Description of the Project

The uniqueness of the project lies in the innovative method of mechanical recycling of various types of waste using efficient high-speed milling. The project deals with the recycling in high-speed milling lines of two types of waste raw materials – soft waste such as plastic waste, RDF, composite packaging, waste paper, etc. and hard waste such as construction and demolition waste, waste concrete, metallurgical slag, fly ash, etc. The unique technology ensures, with the help of mechanical-chemical activation in a high-speed mill, the exceptional properties of the resulting recyclates, which are necessary for their successful application in products. In the case of large format boards, these are mainly strength characteristics, moisture resistance, hygienic safety, low formaldehyde emissions. As far as the construction products concern, reduced water absorption is one of the main goals together with improvement of frost resistance, suppression of the appearance of microcracks (which always arise during the maturation of concrete products), while maintaining the required strength characteristics of the products. In addition to the mentioned exceptional properties of the articles, it is important to underline that the products produced by the proposed technology are recyclable and can be recycled on the projected technological line, even repeatedly without any limits. In area of mechanical recycling, we plan to implement further development and research of recipes, including their testing for the purpose of producing other possible products as well as improving the already manufactured products.

We plan to use progressive innovative technologies in this project that are in technological portfolio thanks to own development and also thanks to cooperation with contractual partners with whom we have been cooperating for a long time. Among this innovation we include:

• High-speed grinding, which can micronize, dry and sanitize waste raw materials in one step, and then they get new properties, which can be successfully used in the replacement of classic raw materials in products such as large format boards for construction and the wood industry (OSB, chipboards, MDF boards), wood-plastic composite boards suitable for exteriors (WPC cladding boards and panels, terrace boards, etc.). It is also possible to apply ground recycled material in concrete recipes in the production of blocks, interlocking paving, curbs, prefabs for various applications and also in production of special concrete for hall floors. The weight of such construction products is reduced up to 50% by the application of recycled plastic, which has huge economic impacts on transport and handling costs. The application of recycled material to the recipes of building materials for 3D printing, which is becoming a hit in the modern construction industry, can be very progressive. The advantage of the high-speed milling technology is the possibility to process other raw materials by simply change of used grinding tools and adjusting of conveyors. This allow us to produce another assortment of commodities than is considered in the project, e.g., secondary fuels, glass recycles for the production of foam glass, or replacement of cement by processing blast furnace slag or ash from the combustion of solid fuels. Thanks to close cooperation with the manufacturer, our company has exclusivity on the know-how of high-speed milling in selected markets.
• Hygienizer: in the case that, during the testing of products for special applications, will be found out that it is necessary to additionally sanitize the raw material or products, we have prepared cooperation with manufacturers of suitable hygienizers either from Armenia (process of sanitizing is based on high-voltage electromagnetic discharge), or from Slovakia (Slovak equipment uses electron radiation).
• Pressing line for DTD articles: modified woodworking technologies of moulding, cold pre-press, hot pressing and formatting of large format boards are suitable for the purposes of the project. The most suitable technology seems to be a Czech origin technological line. This producer has experience in the production of large-format plates base on tetra pack as raw material and, in cooperation with us, has already modified the line for processing raw material from milled plastic waste.

Technological procedures used in this project will ensure that the status of the end of waste according to the valid EU legislation will be observed. Such a comprehensive approach will allow to process also waste types that have not yet been materially recycled. The project can significantly sustain creation of a circular economy in the region and will be a good example for Slovak waste management and message for abroad.

Technology:

High-speed mill

Plastic waste grinding line

Pressing line general view

Dosing and crushing of raw material

Products:

Large format boards made of composite recycled

Test: concrete products-forms with the addition of ground plastic waste