices was also stated as

a reason for the lower FP quantities in 2020.

The data used in this report was aligned to the data published on behalf of

PlasticsEurope, but slightly adapted to a different industry segmentation focus.

In total, about 49 kt of FP raw materials were produced in the EU in 2020,

making the EU a net exporter of FP raw materials (export surplus).

Agenda

Introduction and project frame

Management Summary

Fluoropolymer products & applications

Fluoropolymer waste

In-depth waste analysis

Circular economy approach

Appendix

2022-07-19

Fluoropolymer waste in Europe 2020

Fluoropolymers quantities by industry segment in kt

–

differences between FP products

manufactured and FP waste collected in the EU in 2020

FP quantities manufactured vs. FP waste collected

Automotive

Aerospace

Electronics &

semiconductors

12.5 kt

The differences between FP manufactured products & applications

and FP waste collected in different waste streams in the same years

is a result different measures:

▪

0.8 kt

export-import balance of manufactured products,

LCA (average lifetimes) of different FP associated products

and applications,

dated-back FP volumes in total an per industry segment over

the last 30 years,

maintenance measures of FP associated products and

applications in use,

export-import balance of used products (e.g., cars exported for

second use outside the EU),

official waste statistics (i.e., waste collected)

–

often not a

100% coverage of all waste arisings (i.e., waste generated)

incl. statistical gaps, e.g., unknown whereabouts of ELVs, etc.,

▪

4 kt

3.5 kt

0.3 kt

Chemicals (CPI)

11.5 kt

▪

Medical & pharma

Other

2.8 kt

▪

In total almost 60% of

the FP manufacturing

quantities in 2020 were

collected as FP waste

in the same year.

2.7 kt

9.4 kt

2.3 kt

5.3 kt

8.4 kt

▪

continuous adjustments through additional information by

waste management companies, waste producers and existing

Conversio internal databases and reports.

40 kt of FP products & applications

manufactured in the EU in 2020

2022-07-19

Fluoropolymer waste in Europe 2020

23.5 kt of FP waste

collected in the EU in 2020

FP waste collection by industry segment in the EU in 2020

Collected FP waste by industry segment in the EU in 2020

Industry segment

Automotive

Collected FP waste

in kt

3.5

▪

In total, around 23.5 kt of FP waste were collected in different industry

segments in the EU in 2020.

▪

Aerospace

Electronics & semiconductors

Chemicals (CPI)

Medical & pharma

Other

0.3

2.7

9.4

2.3

5.3

In 2017 around 22.9 kt of FP waste were generated and 19.7 kt were officially

collected.

For the calculation of FP waste collected, additional new insights and an

extended research scope (e.g., through maintenance measures of transport

applications) were taken into account.

Statistical gaps between officially collected waste and waste generated still

exist and will be described in more detail in the individual case studies.

One example is the number of officially treated end-of-life vehicles:

According to the Heinrich Böll

Foundation’s European Mobility Atlas 2021,

around 12 million cars leave European roads due to total loss after an

accident, economic write-off, non-compliance with new safety or emissions

standards or a change in design preferences

–

but only around half of them

are handled in authorised recycling facilities respectively are recorded by

official statistics.

▪

Total

23.5

2022-07-19

Fluoropolymer waste in Europe 2020

Waste collection by waste stream in the EU in 2020

–

total, plastics, fluoropolymers

Collected FP waste by waste stream in the EU in 2020

FP relevant waste stream

Residential household waste and municipal waste

generated by commercial activities

Electronic waste collection (WEEE)

ELV incl. auto-shredder residue (ASR)

Commercial & industrial

(various streams; usually commingled)

Total

Other waste streams not further analysed / relevant

e.g., separate collection of LWP waste or separate collection

of commercial packaging waste

Total waste collected

in kt

148,500

5,000

10,000

400,000

563,500

Thereof plastics

in kt

10,300

1,170

1,190

4,700

17,360

in %

6.9

23.4

11.9

1.2

3.1

Thereof FP

in kt

2.2

2.3

3.0

15.1

23.5

in %

<0.01

0.05

0.03

<0.01

51,500

12,090

23.5

<1 kt

<0.01

2022-07-19

Fluoropolymer waste in Europe 2020

Graphical illustration of FP waste collected by industry segment and waste stream

Total: 23.5 kt FP waste collected

Industry segment

Automotive

Aerospace

Electronics &

semiconductors

Chemicals (CPI)

Medical & pharma

Other

Waste stream*

Residential household

Electronic waste collection

waste and municipal waste

(WEEE)

generated by commercial

activities

ELV incl. auto-shredder

residue (ASR)

Commercial & industrial

*excl. ‘Other waste streams not further analysed / relevant’

2022-07-19

Fluoropolymer waste in Europe 2020

Waste stream flow chart

–

collection, treatment and utilization

Collection

Collected

waste

Recovery

Not recovered /

untreated

Landfill

Treatment

Utilization

Mechanical

recycling

Dissolution/

Purification

Chemical

recycling

Recyclates

Recovered

by recovering operations

Recycling

Household and household-like

waste streams

▪

Mixed waste streams

▪

Separately collected waste

streams

Commercial and industrial waste

streams

▪

Mixed waste streams

▪

Separately collected waste

streams

Energy

recovery

Monomers

used for polymerization

Other base chemicals

used for processing and

polymerization

Alternative fuel

RDF / SRF

Incineration with

energy

recovery

1) Including mixed plastics

2) Other base chemicals without polymerization can be utilized

as feedstock for other purposes or for energy recovery

3) Incineration with „Energy-from-waste (EfW)“

Energy

2022-07-19

Fluoropolymer waste in Europe 2020

Circular economy illustration for fluoropolymers

Fluorspar / calcium fluoride (CaF2) is a limited resource. The

circularity of FP materials could offer a way to cope with the growing

market demand for FP materials and the tight supply situation

(import dependency) for relevant secondary raw materials.

Export of FP

products

FP conversion

Mechanical recycling of FP

▪

Melt-processable FP such as

PVDF or PFA

▪

Re-grind and processing of not

melt-processable FP materials

into powders etc.

Export of FP raw

materials

Import of FP raw

materials

FP production

Import of FP

products

FP consumption

products

in use

renewable and fossil

Feedstock

(Pre-)sorting

Export of sorted (FP)

waste for recycling

2022-07-19

Fluoropolymer waste in Europe 2020

Chemical recycling of FP

▪

3M recycling plant for not melt-

processable FP materials

▪

Virgin-like raw material quality for

the manufacturing of new FP

products & applications

Export of

recycled FP

FP recycling

Import of sorted (FP)

waste for recycling

Import of collected

waste for sorting

Waste collection

Export of

collected waste

Landfill

Energy recovery

MSWI / RDF / SRF

Treatment of FP waste by industry segment in the EU in 2020

Industry segment

Automotive

Aerospace

Electronics & semiconductors

Chemicals (CPI)

Medical & pharma

Other

Total

Collected FP

waste

in kt

3.5

0.3

2.7

9.4

2.3

5.3

23.5

Energy

recovery

in kt

2.50

0.24

2.15

7.10

2.00

2.90

16.89

in %

71.4

80.0

79.6

75.5

87.0

54.7

71.9

Landfill

in kt

0.80

0.04

0.25

1.05

0.15

0.80

3.09

in %

22.9

13.3

9.3

11.2

6.5

15.1

Metal

recycling

in kt

0.20

0.01

0.15

0.90

0.05

1.40

2.71

in %

5.7

3.3

5.6

9.6

2.2

26.4

FP recycling

in kt

0.01

0.15

0.35

0.10

0.20

0.81

in %

3.3

5.6

3.7

4.3

3.8

3.4

2022-07-19

Fluoropolymer waste in Europe 2020

(Co-)treatment of FP waste and associated waste streams

FP relevant waste stream

Residential household waste

and municipal waste generated

by commercial activities

Electronic waste collection

(WEEE)

ELV incl. auto-shredder residue

(ASR)

Commercial & industrial

(various streams; usually

commingled)

Total

Other waste streams not further

analysed / relevant

2022-07-19

Collected FP

waste

in kt

Energy

recovery

in kt

in %

Landfill

in kt

in %

Metal

recycling

in kt

in %

FP recycling

in kt

in %

2.2

2.3

3.0

15.1

23.5

0.9

1.35

1.7

2.1

11.04

16.89

0.7

61.4

0.85

0.4

0.7

0.99

3.09

0.15

38.6

0.15

0.2

2.31

2.71

0.05

0.76

0.81

73.9

70.0

17.4

23.3

6.5

6.7

2.2

73.1

6.6

15.3

5.0

71.9

77.8

13.1

16.7

11.5

5.6

3.4

Fluoropolymer waste in Europe 2020

FP waste treatment routes post-consumer FP waste and treatment in the EU in 2020

(Co-)treatment route of post-consumer FP waste in the EU in 2020

FP waste collected (post-consumer)

23.5 kt (100%)

▪

Most FP are (co-)incinerated in MSWI plants or

dedicated hazardous waste incineration plants

which are for example treating different wastes

from chemical waste producers.

The total penetration of FP waste by mass is in

mixed or commingled waste streams typically very

low (<0.01%).

FP waste from commercial and industrial waste

producers with is either pre-sorted or results

directly from dismantling operations is also mainly

incinerated for energy recovery.

Some fractions of pre-sorted PF waste are send to

recycling, either to domestic recyclers or exported

for recycling in intra- and extra-EU countries.

Other recycling includes for example re-grinding

and sintering as well as chemical recycling of FP

materials.

Recovery processes

20.4 kt (86.9%)

Disposal

3.1 kt (13.1%)

▪

Incineration / thermal destruction

19.6 kt (~83.5%)

Recycling

0.81 kt (3.4%)

Landfill

3.1 kt (13.1%)

▪

Energy recovery MSWI / RDF / SRF

16.9 kt (~72%)

Metal recycling

2.7 kt (11.5%)

Other

recycling

>0.7 kt (<3%)

Thermoplast.

recycling

<0.1 kt (<0.5%)

▪

2022-07-19

Fluoropolymer waste in Europe 2020

Pre-consumer processing losses during the manufacturing of FP products and applications

FP raw materials sold to EU FP product manufacturers

FP product manufacturing in the EU

▪

The processing of FP materials such as the machining of PTFE rods and

cubes for the manufacturing of various milled and drilled parts results pre-

consumer FP processing losses.

▪

Due to high costs of FP raw materials, the resulting FP processing losses like

shavings, off-cuts or samples are of high value for other companies.

In total, EU FP product manufactures have process losses of around 20%

which means that roughly 8 kt of FP process losses were generated in the EU

in 2020.

▪

Pre-consumer FP

processing losses

during manufacturing

2022-07-19

Final FP products and

applications

Around 20 - 25% of the FP product manufacturers stated to have own internal

re-processing steps for their process losses. 30 - 35% stated to send their pre-

consumer FP waste to external material re-processing companies and 15%

exported their pre-consumer wastes to other companies inside the EU.

5 - 10% stated that their FP processing losses are exported outside the EU for

re-processing, e.g., to Asian countries. 5% confirmed that they do not know

what happens to their process losses. These companies usually (full-service)

contracts with waste management companies. 15% of all FP process losses

are not recycled and predominantly (co-)incinerated in MSWI plants or

dedicated hazardous waste incineration plants.

Fluoropolymer waste in Europe 2020

Agenda

Introduction and project frame

Management Summary

Fluoropolymer products & applications

Fluoropolymer waste

In-depth waste analysis

Circular economy approach

Appendix

2022-07-19

Fluoropolymer waste in Europe 2020

Case study ELV

–

Produced new vehicles and collected ELVs with the associated FP volumes

▪

According to the European Mobility Atlas 2021 by Heinrich Böll Foundation

around 12 million cars leave European roads due to total loss after an

accident, economic write-off, non-compliance with new safety or emissions

standards or a change in design preferences. According the report only

around half of them are handled in authorised recycling facilities.

Using latest Eurostat data for 2019, around 6.9 million ELVs were statistically

covered for EU27 + 1.6 million from the UK.

For 2020, it was assumed that around 8.6 - 8.7 million ELVs were officially

collected in the EU27+3 countries which means that there are still statistical

gaps between the total number of ELV arisings and the number of ELVs

officially collected.

The FP share in ELVs (usually around 12 years old) is significantly lower

compared to modern cars. It was assumed that the average FP content

ranged between 0.35 - 0.4 kg per ELV which accounted for around 3 - 3.5 kt

of FP materials collected in total in the EU27+3 countries.

Additional 0.3 kt of FP materials were collected as part of end-of life vehicles

>3.5 tonnes, trucks and busses, motorcycles or construction and agricultural

(constr. & agricult.) vehicles.

Most of the collected ELVs undergo a dismantling process where valuable

parts (e.g., front and rear lights) or applications with safety issues such as

airbags and liquids are removed before the further treatment process.

2022-07-19

Fluoropolymer waste in Europe 2020

Fluoropolymers by average weight per new vehicle

Cars & LCV

Trucks & buses

Weight

0.7 kg

1.2 kg

EU27+3 production volume for new vehicles 2020

Number

13.7 million

0.30 million

Motorcycles

0.1 kg

Constr. & Agricult.

1 kg

▪

0.95 million

0.3 million

EU27+3 associated FP volume used in new vehicles 2020

[estimated]

Total weight

9.6 kt

0.36 kt

0.10 kt

0.30 kt

▪

Fluoropolymers by average weight per ELV

Cars & LCV

Trucks & buses

Weight

0.37 kg

0.8 kg

EU27+3 total number of collected ELVs 2020

Number

8.65 million [est.]

0.16 million

Motorcycles

0.1 kg

Constr. & Agricult.

0.7 kg

▪

0.8 million

0.12 million

▪

EU27+3 associated FP waste collected in ELVs 2020

[estimated]

Total weight

3.2 kt

0.128 kt

0.08 kt

Case study ELV

–

Typical ELV processing route

▪

ELVs generated

Waste management

Recovery processes

▪

Official ELV treatment

Unofficial ELV

treatment / Export

Dismantling

ELV collection center

Reuse

Recycling

▪

Thermoplastic

recycling

Other recycling

▪

Shredding

Incineration processes

Metal recycling

Disposal

Landfill

Energy recovery

MSWI / RDF / SRF

▪

After ELV collection by registered ELV collection centres, ELVs are

dismantled and valuable reusable parts or critical applications such as

airbags and liquids, are removed.

The stripped (and compacted) ELV wrack is then shredded. Shredding

facilities often shred ELV wracks together with large appliances. After

shredding post-processing and separation processes focus on the recovery

of metal fractions.

EOL FP parts are usually co-treated with metal fractions (metal recycling

and thermal destruction of FP materials) or incinerated in MSWI respectively

RDF / SRF incineration plants as part of a shredder-light fraction (SLF).

The post-processing of the SLF can differ. Most shredder facilities have

additional recovery steps for the recovery of metals. But only a few plants in

Europe focus on the recovery of plastic fractions such as PP or other

plastics. Small shares (<0.1%) of FP might end up in plastic fractions sorted

for recycling, but the major share (almost 80%) is going into incineration

processes and around 20% end up in landfills.

Lambda sensors are either dismantled separately (recycling of metal- or

ceramic-based catalytic converters with focus on the recovery of platin,

palladium and rhodium) or shredded together with part of the exhaust

system. The attached wire, incl. the FP insulation of Lambda sensors, is

often cut off and collected separately for cable recycling. The FP insulation

is removed and mainly incinerated with energy recovery.

2022-07-19

Fluoropolymer waste in Europe 2020

Case study ELV

–

ELV treatment in Germany, France, Italy and UK

End-of-life vehicles collected and treated in selected European countries

Sources: Eurostat data 2019, individual ELV country reports by

environmental agencies or ELV systems 2019 and 2020, Circular

Economy of Plastics 2020 in EU27+3 (Conversio), own model

calculations

Number of ELVs collected

Total recycling & reuse rate

Total plastics quantity

Recycling rate of plastics

Incineration rate of plastics

Landfill / disposal rate of plastics

Thereof FP quantity

Incineration / thermal destruction rate of FP

Landfill / disposal rate of FP

2022-07-19

Fluoropolymer waste in Europe 2020

0.46 million

(export surplus of used cars)

1.6 million

87.1%

160 kt

41%

(based on figures by Ademe)

27%

32%

0.56 kt

>80%

<20%

1.1 million

84.2%

139 kt

10%

80%

0.39 kt

>50%

<50%

1.6 million (est.)

85% (est.)

273 kt

15%

55%

30%

0.56 kt

>60%

<40%

86.9%

67 kt

25%

69%

0.16 kt

>95%

<5%

Case study Aerospace

Fluoropolymers by weight per average new aircraft

Average

Weight

120 kg

EU27+3 production volume for new aircrafts 2020

Number

566 (Airbus figures, 611 in 2021)

▪

According the Centre for Aviation (CAPA) statistics, around 7,500 commercial aircrafts are in service

by Western and Central + Eastern European airlines.

In Europe, each year about 250 - 300 commercial aircrafts reach their end of service life. Thereof

approx. 180 - 220 aircrafts remain in Europe for further dismantling and recycling operations.

Commercial aircrafts are also exported to extra-EU countries for reuse. In addition, more than 300

aircrafts are stored in large open spaces either for reactivation or for spare parts supply.

The Aircraft Fleet Recycling Association (AFRA) estimated that around 15,000 aircrafts will retire in

the next two decades worldwide incl. around 2,000 - 3,000 aircrafts in Europe.

The French company Tarmac Aerosave has three sites where up to 280 aircrafts can be stored for

longer periods. Over the past years, the company has recycled over 300 aircrafts (75% of all Airbus

A340 aircrafts worldwide). Additional aircraft dismantlers and recyclers in Europe are, for instance,

ecocube (UK) with focus on aircraft EOL treatment (overall market share >40% in Europe and ~20%

worldwide), AELS with >75 aircrafts recycled since business start (Netherlands), Air Salvage

International (UK), Roth International (Germany / Czechia), Cronimet (Germany) and JAS Jet Aircraft

Services (Netherlands).

The focus of aircraft dismantlers and recyclers is to extract valuable and reusable parts as well as

recovery of metal fractions such as skeleton and cladding. Non-recyclable materials are mainly

incinerated for energy recovery operations. Only a small share of plastics, incl. a small share FP

materials, is landfilled, e.g., in the UK or in France.

2022-07-19

Fluoropolymer waste in Europe 2020

▪

EU27+3 associated FP volume used in new aircrafts 2020

[est.]

Total weight

68 tonnes (excl. 10 - 15 kt sold in Boeing aircr.)

Fluoropolymers by average weight per end of life aircraft

Average

Weight

100 kg

EU27+3 total number of EOL aircrafts 2020

Number

200

▪

EU27+3 associated FP waste collected in EOL aircrafts 2020

[est.]

Total weight

20 tonnes

Case study WEEE

–

WEEE management and protentional FP circularity approaches for end-of-life electronic & semiconductor production and processing equipment

▪

In the most European countries WEEE management systems have been

successfully established for the collection, categorizing, dismantling and

treatment of WEEE.

Despite the success of these dedicated WEEE management systems which

provide high market coverage of the generated electronic waste in many

countries, there is still a lot of mismanagement of electronic waste even in

wealthy industrial countries. Illegal exports of electronic waste (often

categorized as ‘used electronics’) to countries with improper recycling

environments is one of the issues that should be addressed by EU

legislators in the coming years.

The domestic WEEE management in countries such as Germany, France,

Italy or the UK, is mostly safe if done properly. Most WEEE arising is

covered by dedicated WEEE streams. Additional volumes are collected, for

example, through residential waste streams and a small share through

mixed commercial and industrial waste streams. The major share of end-of-

life electronics which are not routed for recycling is going into waste

incineration.

There are some WEEE recovery operations established for obtaining

recyclable plastic fractions, incl. ABS, PE-HD, or PS. The recovery of FP

materials is more or less limited to the recycling of production and

processing equipment, e.g., FP piping for ultra-pure water / solvent supply.

Fluoropolymer waste in Europe 2020

▪

The WEEE collection does not cover information about associated

production and processing equipment, e.g., FP materials used

semiconductor or chip manufacturing plants. These material streams are

usually collected as part of commercial and industrial waste streams either

on behalf of specialized service companies or larger waste management

companies.

A circularity approach for end-of-life FP materials should be directly

addressed with electronic & semiconductor manufacturers respectively

users of FP production and processing equipment. Closed-loop recycling

systems will only be functional, if chip manufacturers such as Semikron

(Germany), Diodes Incorporated (UK), GlobalFoundries (Germany),

Nexperia (Germany), STMicroelectronics (France and Italy), Analog

Devices (Ireland), TDK - Micronas (Germany), X-FAB (Germany), etc., will

be involved. The overall FP volumes that can be recovered from end-of-life

production and processing equipment will probably be relatively small, but

it’s one step closer towards the circularity of FP materials.

▪

2022-07-19

Case study WEEE

–

WEEE treatment in Germany, France, Italy and UK

End-of-life vehicles collected and treated in selected European countries

Sources: Eurostat data 2019, individual WEEE country reports by

environmental agencies and WEEE systems, Circular Economy of

Plastics 2020 in EU27+3 (Conversio), own model calculations

WEEE systems

Collection rate of WEEE systems

Total WEEE collected

Thereof plastics

Recycling rate of plastics

None, but Stiftung EAR

(central monitoring of WEEE)

Major two players are

Ecosystem and Ecologic

60 - 70%

855 kt

160 kt

59%

(based on figures by Ademe)

13 non-profit WEEE

collection systems

40 - 50%

365 kt

85 kt

23%

Around 25 - 30 WEEE

collection systems

40 - 60%

680 kt

135 kt

44%

n.a.

(60 - 70% collection rate)

1,030 kt

240 kt

28%

Incineration rate of plastics

Landfill / disposal rate of plastics

Thereof FP quantity

Incineration / thermal destruction rate of FP

Landfill / disposal rate of FP

2022-07-19

Fluoropolymer waste in Europe 2020

72%

<1%

0.47 kt

>99%

<1%

28%

13%

0.39 kt

>85%

<15%

46%

31%

0.17 kt

>70%

<30%

47%

0.31 kt

>90%

<10%

Case study industrial processes

–

Chemical, Energy, Food & beverage, Pharma, Semiconductor 1

▪

The Chemical industry is using FP materials for many different applications,

mainly for corrosive substances or environment with higher temperature

levels.

After a certain period of time these FP applications need to be dismantled

and replaced to keep downtimes of production processes and risk of

malfunctions as low as possible.

Average lifetimes of liners and other affiliated FP products used for

chemical production processes range between 10 and 20 years. Lifetimes

can be as low as 1 year, e.g., for high-purity applications and very

aggressive substances and demanding production environments and can

go up to 50 years for (thicker) tubes and pipes used for less aggressive

substances in less demanding production environments.

For the replacement of FP applications used in production and processing

equipment different practices are common. Either internal maintenance

service departments (often contracted third-party companies on site) are

responsible or external (and specialized) service companies provide

services on request. A combination of both practices on one site is also

possible.

After dismantling end-of-life pipes, valves, pumps, tanks, etc., (incl. FP

liners) or PF tubes, pipes, hoses, seals, filters, etc., are collected as waste

and mainly separated on site for further waste treatment.

Fluoropolymer waste in Europe 2020

▪

Steel pipes incl. FP liners are usually collected for metal recycling. Some

companies extract the FP content for further processing or to simply

increase the average recyclable metal content which is then sold to metal

recycling companies.

▪

Most of the FP materials from chemical industry applications are usually

collected (separately) by private waste management companies for waste

incineration, either in MSWI or hazardous waste incineration plants. Smaller

FP quantities are also collected in commingled (mixed) waste fractions

which usually are also send to waste incineration processes.

Within the power industry segment, larger volumes of FP are, for example,

collected from flue gas lining and piping with an average lifetime/

replacement frequency of about 10 to 15 years, for instance, in coal-fired

power plants as well as in other processes where industrial flue gas coolers

are used. Hereby also larger volumes of pre-sorted

and ‘clean’ FP material

streams can be obtained, e.g., for chemical recycling processes.

▪

2022-07-19

Case study industrial processes

–

Chemical, Energy, Food & beverage, Pharma, Semiconductor 2

▪

Europe is one of the largest chemical production location in the world.

Companies such as BASF, DuPont, Ineos, LyodellBasell, Air Liquide, Linde,

Evonik, Covestro, TotalEnergies, Bayer, etc., are only a couple of exemplary

users of FP production and processing equipment as well as possible

contributors to a potential FP circularity model.

In addition, a cooperation between waste service companies and larger

chemical parks with many different companies on site could also contribute

to substantial quantities of recyclable FP materials.

▪

Concerns were raised, e.g., for materials that have previously been used to

produce drugs or specific production aids.

Besides all concerns, end-of-life industrial production and processing

equipment offers the best opportunity to collect significant volumes of

recyclable FP materials. The post-sorting of commingled waste streams to

obtain FP materials for recycling is not an option as the overall penetration

of FP is too small (often <0.01% by total mass). The industry should focus

on pre-sorted material streams such extracted FP pipe liners or FP tubing

and piping to create a robust circularity model for end-of-life FP waste.

▪

Some users of FP production and processing equipment stated concerns

related to product safety issues that might occur for some of the FP material

▪

Circular economy approaches for FP materials should be targeted for

equipment that has previously been used for hazardous substances such

Chemical, Energy, Pharma and Semiconductor production and processing

as aggressive chemical media, that might lead to health and safety issues.

equipment as these industry segments account for significant volumes of

Accordingly, companies often require third party waste management

FP waste collected.

companies or service providers to treat their end-of-life

EU27+3 Fluoropolymers utilized for different production and processing applications 2020

materials as safely as possible (i.e., hazardous

Chemical

Energy

Food & beverage

Pharma

Semiconductor

Total

waste incineration).

Another issue was raised by Pharmaceutical companies.

Due to patent and legal requirements these companies

could restrict the recycling opportunities of end-of-life FP

production and processing equipment.

Fluoropolymer waste in Europe 2020

FP quantity

9.5 kt

2.0 kt

1.2 kt

1.6 kt

1.7 kt

16.0 kt

▪

EU 27+3 Fluoropolymer waste collected 2020

[estimated]

FP quantity

7.6 kt

1.8 kt

0.9 kt

1.2 kt

1.5 kt

13.0 kt

2022-07-19

Case study industrial processes

–

Chemical, Energy, Food & beverage, Pharma, Semiconductor 3

Commercial & industrial waste treatment in Germany, France, Italy and UK

Commercial & industrial (mixed) waste collected and treated in selected European countries

Sources: Individual country reports by environmental agencies,

Circular Economy of Plastics 2020 in EU27+3 (Conversio),

own model calculations

Waste separation

Total C&I mixed waste collected

Thereof plastics

Recycling rate of plastics

Incineration rate of plastics

Landfill / disposal rate of plastics

Thereof FP quantity

Incineration / thermal destruction rate of FP

Landfill / disposal rate of FP

2022-07-19

Fluoropolymer waste in Europe 2020

Extended source / on site

separation into different fractions

Limited source / on site

separation into different fractions

Limited (Central/South) to

extended (North) source / on site

separation into different fractions

Limited source / on site

separation into different fractions

54,000 kt

1,010 kt

26%

73%

2.7 kt

>99%

<1%

55,000 kt

580 kt

46%

47%

2.0 kt

>80%

<20%

48,000 kt

560 kt

10%

43%

47%

1.3 kt

>80%

<20%

21,000 kt

(different collection scope)

420 kt

(different collection scope)

55%

37%

1.8 kt

>85%

<15%

Case study cookware

▪

Metal-based consumer and professional cooking equipment such as pans,

pots and trays, is usually made of different metals incl. steel, aluminium and

copper and a coating.

Coatings of cookware usually focus on reducing the stickiness of bakery

and other food products as well as minimizing the risk of burning in. These

characteristics are, for example, beneficial for industrial sized food

processing equipment or regular pans and pots which can be found in

households.

The overall FP content which is used for a regular frying pans (i.e., often

referred to as Teflon coating) ranges between 6 - 12 g (on average 8 g).

Frying pans weigh between 0.5 and 3 kt (on average 0.8 - 1 kg),

accordingly the average FP mass per frying pan by weight is just below the

1% mark. According to different Eurostat product datasets, it can be

estimated that around 250 Mio. t of coated (consumer) pans, pots and trays

were put on the market in the EU in 2020.

▪

In addition, recyclable pans or often disposed of in mixed residential waste

streams and, therefore, lost for any recycling approach (waste incineration

or landfill). Mixed recyclables collection such as the ‘Wertstofftonne’, where

different recyclable waste materials made from plastic or metal are

collected, offer the opportunity to reach significantly higher recycling shares

from end-of-life cookware via automated sorting facilities compared to

recyclables bring-in stations or dedicated metal scrap collectors.

Manufacturer take-back systems for old pans when buying new ones, are

also an opportunity to collect ‘clean’ fractions of end-of-life

cookware for

metal recycling.

▪

The recovery of plastic fractions for recycling (e.g., handles) is not targeted

by most recycling companies. These materials are incinerated, landfilled or

thermally destructed (metal recycling furnace). There are also no

technologies available to recycle the FP content from coatings.

EU27+3 Fluoropolymers in new cookware 2020

FP quantity

2.3 kt

▪

The total FP weight used for coated consumer and professional cookware

was estimated to approx. 2 - 2.5 kt in 2020 of which the largest share

accounted for consumer frying pans.

After use, coated end-of-life frying pans are collected in different waste

streams. Some countries have restrictions for the collection of coated pans

due to safety concerns related to waste treatment and recycling.

Fluoropolymer waste in Europe 2020

▪

EU27+3 Fluoropolymer waste in EOL cookware 2020

[estimated]

FP quantity

2.1 kt

2022-07-19

Agenda

Introduction and project frame

Management Summary

Fluoropolymer products & applications

Fluoropolymer waste

In-depth waste analysis

Circular economy approach

Appendix

2022-07-19

Fluoropolymer waste in Europe 2020

Status quo

–

recycling of FP materials

▪

The recycling of FP materials today is often limited to ‘clean’ pre-consumer

materials from FP manufacturers. Only small volumes of post-consumer FP

materials are recovered for recycling.

20 - 25% of all FP product manufacturers stated to have own internal re-

processing steps for their own process losses. 30 - 35% pass on their FP

pre-consumer waste to external material re-processing companies

(recyclers). 15% export their pre-consumer wastes to other companies

inside the EU (export for recycling intra-EU). 5 - 10% export their FP

processing losses to countries outside the EU, e.g., to Asian countries for

further processing (export for recycling extra-EU).

Recycling of post-consumer FP waste from commingled (mixed) waste

streams either from households and comparable sources or from

commercial and industrial end-users is not existent and will not be a

promising option for circularity of FP in the coming years. The overall share

of FP is too low to establish any sorting and recycling approach.

▪

A common recycling process is to grind PTFE waste into a fine powder and

blend this powder with pure PTFE to be used either in compression

moulding or ram extrusion processes. Before grinding, PTFE waste is

usually heated to above its melting point to remove any organic

contaminants. Once ground, it is treated with acid to dissolve inorganics

after which it is washed and re-heated to vaporise any volatiles (i.e.,

recycling could be described as a sintering process).

▪

Extract of existing FP recyclers in Europe

(excl. chemical recycling and trading / export of FP waste for recycling)

▪

Krall Kunststoff-Recycling with focus on technical plastics waste such as PC

and PMMA but also PA, PEEK, PPSU, PSU, PVDF, PTFE, PEI

Heroflon (Daikin) with focus on PTFE waste

MCAM Symalit (Mitsubishi Chemical Holdings Corporation) with focus on

PVDF, ECTFE, ETFE, PFA, FEP, PEEK

▪

The recycling of post-consumer FP waste is more or less limited to the

recovery and separation of ‘clean’ fractions, e.g., from commercial and

industrial production and processing equipment (around 13 kt in total).

The accessible quantity of post-consumer FP waste suitable for recycling is

significantly smaller. Only if all stakeholders along the FP value chain work

more closely together, progress can be made on the circularity of FPs.

Fluoropolymer waste in Europe 2020

▪

Ambofluor with focus on PVDF, ETFE, ECTFE, FEP, MFA, PFA, PTFE

Prodotti (Fluormetal) with focus on PTFE

Shamrock Technologies with focus on PTFE

Mikro-Technik with focus on PTFE

United Polymer Mixers (UPM Kunststoffen) with focus on PTFE

2022-07-19

Critical success factors for the circularity of FP

–

drivers & barriers

Drivers

High cost of raw materials / limitation of accessible raw materials

Existing chemical recycling plant with a capacity of 500 t p.a.

Cooperation only between few stakeholders necessary

Relatively ‘clean’ material streams if selected properly

Barriers

Various applications with overall small FP volumes

Limitation to selected and pre-sorted EOL material streams

Logistical efforts to collect sufficient volumes for recycling

Objections from the industry related to ‘product safety issues’

2022-07-19

Fluoropolymer waste in Europe 2020

In-depth circular economy approach for FP pipe liners

PTFE converting

(e.g., PTFE liners)

▪

PTFE production

Possible EOL

management of

post-consumer

FP liners

Target PTFE

Chemical recycling

PTFE applications

in use

▪

Collection,

processing and

pre-sorting of EOL

PTFE products

▪

Non-target PTFE

Waste incineration

2022-07-19

Fluoropolymer waste in Europe 2020

▪

Today, the recovery of post-consumer EOL fluoropolymer waste often relies on

(co-)incineration in waste incineration plants.

After production and converting of PFTE into products and applications, commercial

end-users such as large petrochemical companies (e.g., BASF or Bayer), usually send

their EOL products to MSWI plants, mainly via contracted service or waste

management companies.

The existing pilot plant by 3M (former Dyneon) in Gendorf/Germany is capable to

recycle 500 t of post-consumer PTFE, PFA or ETFE materials per year by cracking

fluoropolymers into monomers (chemical recycling). These monomers can be used to

produce new fluoropolymer raw materials. Besides 3M, InVerTec is also able to provide

turn-key chemical recycling plants for fluoropolymer end-of-life applications.

A circularity target could be the set-up of a closed material circle in the coming years.

Collected EOL FP products from commercial end-users

could be sent to ‘up-cycling

plants’ and the extracted monomers could be distributed back to PTFE raw material

producers.

In order to create more economic viable chemical recycling opportunities. A plant

should cover a processing capacity of about 2 kt/p.a.. If 5 of these plants are built in the

coming years, about 10 kt of post-consumer FP material could be recycled in the EU,

which would represent about 20 - 30% of the annual FP processing capacity.

Together with other companies, the manufacturer BAUM is currently working on a

closed-loop solution for the recovery of PTFE and other PF EOL products.

In-depth circular economy approach for FP coated cookware

▪

The average use phase (i.e., lifetime) of coated cookware is highly

dependent on the frequency of use or disregard of the maximum approved

temperature respectively scratching of the coating, e.g. with metal

cookware. Small scratches and slight colour changes of FP based coatings

are often only aesthetical disadvantages and do not impact the mechanical/

chemical characteristics of the coating. Coated cookware should be

replaced, if proper functionality (i.e., reduced anti-stick characteristics) is

not given anymore.

Another option is applying a new FP based coating. Some manufacturers of

cookware and coatings (e.g., BAF, Olav and ITN) already offer a solution

where the used pans and pots can be sent in for renewal of the non-stick

coating. ITN offers its services for all metals and all cookware

manufacturers. The company removes the old coating (sandblasting) under

controlled conditions, incl. dust and particle extraction measures, and

applies new PTFE based coatings.

The renewal of anti-stick coatings is one way to extend the longevity of

coated cookware. The service life of FP-based coatings is estimated by

manufacturers to around 4 to 5 years on average. Applying a new FP based

coating would accordingly double the average lifetime and offer another

opportunity to reuse ‘old’ cookware with the characteristics of a new

product.

Fluoropolymer waste in Europe 2020

Raw material

suppliers

(metals, coatings etc.)

Recyclable scrap /

waste collection;

metal recyclers

▪

Reuse of coated

cookware; renewal

of FP coatings

FP coated

cookware in use

(4 - 5 years)

FP coated

cookware

manufacturers

▪

FP coating renewal;

reuse of coated

cookware

2022-07-19

Agenda

Introduction and project frame

Management Summary

Fluoropolymer products & applications

Fluoropolymer waste

In-depth waste analysis

Circular economy approach

Appendix

2022-07-19

Fluoropolymer waste in Europe 2020

Typical treatment route of mixed residential and commercial & industrial waste streams

FP waste collection and treatment route

▪

Waste generation

Waste management

Export

Recovery processes

FP pre-consumer waste respectively reusable materials are often

sent to recyclers or are internally re-processed again. Intra and

extra-EU export of pre-consumer FP waste is also common.

Post-consumer waste incl. FP waste from commercial & industrial

end-users is primarily managed by private waste management

companies. Post-consumer FP waste from private households is

mainly managed by municipal waste management companies

and (co-)contracted private waste management companies.

The largest share of FP waste in commingled waste streams

such as mixed residential household waste, commercial and

industrial mixed waste or shredder light-fractions of ELV and

large appliances shredder facilities is not post-sorted for

recycling. Accordingly, almost all FP waste fractions are

(co-)incinerated in MSWI or hazardous waste incineration plants.

A smaller share of FP waste is incinerated in commingled

fractions in dedicated RDF or SRF plants, e.g., cement kilns.

Only pre-sorted

and ‘cleaner’ FP waste fractions from end-of-life

applications such as pipe liners or tubes and pipes are suitable

waste streams for recycling. Post-sorting of FP materials from

mixed waste streams is not feasible, neither technical nor

economical.

▪

Recycling

Thermoplastic

recycling

Other recycling

Pre-consumer waste

Production and processing

waste, re-processable internal

FP offcuts, samples etc.

Inhouse

re-processing

▪

Post-consumer waste

Commercial & industrial

ELV waste, Commercial &

industrial mixed waste, pre-

sorted FP waste fractions

Waste collection &

(pre-)sorting by

municipal and / or

private waste

management

organizations

Incineration processes

Metal recycling

Energy recovery

MSWI / RDF / SRF

Post-consumer waste

Household & comparable

▪

Residential household waste,

municipal waste generated by

commercial activities, WEEE

Disposal

Landfill

2022-07-19

Fluoropolymer waste in Europe 2020