3 Matl Recycle PDF

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 1

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 converter´s
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

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

Cardbox Composition
• Linerboard - The inside and outside of a box that confers strength

• Medium(fluting) - fluted section in between linerboard
• Containerboard – a box

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

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

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”

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

Paper Recycling 10: Old Magazines (OMG)
• Coated magazine and catalog papers

• OMG facilitates ONP ink flotation
• Ample market capacity given high demand for ONP

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

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

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%

Paper Recycling 14: European paper flows
Million tonnes
Ref: CEPI, 2004

Paper Recycling 15: Paper market prices
Ref: Danfiber, 2009

Container Glass: Short version
• Glass is made primarily from sand (quartz), soda and lime; none-
renewable 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

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, 13-
15% 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.
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

• 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

 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

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

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

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

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.)

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

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

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

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

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)

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
Ref: Danfiber, H.J. Hansen, Westmetall, 2009
• Pricing (Dec. 2012)
Cans 100-200 $/ton

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

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

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

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

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

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)

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
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

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

Composition of Plastic Waste Stream
(2005) (See Table 7 for 2010 data)
Resin Type Durables % Non- Durables %
PET 5.5 3.7
HDPE 7.5 10.8
PVC 5.9 10.0
LDPE/LLDPE 8.8 37.0
PP 15.7 13.7
PS 8.4 23.0
Other 48.2 1.5

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

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

Barriers To Recycling
1 Collection/participation
2 Cost of resin fluctuates
50
Wood Waste
• Pallets, tree trimmings, land clearing debris
• Typically comes in ”Monoloads"
• Markets BioCycle,Jan., 1995: $/ton
– Paper pulp 2-5
– Wood composite materials 5-35
– Fuel (8500 BTU/lb) 0-20
– Mulch 0-10
– Landfill cover 0-2
– Road stabilization ?
– animal bedding 0-20
The distance to market is critical as the value is low: transportation
cost - 0.1 $/ton-mi

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

Tire Recycling
• Alternative uses for tires

– Retreading
– Direct reuse
– combustion – tire derived fuel (TDF)
– Reuse in other products

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

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/

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

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)

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

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

Material Markets
• Prices are volatile
BLS OCC National
300
250
Monthly Price Index
200 Deflated by the ppi

Base 12/86
150
100
50
0
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

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

3 Matl Recycle PDF

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Material recycling

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 1

• Examine recycling process for each material, alternative

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 2

• Ensure raw materials to national industry: Paper, glass, metal.

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 3

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 4

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 5

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 6

• There are about 80 grades of fiber

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 7

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 8

5. Residential mixed paper (RMP)

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 9

• ~4% of MSW in 2010 (includes 18.8% advertising)

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 10

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 11

• Linerboard - The inside and outside of a box that confers strength

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 12

• ~12% of MSW (2001)

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 13

• There are a number of grades of office paper:

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 14

• ISRI Grades & 2006 Price:

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 15

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 16

• Coated magazine and catalog papers

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 17

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 18

• May be used where shortages of other paper grades develop

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 19

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 20

Ref: CEPI, 2004

Ref: Danfiber, 2009

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 22

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 23

• Soda-lime glass, which is used for bottles, jars, drinking glasses

• Glass is about 5.5% of MSW / 90% containers

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 25

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 26

 Pricing ($/ton) – Dec. 2009

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 27

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 28

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 29

• Aluminum is obtained under great energy expenses from mined

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 30

• Al is about 0.7% of MSW

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 31

 What can be recycled?

delivered to end user

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 32

• The aluminum companies will buy as much as they can get

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 33

• Processing of used aluminum

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 34

• Iron / steel is obtained under great energy expenses from mined

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 35

• 7.9% of solid waste stream

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 36

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 37

• ~12% of MSW stream by weight

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 38

Copyright Anders Damgaard & Morton A. Barlaz, NC State University 39