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A novel process for the complete recycling of exhausted coffee capsules with a fully circular approach: Design of the industrial plant and Techno-Economic analysis of the process.

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Title: A novel process for the complete recycling of exhausted coffee capsules with a fully circular approach: Design of the industrial plant and Techno-Economic analysis of the process.
Authors: Nanni, A.1,2,3 (AUTHOR) alessandro.nanni@re-sport.it, Colonna, M.1,2 (AUTHOR), Liberati, G.4 (AUTHOR), Bonoli, A.4 (AUTHOR)
Source: Waste Management. Feb2024, Vol. 174, p114-125. 12p.
Subjects: Factories, Industrial design, Waste recycling, Coffee grounds, Factory design & construction
Abstract: [Display omitted] • Exhausted coffee capsules are mechanically recycled in new bio-compounds (EP) • EP compound has mechanical and rheological properties better than neat polypropylene. • Recycled bio-compounds can be injected moulded in new capsules shells. • An industrial plant able to recycle up to 190 million of capsules is designed. • The Net Present Value (NPV) of the plant ranges between 800 k€ and 2000 k€. The objective of this paper is to present the technical and feasibility analysis of an innovative mechanical recycling system for exhausted coffee capsules. This recycling process involved the sorting of spent coffee grounds (SGC) and the subsequent drying and melt-mixing of a portion of these grounds with the remaining capsule components, mainly composed of polypropylene (PP), along with optional virgin PP. These newly developed composite materials exhibited mechanical and rheological properties comparable or even surpassing those of virgin PP. They were also successfully utilized for the injection of new capsule shells, thus alignin with the principles of the circular economy. In addition to the technical aspects, this paper present a comprehensive Techno-Economic Analysis (TEA) of the proposed recycling processes, considering the inclusion of virgin PP (0–20 %) and the initial moisture content (M SGC) of SGC(5–55 %) as varying factors. An industrial plant, designed to handle up to 190 million exhausted coffee capsules and produce up to 1500 tons of recycled compund was appropriately sized. The analysis revealed that processes are profitable across all examined scenarios and that the Net Present Value ranged between 800 k€ (for vPP = 20 % and M SGC = 55 %) and 2000 k€ (for vPP = 0 % and M SGC = 5 %). [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
Description
Abstract:[Display omitted] • Exhausted coffee capsules are mechanically recycled in new bio-compounds (EP) • EP compound has mechanical and rheological properties better than neat polypropylene. • Recycled bio-compounds can be injected moulded in new capsules shells. • An industrial plant able to recycle up to 190 million of capsules is designed. • The Net Present Value (NPV) of the plant ranges between 800 k€ and 2000 k€. The objective of this paper is to present the technical and feasibility analysis of an innovative mechanical recycling system for exhausted coffee capsules. This recycling process involved the sorting of spent coffee grounds (SGC) and the subsequent drying and melt-mixing of a portion of these grounds with the remaining capsule components, mainly composed of polypropylene (PP), along with optional virgin PP. These newly developed composite materials exhibited mechanical and rheological properties comparable or even surpassing those of virgin PP. They were also successfully utilized for the injection of new capsule shells, thus alignin with the principles of the circular economy. In addition to the technical aspects, this paper present a comprehensive Techno-Economic Analysis (TEA) of the proposed recycling processes, considering the inclusion of virgin PP (0–20 %) and the initial moisture content (M SGC) of SGC(5–55 %) as varying factors. An industrial plant, designed to handle up to 190 million exhausted coffee capsules and produce up to 1500 tons of recycled compund was appropriately sized. The analysis revealed that processes are profitable across all examined scenarios and that the Net Present Value ranged between 800 k€ (for vPP = 20 % and M SGC = 55 %) and 2000 k€ (for vPP = 0 % and M SGC = 5 %). [ABSTRACT FROM AUTHOR]
ISSN:0956053X
DOI:10.1016/j.wasman.2023.11.029