Matl Recycle

Material recycling
Outline Objective of material recycling Purpose of reuse in industry Recycling Components of the MSW Stream Aluminum Glass Steel Plastics Paper Tires
Copyright Anders Damgaard & Morton A. Barlaz, NC State University
Objective
Examine recycling process for each material, alternative technologies, projected markets Demand and economics have a significant influence on recycling activity Is it consistently marketable? What limits recycling?
Purpose of reuse in industry

Ensure raw materials to national industry: Paper, glass, metal. Economy: Waste materials are cheaper than virgin materials at the gate of the plant (price of raw materials, transport of raw materials) Manufacturing is cheaper (energy, emissions, waste & costs) Life-cycle assessment shows overall benefits (less virgin materials used, less landfilling and maybe less treatment)
In the latter case, global assessment may be different than that of the industry and regulations / incentives may be needed to improve recycling
Paper and paper products: Short version

Paper is primarily based on wood fiber (renewable) Paper recycling in terms of damaged products and converters waste has a long history. Characteristics: large quantities from the individual source, defined quality and clean Problems with post-consumer paper: Ink/printing, fiber length, composite materials, foreign objects (clips, tape, strings, etc.) Major benefits: Savings in wood and pulp production (upstream activities) Products: Newspaper, tissue, cardboard, etc.
Paper: Remanufacturing 1
Chemical-mechanical re-pulping
Chemical-mechanical re-pulping is used for higher-quality products requiring removal of ink and maybe bleaching. Chemical-mechanical re-pulping including the cleaning process typically consists of seven steps (Virtanen & Nilsson, 1993): Feeding and pulping including pH adjustment (caustic soda, aluminum sulfates) and addition of dispersing agent (e.g. glycol ether) Pre-cleaning (mechanical) removes solid foreign items using centrifuges and pressure sorters Refining provides washing, sorting and milling of the pulp De-inking and pigment removal by chemical (water glass, etc,) and mechanical (flotation) treatment steps. Final cleaning (mechanical) Thickening and bleaching (heating with hydrogen peroxide or sodium hypochlorite) and storing Drying
Paper: Remanufacturing 2
Mechanical re-pulping
Mechanical re-pulping is used for less demanding paper qualities such as brown paper, boards, egg containers, etc. Mechanical re-pulping including the cleaning process typically consists of six steps (Virtanen & Nilsson, 1993): Feeding and pulping including pH adjustment (caustic soda, aluminum sulfates) and addition of dispersing agent (e.g. glycol ether). Pre-cleaning (mechanical) removes solid foreign items using centrifuges and pressure sorters. Refining provides washing, sorting and milling of the pulp. Final cleaning (mechanical) to remove items released in the refining step. Thickening reducing the water content and allowing for storing. Drying
Paper Recycling 1: Major Grades

There are about 80 grades of fiber Major grades: 1. Pulp substitutes Unprinted trimmings from envelopes and high grade paper Generated in paper mills only Primarily reused in tissue, also in book stock
Paper Recycling 2: Major Grades

Post Consumer 2. High grade deinking Office white paper 3. Old corrugated (OCC) 4. Old newsprint (ONP)
Paper Recycling 3 Major Grades

5. Residential mixed paper (RMP) office waste, third class mail, boxboard (cereal boxes), magazines, telephone books, OCC, coated packaging 6. Mixed office paper 7. OMG - old magazines 8. OTP - old telephone books
Paper Recycling 4: ONP

~4% of MSW in 2010 (includes 18.8% advertising) ~70% recovery rate Uses: largest use is in new newsprint recycled paperboard cereal & shoe boxes, tablet backs cellulose insulation, roofing felt animal bedding export
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Paper Recycling 5: ONP

Specifications #6 news - <1% prohibited material #8 news - 0.25% prohibited material, bought by mills Dec., 2012 Prices #6 50 $/ton #8 90 $/ton
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Cardbox Composition
Linerboard - The inside and outside of a box that confers strength Medium(fluting) - fluted section in between linerboard Containerboard a box
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Paper Recycling 6: OCC

~12% of MSW (2001) ~71% recovery rate Uses: Container board (linerboard and corrugating medium) news boxes require 20% OCC construction products wallboard, roofing felt Paperboard Dec. 2012 Prices 70-130 $/ton
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Paper Recycling 7: OFF

There are a number of grades of office paper: office paper only white copy and pad paper standard office mix that may include: envelopes (with and without plastic) mail including coated papers colored paper folders and card stock
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Paper Recycling 8: Office Paper (OFF)
ISRI Grades & 2006 Price: 127: sorted white ledger 119: sorted color ledger Mixed Office Paper Clean, sorted ledger & writing papers, free of brown grades, cardboard, boxboard, may contain up to 10% groundwood paper fiber content
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Paper Recycling 9: Office Paper (OFF)

Problems no consistent definitions/varying markets adhesive labels, stamps paper clips, plastics grey and brown products (brightness) Uses: historically tissue paper printing and white (somewhat grey) paper is a newer use Federal agencies must use paper with 30% recycled content by 1998
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Paper Recycling 10: Old Magazines (OMG)

Coated magazine and catalog papers OMG facilitates ONP ink flotation Ample market capacity given high demand for ONP
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Paper Recycling 11: Residential Mixed Paper (RMP)

May contain OMG, books, ONP, third class mail, envelopes,food cartons and OCC A relatively low quality fiber but incentives to use: cheap and in large supply Uses are limited due to fiber length: Egg cartons, roofing felt, fruit, separators Boxboard and wallboard backing
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Paper Recycling 12: RMP

May be used where shortages of other paper grades develop Price will depend on availability of better papers Solid waste manager must figure out what to separate and what to leave as mixed paper Flexibility is key
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Paper Recycling 13
Effects of recycling weaker fibers decreased burst strength stiffer paper This decreases ability to light weight a box Losses During Recycling: OCC: 10-15% OMG: 40-60% OFF: 8-20%
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Paper Recycling 14: European paper flows

Million tonnes
Ref: CEPI, 2004
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Paper Recycling 15: Paper market prices
Ref: Danfiber, 2009
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Container Glass: Short version

Glass is made primarily from sand (quartz), soda and lime; nonerenewable but not scarce resources Problems with post-consumer glass: Mix of colors, foreign objects (ceramics, metal caps). More than a few percent of wrong color affects the color of the remanufactured product Major benefits: Energy savings in production Products: Glass containers/bottles, insulation material
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Glass: Types
Soda-lime glass, which is used for bottles, jars, drinking glasses and window glass, is typically produced from 70-75% quartz sand (SiO2, particle size 0.1-0.4 mm), 12-16% soda (Na2O, Na2CO3), 10-15% lime (CaO, CaCO3) and traces of other materials. Crystal glass, which is used for high-quality drinking glasses, vases, art etc, is typically produced from 54-65% SiO2, 18-38% PbO, 1315% Na2O or K2O and various other oxides. Borosilicate glass (Pyrex glass), which is used for laboratory glass ware, kitchen glass ware and high temperature lamps, is typically produced from 70-78% SiO2, 7-13% B2O3, 4-8% Na2O and K2O, and 2-7% Al2O3. Borosilicate glass is corrosion and temperature resistant.
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Container Glass Recycling 1

Glass is about 5.5% of MSW / 90% containers beer and soda food jars wine/liquor ~55% clear (flint) ~6% green (50% imported) ~38% brown (amber) Only container glass can be recycled
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Recycling processing Color separation is critical due to tight specs on end product (glass containers) optical sorting possible at regional level Source separation is most efficient as breakage reduces ability to separate colors
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Pricing ($/ton) Dec. 2009 end user Clear 29 Brown 17 Green 8 Market for recycled glass historically stable (except green) market share is shrinking due to plastic
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Uses new beverage containers these alternates provide a market for mixed color glass substitute for stone and sand in asphalt (up to 20%) fiberglass insulation drainage material 1992: California required fiberglass manufacturers to use 30% recycled glass
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Processing Shipped either crushed or loose Cullet (crushed glass) requires less energy to melt compared to sand & already contains additives Specifications clear - 95%, green and brown - 90% no metal, rocks, ceramic
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Aluminum: Short version

Aluminum is obtained under great energy expenses from mined bauxite, a limited non-renewable mineral Problems with post-consumer aluminum: Few if clean from other metals Major benefits: Energy savings in production, preserving a resource with a large environmental signature Products: Any new aluminum product. No loss of quality
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Aluminum Recycling
Al is about 0.7% of MSW The aluminum stream contains: ~63% Beverage containers ~14% Other non-durables Foil & other packaging ~23% Durables Appliances, lawn furniture, construction waste (gutters, etc.)
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Aluminum Recycling
What can be recycled? Essentially everything - the only limit is cleanliness and price paid Price structure (Dec. 2012): delivered to end user UBC - Used beverage can 1200-1800 $/ton Clean scrap higher Foil lower
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Market Conditions
The aluminum companies will buy as much as they can get Recycled aluminum is used for:
New beverage cans - 27% Building and construction - 21% Transportation - 21% Electrical goods - 9% Other - 23%
Major barrier to aluminum recycling is collection National UBC recovery rate is <50% (2007), Higher (70 - 95%) in states with bottles bills
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Aluminum Recycling
Processing of used aluminum Shred, flatten or bail for transport, cans are actually blown into a trailer Tremendous energy savings realized with use of recycled aluminum ~95% energy saving in production Eliminates energy for mining Requires energy for collection
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Iron / steel: Short version

Iron / steel is obtained under great energy expenses from mined ore. Iron is a non-renewable mineral, but rather abundant Problems with post-consumer : Few if clean from other metals (tin as plating, lead as solder) Major benefits: Energy savings in production, preserving a resource with a large environmental signature Products: Any new iron product. If tin or lead have penetrated into the iron, the quality may be lower
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Steel Recycling
7.9% of solid waste stream 22% of steel is food and beverage cans 58% -appliance, furniture, tires, other durables (excludes - cars, construction waste) Ferrous metal is easily separated from shredded MSW with magnets but this is quite rare (~95% pure)
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Steel Recycling
Depending upon the furnace type - can utilize 20 to 100% scrap as raw material Market is soft and fluctuates but overall market capacity is adequate
Controlled by price at scrap yard White goods - dealers may charge if they contain CFCs
Pricing (Dec. 2012) Cans 100-200 $/ton
Ref: Danfiber, H.J. Hansen, Westmetall, 2009
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Plastics Recycling
~12% of MSW stream by weight Plastics - polymers that can be formed into shapes, typically by the application of heat and/or pressure Two categories thermoplastics: soften when heated and can be remolded (recycled) 85% of manufactured plastic thermosetting: do not soften when heated and cannot be remolded, limited opportunity for recycling 15% of manufactured plastic
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Plastics Production
Raw materials: ethylene oxide, benzene Raw materials ---> resin (petrochemical industry) ~300 Resin ----> molded products (independent producers) 1000's hundreds of types of resins
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Plastic Recycling
Plastics can only be recycled if separated by resin type Currently no mechanical processes are available to sort plastic from mixed refuse Sortation of HDPE/PET/PVC can be done
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Types Of Thermoplastics: HDPE

High density polyethylene (HDPE) Consumer products: Containers for milk, water, foods, oil (~0.3% of MSW) Major division for recycling: translucent HDPE - milk and water jugs (0.05 0.30 $/lb baled) pigmented HDPE - household industrial chemical containers (HICs) (0.13 0.22 $/lb): oil, detergent, shampoo
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Types Of Thermoplastics: HDPE

Recycle market: Need for translucent/pigment separation is not always necessary some MRFS ship mixed PET/HDPE (lower value) Products: Garbage bags, flower pots, speed bumps, drain pipes, auto parts, films, toys, Sandwich layer in bottles
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Types Of Thermoplastics: PET

Polyethylene terephthalate (PET) Consumer products: soda and liquor bottles beverage bottles - ~0.4% of MSW custom PET is other recyclable component Major recycled markets: carpets, polyester fiberfill, auto parts, textiles (~70%) approved for contact with food (1998)
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Types Of Thermoplastics: PET

The most widely recycled resin because 30% of the U.S. population lives in bottle bill states Also the most valuable plastic resin ethylene glycol plus dimethyl terephthalate
44 Copyright Anders Damgaard & Morton A. Barlaz, NC State University
44
Types Of Thermoplastics: Polystyrene (PS) (Styrofoam)

Consumer products: Fast food packaging, packing for shock insulation, eating utensils, dairy containers Recycled markets: Packing for shock insulation, desk accessories Recycling: Technically feasible Limitations: cost due to light weight cost to wash
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Types Of Thermoplastics: PVC

Polyvinyl chloride (PVC) has been a shift away from use in household containers it burns before PET melts Polypropylene (PP) Films, Textiles
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Composition of Plastic Waste Stream (2005) (See Table 7 for 2010 data)
Resin Type PET HDPE PVC LDPE/LLDPE PP PS Other Durables % 5.5 7.5 5.9 8.8 15.7 8.4 48.2 Non- Durables % 3.7 10.8 10.0 37.0 13.7 23.0 1.5
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Products for which the majority is made from one resin

Item Resin/ Share of Product Food Packaging Film LDPE/ 65% Carryout bags HDPE/ 63% Dairy containers HDPE/52% Pipe and conduit PVC/ 96% Trash bags LLDPE/ 62% HIC bottles HDPE/ 80% LLDPE - Linear Low Density Polyethylene
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Plastic Recycling
What left must be treated as commingled plastic it can be made into plastic lumber development of construction specifications expensive relative to wood for all but high end uses, need specific uses new life as CCA treated lumber is banned Other sources of pure material: pallet wrap process trimmings
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Barriers To Recycling
1 Collection/participation 2 Cost of resin fluctuates
50 Copyright Anders Damgaard & Morton A. Barlaz, NC State University
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Wood Waste
Pallets, tree trimmings, land clearing debris Typically comes in Monoloads" Markets BioCycle,Jan., 1995: $/ton
Paper pulp Wood composite materials Fuel (8500 BTU/lb) Mulch Landfill cover Road stabilization animal bedding 2-5 5-35 0-20 0-10 0-2 ? 0-20
The distance to market is critical as the value is low: transportation cost - 0.1 $/ton-mi
Copyright Anders Damgaard & Morton A. Barlaz, NC State University 51
Tire Recycling
Generation rate ~ 1 per person per year 290 million generated in 2003 Proper inflation = source reduction!! Unique problems Whole tires do not stay buried in landfills Serve as breeding grounds for mosquitoes Present a special fire hazard
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Tire Recycling
Alternative uses for tires Retreading Direct reuse combustion tire derived fuel (TDF) Reuse in other products
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Tire Recycling
A tire contains three components: Rubber (~12 lb) Fabric (~4 lb) Metal (~4 lb) In several layers: Rubber Beads Fabric and steel Rubber / tread
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Tire Recycling
Combustion As "tire derived fuel" in industrial boilers (~50% of all tires) Cement kilns where the lime in cement neutralizes the SO2 Whole or 2" chips Paper industry boilers 2" chips Utilities -- ? http://www.rma.org/scrap_tires/
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Tire Recycling
Reuse in other products Drainage material CE Applications (14.2% in 2001) leachate distribution septic fields erosion control subgrade fill backfill for walls and bridge abutments
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Tire Recycling
Crumb rubber for low end rubber products (11.7% in 2001) car mats mud flaps shoe soles carpet backing tires for wheel barrel and tricycles recreational surfaces (e.g. tennis courts)
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Tire Recycling
Low end rubber products (contd.) Overall demand is not adequate Over 50% of U.S. demand for rubber is for tires Any time crumb rubber is produced, steel and fiber remain for disposal Use in asphalt rubber mixtures Technically feasible but typically not as viable as combustion
Copyright Morton A. Barlaz, NC State University 58 Copyright Anders Damgaard & Morton A. Barlaz, NC State University
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Tire Recycling
SUMMARY 1. Use in cement kilns, and use in other boilers as TDF works well and is dominant outlet 2. Demand for use as a drainage material varies with location
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Material Markets
Prices are volatile
BLS OCC National
300 250
Monthly Price Index
200 150 100 50 0
Deflated by the ppi Base 12/86
12/1/1986 3/1/1988 6/1/1989 9/1/1990 12/1/1991 3/1/1993 6/1/1994 9/1/1995 12/1/1996 3/1/1998
Overview of Futures Markets Copyright Anders Damgaard & Morton A. Barlaz, NC State University 60
Material Specifications
Often subjective but reputation is critical MRFs and processors must have end users (purchasers) Often will take less money for sales guarantees Specifications vary with the plant capability with material demand over time
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Material recycling

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Purpose of reuse in industry

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper and paper products: Short version

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 1: Major Grades

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 2: Major Grades

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 3 Major Grades

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 4: ONP

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 5: ONP

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 6: OCC

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 7: OFF

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 8: Office Paper (OFF)

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 9: Office Paper (OFF)

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 10: Old Magazines (OMG)

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 11: Residential Mixed Paper (RMP)

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 12: RMP

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 14: European paper flows

Ref: CEPI, 2004

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Paper Recycling 15: Paper market prices

Ref: Danfiber, 2009

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Container Glass: Short version

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Container Glass Recycling 1

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Container Glass Recycling 2

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Container Glass Recycling 3

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Container Glass Recycling 4

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Container Glass Recycling 5

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Aluminum: Short version

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Iron / steel: Short version

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Pricing (Dec. 2012) Cans 100-200 $/ton