12.83 / T. Gutowski & J. Dahmus / April 22, 2004Recycling2.83 / T. Gutowski & J. Dahmus / April 22, 2004Outline1. What gets recycled and why2. Recycling visits3. Separation technologies4. Cost and energy accounting5. Design for recycling2.83 / T. Gutowski & J. Dahmus / April 22, 20041. What gets recycled?• Metals• Paper• Tires• Auto Batteries• beverage containers• PET• HDPE2.83 / T. Gutowski & J. Dahmus / April 22, 2004Markets for HDPE from bottles 2.83 / T. Gutowski & J. Dahmus / April 22, 2004Plastic bottle recycling rates2.83 / T. Gutowski & J. Dahmus / April 22, 2004Why?• Economics• Mandates• Landfill Bans• Extended Producer Responsibility• Liability Avoidance22.83 / T. Gutowski & J. Dahmus / April 22, 2004Landfill Bans2.83 / T. Gutowski & J. Dahmus / April 22, 2004Purchasing preference laws2.83 / T. Gutowski & J. Dahmus / April 22, 20042. Recycling visits• Wheelabrator• CFR• Autos (Chaparral Steel)• Onyx• Metech• HP/Noranda• DEER2• RRT2.83 / T. Gutowski & J. Dahmus / April 22, 2004Wheelabrator – Trash to AshWorcester, MAHand Sort Burn MagneticEddy CurrentTestingConsumer TrashToxics EmissionsHeatElectricityFerrous MetalsNon -ferrous MetalsAshLandfillHazardous LandfillRevenues Costs2.83 / T. Gutowski & J. Dahmus / April 22, 2004Wheelabrator – Trash to Ash2.83 / T. Gutowski & J. Dahmus / April 22, 200432.83 / T. Gutowski & J. Dahmus / April 22, 20042.83 / T. Gutowski & J. Dahmus / April 22, 20042.83 / T. Gutowski & J. Dahmus / April 22, 20042.83 / T. Gutowski & J. Dahmus / April 22, 20042.83 / T. Gutowski & J. Dahmus / April 22, 20042.83 / T. Gutowski & J. Dahmus / April 22, 2004Wheelabrator• 70% reduction in weight to landfill• 500,000 tons processed per year• 45 MW (produced) – 5 MW (used) = 40 MW to grid• 2.8 MJ/kg (coal ~29 MJ/kg)• dioxin issue / emissions42.83 / T. Gutowski & J. Dahmus / April 22, 2004Curbside Recycling (CFR Charestown, MA)Hand SortNon-recyclables –to landfillMagneticFerrous MetalsSeparated Containers and BottlesAir ClassificationGlass – to landfillEddy CurrentAluminumMilk Cartons, Aseptic Containers, Other Plastics –to landfillHDPEHand SortPET2.83 / T. Gutowski & J. Dahmus / April 22, 2004FCR Recycling – PaperHand SortPaper BagsSeparated Paper ProductsNon-recyclablesNewspaperOffice Paper2.83 / T. Gutowski & J. Dahmus / April 22, 2004FCR Recycling• Recycle ferrous, non-ferrous, paper, HDPE, and PET• Landfill glass, all other plastics, aseptic containers, and material contaminated by food products• Hand and automatic sorting2.83 / T. Gutowski & J. Dahmus / April 22, 2004Automobile RecyclingDisassembly Crush MagneticEddy CurrentAutomobilesHazardous ComponentsRevenues CostsValuable ComponentsResaleableComponentsShredNon -ferrous metalsFerrous metalsASR (to landfill)2.83 / T. Gutowski & J. Dahmus / April 22, 2004Automobile Recycling• Over 94% of cars are recycled• Over 75% of each car is recycled• European Union automobile take-back legislation– by 2006, • 80% reuse/recycling by weight• 85% reuse/recovery by weight – By 2012,• 85% reuse/recycling by weight• 95% reuse/recovery by weight2.83 / T. Gutowski & J. Dahmus / April 22, 2004Onyx Electronics Recyling52.83 / T. Gutowski & J. Dahmus / April 22, 2004Onyx• Customers pay to dispose of items– 15-25¢/ lb for electronic scrap• Certificate of destruction• Fluorescent Bulb Recyling– 6¢/ linear foot for fluorescent bulbsMercury Relays2.83 / T. Gutowski & J. Dahmus / April 22, 2004Metech Computer RecyclingDisassemblyHammer MillRoasting (2400 ° F)Ball MillElectronicsHazardous ComponentsPWBsFinesRevenuesCostsResaleableComponentsFrames and HousingsRing MillEmissionsAshAsh with metal (to smelter)2.83 / T. Gutowski & J. Dahmus / April 22, 2004Metech• Customers pay to dispose of computers– 20¢/ lb without CRT– 35¢/ lb with CRT• Certificate of destruction2.83 / T. Gutowski & J. Dahmus / April 22, 2004HP/Noranda, Roseville, CAhazardous components (including CRT glass) and resalable componentsreusableresalableresiduedustsmall metal particlesferrousnon-ferrousaluminumTestDisassembleShredGranulateShake TableMagneticEddy CurrentGravityotherplasticsPCPlastic Separation…ABSDone offsite2.83 / T. Gutowski & J. Dahmus / April 22, 20042.83 / T. Gutowski & J. Dahmus / April 22, 2004HP/Noranda• Customers pay to return HP products– Monitor $29– PC (without monitor) $21– Ink printer $17• 1.6 million lbs processed per month• 400 hp shredder motor• $4-5 million capital investment in plant• No water used in process62.83 / T. Gutowski & J. Dahmus / April 22, 2004DEER2 (Tampa, FL)ShreddingManual DisassemblyGranulationElutriationDust, debrisPlasticsNon-ferrous metalsEddy CurrentFerrous metalsMagneticShreddingPrinted Circuit BoardsComputer HousingsManual DisassemblyGranulation2.83 / T. Gutowski & J. Dahmus / April 22, 2004DEER2 – Plastics ModuleHydrocycloneLightsHeaviesHydrocyclonePolyolefinsHydrocycloneHeaviesLightsHeaviesHydrocycloneLightsHeaviesHydrocycloneHydrocycloneHIPSSink/FloatPVC, nylonPC, PC/ABSPCElectrostaticPC/ABSPC, PC/ABSABS, HIPSLightsHeaviesLightsHeaviesABS, HIPSElectrostaticABSPlasticsHydrocycloneSink/Float Electrostatic2.83 / T. Gutowski & J. Dahmus / April 22, 2004DEER2• Funded by the DOD• Technology demonstration• $1.2 million for plastic separation module• Max throughput = 1000 lb/hr• Wash/Rinse most expensive step• Metal contaminants cause problems in electrostatic separation• Shape factors cause problems in hydrocyclone and electrostatic separation• 15-17¢ / lb for plastics shred and separate2.83 / T. Gutowski & J. Dahmus / April 22, 2004RRT Design and ConstructionCRT recyclingEnvirocycle (largest CRT tube recycler in US)Techniglass (one of few US CRT manufacturing, produces high quality tubes for military, hospitals)Doe-Run (primary Pb smelter in US, uses Pb-glassas flux)RRT has designed and built systems to crush 300 tubes/hr at capital cost of $250,000 for automated system. Compare to manual 500 monitors/day by 4 people2.83 / T. Gutowski & J. Dahmus / April 22, 20043. Separation Technologies• Magnetic• Eddy Current• Sink-Float• Hydro-cyclone• Electrostatic2.83 / T. Gutowski & J. Dahmus / April 22, 20044. Cost and energy Accountingpre-mfg mfguse collectendoflifereprocess72.83 / T. Gutowski & J. Dahmus / April 22, 2004Cost Questions1. Can you reduce disposal costs?2. Can the recycler make a