1 Post-shredder Residue Recovery Options BEST PRACTICES ON ELVs MANAGEMENTValencia 12-13 June.

1

Post-shredder Residue Recovery Options

BEST PRACTICES ON ELVs MANAGEMENT Valencia 12-13 June

2BEST PRACTICES ON ELVs MANAGEMENT Valencia 12-13 June

Why post-shredding?


What is post-shredding?

LIGHT FRACTION“FLUFF”

HEAVY FRACTION“DIRTY METALS”

FERROUS SCRAP


Light fraction properties

COMPONENT %

Plastic (rigid) 43,33 Film 0,48 Elastomers 3,05 PASTICS 46,69

TEXTILES 12,84

PAPER/CARDBOARD 1,37

WOOD 2,42

Cables (PVC+Cu) 0,52 Adhesive 0,16 Painting cover 0,03 OTHER 0,70 Metal 2,29 Circuit boards 0,00 METALS 2,29

INERT MATERIALS 0,87

FINES (<1mm) 33,11

TOTAL 100

Property Kcal/Kg HHV 5.154 LHV 4.807


Heavy fraction properties

%

COMPONENT

Rigid plastic 35,51 Film 0,02 Elastomers 35,38 PLASTICS 70,91

TEXTILES 6,37

PAPER/CARDBOARD 0,10

WOOD 9,91

Cables (PVC+Cu) 0,42 Adhesive 0,30 Mixed materials 7,75 OTHERS 8,47

Metal 0,30 Circuit boards 0,04 METALES 0,34

INERT MATERIALS 0,93

FINES (<1mm) 2,99

TOTAL 100

Property Kcal/Kg

HHV 6.600,5 LHV 6.162,5


Light fraction treatment

ASR or “FLUFF”

TEXTILES AND LIGHTPLASTICS

HEAVY PLASTICSMETAL MIX

SAND AND FINES

MEDIUM SIZEINNERT MATERIALS


Heavy fraction treatmentHEAVY FRACTION


Technologies

1 Cement Kilns

2 Citron

3 Galloo

4 REA-Distillation

5 Reshment

6 Sicon-VW

7 TwinRec (EBARA)


Cement kilns

INFORMATION PROVIDER

WASTE TREATED LEVELS REACHED

Cement kilns association

www.oficemen.es

Light fraction and heavy fraction w/o metals

5-10% recycling

90-100% recovery

MATERIALS OBTAINED

Clinker and gases

DESCRIPTION OF THE TECHNOLOGY

After milling of raw materials (limestone, marl, clay, slate, etc.) the following compounds are obtained: calcic carbonate, silicon oxide, aluminium oxide and iron oxide. These compounds are fed in rotatory kilns at 1450 ºC, and

then abruptly cooled to obtain clínker. Milling of clínker with other components produce different types of cement. The system includes a cyclone tower for heat interchange in which material is preheated. The

calcination is improved precalcinator is added. INSTALLED CAPACITY

There are almost 40 plants in Spain but only about 19 of them have authorization for using alternative fuels obtained from waste


Cement kiln process


Citron



CITRON

www.citron.ch

Light fraction 50% recycling

50% recovery

MATERIALS OBTAINED

Metals, Mineral products, Gas, ashes


The process used by CITRON consists of a rotatory furnace with reducing atmosphere but with a series of burners that produce an oxidating zone that causes that the residual organic part is destroyed before taking the gas to a

humid cleaner. The process serves to volatilize some heavy metals, to take it to the gaseous phase to disturb organic compounds 1200ºC so that the

residual ashes can serve as feed material in the cement plants

INSTALLED CAPACITY

A plant in Rogerville exists (France) that treats 120,000 Tn/year which 20,000 are of shredder light fraction.


Citron process


Galloo



GALLOO GROUP

www.galloo.com

Light fraction 15-45% recycling

15% recovery

MATERIALS OBTAINED

Mineral fraction(40%) light fraction (30%), heavy caloric fraction (15%) plastic fraction (10%) Rest (5%)


By different mechanical processes the plants of Galloo Group obtain different fractions that are used in other industries. The process has been developed in a way that, as it has been mentioned above, allowe to obtain five different

fractions that in some cases are used in other processes

INSTALLED CAPACITY

The more specialized plants are the one of Galloo plastics in Halluin (France) 100,000 tn/año and Galloo metals in Menen (Belgium) 100,000 tn/año.


Galloo process


REA (Distillation)



Reciclados Ecológicos Andaluces S.L.

Heavy fraction, light fraction and tyres

70% recycling

30% recovery

MATERIALS OBTAINED

Crude oil, Carbon powder, Steel.


In the process, the wastes are mixed in the distillator along with used oil, that is warmed up in its external part with hot air, coming from the boiler of

biomass. The dissolution-distillation process is carried out in two steps. In first the dissolution in a hot oil bathtub is realised, so that temperature facilitates the desvulcanization of rubbers and the gradual dissolution of plastics. The second step is the distillation itself that produces the crude oil and the black

carbon liberating the steel from the tyres.

INSTALLED CAPACITY

A plant in Aznalcollar is expected to start operating on July 2008 with capacity between 5,000 and 10,000 tn/year. The strategy of expansion of the

company is to have 9 similar plants in 2009. .


REA-Distillation process


Reshment



Swiss Auto-Rec Foundationwww.stiftung-autorecycling.ch


43% recovery

MATERIALS OBTAINED

Metals, Vitrified granulate, energy, ashes


The process used by Reshment is similar to the Twin-Rec Ebara process although it is designed to work with a mixture approximately 50% RLF 50% of

another waste with similar heating value. The main differences are in the atmosphere of the cyclonal combustion chamber of the Reshment process

which is reductant and that uses a mechanical pre-treatment of the fluff before introducing it in the cyclone and not a thermal process as in Ebara.

INSTALLED CAPACITY

There are plants in operation in Japan and Switzerland had approved the construction of a plant but the cost was too high for the 155,000 ton/year

dimension needed.


Reshment process


Sicon-VW



SICon GmbH www.sicontechnology.com

Light fraction 82,5% recycling

0% recovery

MATERIALS OBTAINED

Shredder plastic granulate , High PVC plastics fraction, Shredder fibres, Shredder sand, Fracción Metálica


The technology essentially is based on the crushing and the mechanical separation of the shredder light fraction. The process of Sicon-VW is based on the generation of flows of materials through specific treatment and the

refining of the residues of the shredder with the aim of being able to use the materials obtained in other industries like secondary raw materials replacing

the primary ones.

INSTALLED CAPACITY

There is a plant at Belgian Scrap Terminal (BST) located in Kallo (Belgium) for 20,000 ton/year. In addition Netherlands and Austria (Enns) are building

two industrial plants for 100,000 ton/year that should be running in 2008.


Sicon-VW process


Twinrec-EBARA



EBARA

www.ebara.ch


50% recovery

MATERIALS OBTAINED

Metals, Granulated Glass, Ashes


The process of Ebara TwinRec is a combination of two existing technologies as gasification in fluidised bed furnace and vitrification of ashes in a cyclonal combustion chamber at high temperature. The furnace is fed by a mixture on

ASR and ashes coming from plants treating MSW but the technology has been proven with ASR and is perfectly applicable with mixtures of residues if

they have a calorific power inferior similar to the one of the ASR.

INSTALLED CAPACITY

There are 17 lines that use this technology in Japan but 2 important tests with light fraction have been carried out: one in Aomori (Japan) with 420 Tn and

another one in Baden (Germany) with 400 Tn.


Twinrec-EBARA process


Other technologies have failed

Due to different reasons (undefinition of the recycling definitions, lack of regulations, lack of profit, stricter legislations, etc. many technologies have failed in the last years. Some examples are:

- SALYP- Thermoselect- Catalytic processes- Thermolisis- etc.


Commission Report on targets

THE CONCLUSION IS THAT

THE TARGETS MUST BE MANTAINEDBECAUSE THEY GENERATE BENEFITS

BOTH ECONOMIC AND ENVIRONMENTAL. THE COMMISSION WILL PROMOTE ECO-INNOVATION IN THE SECTOR MAINLY IN

INNOVATIVE SHREDDINGTECHNOLOGIES AND PLASTIC RECYCLING


The actual situation

All Member States are in a similar situation with regards the levels achieved.

Post shredding technologies are very promising but there is not enough capacity installed (see “A study to examine the benefits of the End of Life Vehicles Directive and the costs and benefits of a revision of the 2015 targets for recycling, re-use and recovery under the ELV Directive”, GHK / BIOIS, May 2006. on the

Commission’s webpage)


The recycling definition

The definitions of reuse, recycling, energy recovery, elimination, etc. are not clear enough and it is necessary to be more precise

DEFINITION PROPOSED BY EP:

“'recycling' means the reprocessing of materials or substances in wastes through a production process in such a way that they

produce or are incorporated in new products, materials or substances whether for the original or other purposes. It includes reprocessing of organic material, but does not include, inter alia, energy recovery, conversion for use as a fuel, processes involving

combustion or use as a source of energy, including chemical energy, or backfilling operations; ;

INITIAL COM PROPOSAL SUPPORTED BY INDUSTRY:

recycling’ means the recovery of waste into products, materials or substances whether for the original or other purposes. It does not

include energy recovery;Only a broad and consistent recycling definition, as proposed by the EU Commission, will create legal certainty and thereby would ensure continued development, investment and operation of innovative and eco-efficient recycling plants


The recycling definition Independent and externally reviewed LCA studies show that the affected recycling plants have excellent environmental performance, because they have the technological means to save valuable scarce resources. This means significant savings of CO2 and other environmentally detrimental emissions. DG ENV has recognized this activity in its awarding the SiCon process with the European business award for the Environment.

Some examples for endangered investments of SMEs:

• By exclusion of “conversion for use as a fuel”: Some activities, that are on the way, exploring the possibilities of transferring waste-derived fractions in a CO2-efficient manner into fuel (Waste to liquid: Diesel,…)

• By exclusion of ”processes involving combustion or use as a source of energy, including chemical energy”: Bernegger/Voest in Austria and future Sicon plants in the Netherlands, Belgium, France and Germany and under evaluation in other countries as well as SVZ (methanol production from waste, Germany).


SIGRAUTO’s activities

SIGRAUTO is also working on other technologies that seem could be a great solution for the shredder residues. Some trials

have already been made and further work is needed before making any decision.

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