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SYNTHESIS REPORT OF BASELINE STUDY REPORTS (BSR-R)

OF SARMα MODEL SITES

Activity 3.3 (Recycling)

June 1st, 2011

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DELIVERABLE SUMMARY

PROJECT INFORMATION

Project acronym: SARMa

Project title: Sustainable Aggregates Resource Management

Contract number:

Starting date: 1. 5. 2009

Ending date: 31. 10. 2011

Project website address: www.sarmaproject.eu

Lead partner organisation: Geological Survey of Slovenia

Address: Dimičeva ulica 14, SI-1000 Ljubljana

Project manager: Slavko V. Šolar

E-mail: [email protected]

DELIVERABLE INFORMATION

Title of the deliverable: Activity 3.3 (Recycling) Synthesis Report

WP/activity related to the deliverable:

WP3 / Activity 3.3

Type (internal or restricted or public):

Public

Location (if relevant): -

WP leader: IGME

Activity leader: RER/Politecnico di Torino

Participating partner(s): All partners

Author: Gian Andrea Blengini, Elena Garbarino

E-mail: [email protected]; [email protected]

DELIVERY DEADLINES

Contractual date of delivery to the JTS:

Actual date of delivery to the JTS:

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TABLE OF CONTENTS

EXECUTIVE SUMMARY ______________________________________________________________________ 4

1. INTRODUCTION _________________________________________________________________________ 6

1.1 THE ROLE OF RECYCLING IN THE SARMA PROJECT _____________________________________________ 6

1.2 REFERENCE FRAMEWORK: EU DIRECTIVES & COM RELEVANT TO AGGREGATE RECYCLING _____________ 8

1.3 PROPOSED CLASSIFICATION OF RECYCLING ACTIVITIES WITHIN SARMA ____________________________ 9

2. METHODOLOGY AND SYNTHESIS OF BASELINE STUDY REPORTS (BSR-R) ________________ 11

2.1 CASE STUDY 1 - ALBANIA (METE): THE CHROMIUM DRESSING PLANT OF BULQIZA __________________ 14

2.2 CASE STUDY 2 – GREECE (IGME): THE MAGNESITE MINE OF GERAKINI ____________________________ 15

2.3 CASE STUDY 3 – ITALY (RER/PARMA): THE RECYCLING PLANT OF COLLECCHIO/MADREGOLO _________ 17

2.4 CASE STUDY 4 – ITALY (RER): THE RECYCLING PLANT OF CASTELLARANO _________________________ 19

2.5 CASE STUDY 5 – ROMANIA (IGR/FGG): THE DEVA-RUSCHITA MARBLE QUARRY _____________________ 22

2.6 CASE STUDY 6 – SLOVENIA (GEOZS): THE DOLOMITE QUARRY OF VELICA PIRESICA __________________ 24

2.7 CASE STUDY 7 – SLOVENIA (GEOZS): THE LIMESTONE QUARRY OF SEŽANA ________________________ 26

2.8 CASE STUDY 8 – SLOVENIA (GEOZS): THE SAND AND GRAVEL QUARRY OF DOGOŠE __________________ 27

2.9 CASE STUDY 9 – SLOVENIA (GEOZS): THE DOLOMITE QUARRY OF SMARJE-SAP ______________________ 28

3. DISCUSSION AND RECOMMENDATIONS _________________________________________________ 29

3.1 RECOMMENDATIONS ___________________________________________________________________ 32

4. CASE STUDIES –FULL TEXT BASELINE STUDY REPORT (BSR-R) ___________________________ 34

CASE STUDY1 - ALBANIA (METE): THE CHROMIUM DRESSING PLANT OF BULQIZA ______________ 35

CASE STUDY 2 - GREECE (IGME): THE MAGNESITE MINE OF GERAKINI __________________________ 49

CASE STUDY 3 - ITALY (RER/PARMA): THE RECYCLING PLANT OF MADREGOLO _________________ 63

CASE STUDY 4 - ITALY (RER/PARMA): THE RECYCLING PLANT OF CASTELLARANO ______________ 79

CASE STUDY 5 - ROMANIA (IGR/FGG): THE MARBLE QUARRY OF DEVA-RUSCHITA _____________ 100

CASE STUDY 6 - SLOVENIA (GEOZS): THE DOLOMITE QUARRY OF VELICA PIRESICA ____________ 109

CASE STUDY 7 - SLOVENIA (GEOZS): THE LIMESTONE QUARRY OF SEŽANA ____________________ 116

CASE STUDY 8 - SLOVENIA (GEOZS): THE SAND AND GRAVEL QUARRY OF DOGOŠE ____________ 123

CASE STUDY 9 - SLOVENIA (GEOZS): THE DOLOMITE QUARRY OF SMARJE-SAP ________________ 130

5. REFERENCES _________________________________________________________________________ 137

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EXECUTIVE SUMMARY

This synthesis report was drawn from the Baseline Study Reports (BSR-R) prepared by the

SARMa partners involved in Activity 3.3, focused on aggregate recycling.

The overall objective is to provide an overview on aggregate recycling at local scale, based on

meaningful case studies selected during the SARMa project.

According to the SARMa workprogramme, this report is relevant to Work Package 3 / Activity 3.3.

The activity leadership was subcontracted to Politecnico di Torino through Regione Emilia

Romagna (RER).

As South East Europe is concerned and according to the experience gathered through the SARMa

project case studies, the overall attitude to recycle, and the way recycling activities are conceived

and managed in order to become source of unconventional aggregates, appears to be sensibly

different from one country to another. As a consequence, giving a comprehensive picture of

aggregate recycling appeared to be nearly impossible, while it was considered more meaningful to

the SARMa project to pick up examples of successful recycling operations that, even though

sensibly different in terms of context and technologies, might be used in order to exchange know-

how and promote recycling among partner countries.

All this considered, the layout of this synthesis report is the following.

After a short introduction in order to better frame aggregate recycling within Sustainable Aggregate

Resource Management (SARM) and Sustainable Supply Mix (SSM), also in the context of the most

relevant EU Directives and Communications, the first section is dedicated to a proposed

classification of recycling activities, thought as potential sources of unconventional aggregates (i.e.

aggregates other than natural aggregates extracted from a quarry run on purpose).

Four types of recycling are considered:

R1: Recycling of by-products, waste and residues from extractive activities

R2: Recycling of Construction and Demolition Waste (CDW)

R3: Recycling of excavated soils/rock from civil works

R4: Recycling of industrial waste (e.g. slags from civil ferrous metal production, bottom ash from

Municipal Solid Waste (MSW) incineration, ashes from coal combustion)

The second section presents a synthesis of the case studies, pointing out why they are relevant to

the SARMa project and what message can be delivered to the SARMa partners and stakeholders

in order to promote recycling, SARM and SSM.

The third section is dedicated to a brief discussion on the main outcomes that were obtained from

Activity 3.3. On this point it is useful to remarks that collected data and background information

were useful in order to set up the Life Cycle Assessment guidelines also included in Activity 3.3.

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A preliminary set of recommendations was provided:

In order to enforce EU strategies, a strong synergy between mining, traditional mineral

processing and recycling has to be promoted.

Because natural aggregates producers own the technical know-how on natural aggregates

processing, they can usefully apply it in recycling of aggregates.

Conventional natural aggregates and aggregates from unconventional sources (recycling)

should not be considered competitors, but rather their joint utilisation is strategic to SSM.

It is not always necessary to develop new technologies for recycling; rather innovation in

recycling can be regarded as extension and adaptation of already available and well-accepted

technologies.

Cooperation between mining and recycling has to be encouraged to maximise economic and

environmental benefits.

Where possible, recycling should be an evolution of traditional extractive or mining activities.

Recycled/manufactured aggregates can substitute/integrate natural aggregates in applications

such as road construction and concrete production, always with respect to the required quality

standards.

It is advisable to shift the focus from the origin of aggregates (natural, recycled or

manufactured) to the technical quality of the aggregate itself, as recommended by the

80/106/EEC Directive on construction products.

CE marking is mandatory for aggregates. This represents a very important tool for removing

obstacles to the use of recycled/manufactured aggregates for several end-uses and it’s an

incentive for producing high quality aggregates.

To avoid decay of end-products technical performance, high-grade recycled aggregates must

be produced using advanced/appropriate technologies.

Life Cycle Assessment (LCA) can be used to enhance environmental efficiency of aggregates

quarrying, as well as recycling, and help understanding the role of natural and recycled

aggregates in the SSM.

The fourth and last section reports the full text BSR-Rs.

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1. INTRODUCTION

The approach to Activity 3.3 of the SARMa project is based on first, understanding the role of

recycling within SARMa, then placing that within the appropriate reference framework, followed by

a discussion of how recycled materials should be classified.

This is followed in chapter 2 by first a general introduction to the case studies conducted by the

partners, followed by a vertical description of characteristics of each.

1.1 The role of recycling in the SARMa project

As one of the main challenges of SARMa is to promote recycling and encourage sustainable

supply mix (SSM) policies, the focus of Activity 3.3 is on recycling activities, thought as potential

sources of unconventional aggregates, as opposed to conventional natural aggregates (i.e. natural

aggregates extracted from a quarry run on purpose).

Aggregates are essential and valuable resources for the economic and social development of

mankind, but they must be produced and used according to Sustainable Development principles.

In such a context, Sustainable Supply Mix (SSM) can be defined as: “Procurement from multiple

sources, according to criteria of economic, environmental and social efficiency”. SSM can therefore

be regarded as a blend of natural aggregates, quarry/mine by-products, excavated rock/soils and

recycled waste, which together maximize net benefits of aggregate supply across generations.

Coming to the SARMa project and SEE countries, at the site level the key issues are high

environmental impacts, limited recycling, need for stakeholder consultation and capacity, and lack

of social license to operate.

At the regional/national level, the issues are policies and regulations dealing with aggregates that:

do not address resource and energy efficiency; preclude the use of recycled materials and

industrial by-products; and fail to address aggregate consumption in long-term sustainable

development and spatial planning.

Moreover, it has to be remarked that some recycling activities (e.g. recycling of quarry by-products

and residues) are strictly connected to quarrying of natural aggregates. In this sense, Sustainable

Aggregate Resource Management (SARM) makes quarrying and recycling of by-products and

residues inseparably connected.

This said, recycling should not be considered a stand-alone activity, but should rather be framed in

a wider context of integrated resource and waste management.

One advantage of recycling is landfill avoidance, which implies saving of waste dump capacity, i.e.

space: a very important and scarce resource nowadays in many European countries. According to

the statistics, landfill is in fact the current practice for most of inert waste (e.g. 70% of construction

and demolition waste in Europe), far away from the target of the European Union directive

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2008/98/CE which has set up the minimum rate of recycling at 70% by the year 2020. Moreover,

illegal landfill is still largely adopted in some areas of Europe.

Several kinds of mineral by-products, waste and residues can be effectively turned into secondary

products through recycling and thus these recycled products (i.e. unconventional aggregates) can

be used in substitution or in mix with natural aggregates for several end-uses, saving, at the same

time, land and non-renewable resources.

Bearing this in mind, and given the ever increasing quantity of mineral by-products, waste and

residues to be handled or disposed of, a challenging issue presently facing policymakers and

public administrators concerns how to organize and manage collection and recycling and to

understand whether and to what extent alternative aggregates can complement conventional

natural aggregates in the sustainable supply mix.

Due to the fact that the quality of recycled aggregates, as well as the subsequent potential end-

uses, mostly depends on the adopted processing technologies, special attention has to be paid to

the features of the recycling plants. It is well known, in fact, that the quality of recycled aggregates

generally depends more on the technical features of the processing plant rather than on technical

characteristics of the waste to be recycled. On the contrary, the quality of natural aggregates

depends more on the physical and chemical characteristics of the natural resource in ground and

comparably less on the features of the processing plant.

In Europe, per capita requirement of building aggregates is 6 to 12 t/y, while per capita production

of construction and demolition waste C&DW (which is one of the main potential sources of

alternative aggregates) is around 0.8 t/y. No reliable and comprehensive statistics are available for

other potential sources of unconventional aggregates. However, also because of the existence of

physical limits to recycling, it clearly emerges that the potential contribution of unconventional

aggregates is reasonably below 20%, depending on the recycling efficiency and quality of recycled

products.

Conventional natural aggregates and aggregates from unconventional sources (recycling) are not

therefore in competition, but rather their joint utilisation is strategic to SSM.

Moreover, it has to be stressed that recycling can avoid landfill and partially displace environmental

impacts of quarrying but, similarly to any other industrial activity, it is responsible of environmental

impacts and might increase transport-related impacts. It is therefore possible that more energy is

spent and higher impacts are caused by one or more activities in the recycling chain, in

comparison with saved energy and impacts. In such a context, Life Cycle Assessment becomes a

necessary tool in order to optimise the environmental and resource use efficiency of the SSM,

helping us to determine the best proportion between conventional and unconventional aggregates

and to identify the most efficient recycling chains.

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1.2 Reference framework: EU Directives & COM relevant to aggregate recycling

As already mentioned, recycling is regarded in SARMa as potential source of aggregates.

However, as these potential sources are many in number and context, as well as they are strictly

connected with industrial operations and/or waste management activities which might be

associated with potential release of substances harmful to human and/or ecosystem health, the

juridical and normative framework is quite complex.

For this reason, the following EU Directives, Communications and Reports relevant to Waste

management, Sustainable use of resources, Recycling, as well as Construction Products, were

considered as fundamental background knowledge for the Activity 3.3.

1. Directive 2006/21/EC of the European Parliament and of the Council of 15 March 2006 on the management of waste from extractive industries

2. Directive 2008/98/EC of the European Parliament and of the Council of 19 November 2008 on waste and repealing certain Directives

3. Commission Communication of 21 February 2007 on the Interpretative Communication on waste and by-products [COM(2007) 59]

4. Commission Communication of 21 December 2005: “Taking sustainable use of resources forward: A Thematic Strategy on the prevention and recycling of waste” [COM(2005) 666]

5. End-of-waste criteria. Final Report - JRC Scientific and Technical Reports, 2008

6. European Directive 89/106/EEC of 21.12.1988 on the Approximation of Laws, Regulations and Administrative Provisions of the Member States on Construction Materials

7. AGGREGATES CASE STUDY, Final Report to contract n° 150787-2007 F1SC-AT, http://susproc.jrc.ec.europa.eu/activities/waste/documents/Aggregates_Case_Study_Final_Report_UBA_080331.pdf

Involved partners were warmly invited to consider all the above references and collect all the

related laws and regulations at national/regional level.

It is important to remark that, despite the relatively large number of EU directives and documents

dealing with all possible recycling activities, there is only a single Directive on Construction

Products, under which fall all kind of conventional and unconventional aggregates.

An important reason is because the Directive on Construction Products takes into account the

chemical-physical characteristics of products, regardless to their origin, while recycling and waste

management Directives are mostly focused on the origin of the unconventional aggregates.

In this sense, it has to be remarked that the CE marking, which was introduced by the Directive on

Construction Materials and which is presently mandatory for aggregates, but not fully operational

yet, is in fact unique for natural and alternative aggregates and thus it might represents a very

important tool for removing obstacles to the use of recycled aggregates for several end-uses.

Making CE marking fully operational in the aggregate industry would mean shifting the focus from

the origin of aggregates (natural or alternative) to the technical quality of the aggregate itself. This

would likely be a powerful tool in order to increase both the recycling rate and the efficiency of the

recycling chain.

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1.3 Proposed classification of recycling activities within SARMa

As Sustainable Supply Mix was defined in par. 1.1 as a “Procurement from multiple sources...”, i.e.

a blend of natural aggregates, quarry/mine by-products, excavated rock/soils and recycled waste,

a comprehensive classification of the different types of aggregates appeared to be necessary.

A first attempt was made to adopt the classification proposed in the AGGREGATES CASE STUDY

(see par. 1.2), according to which aggregates can be classified into:

natural aggregates, produced from mineral sources. Sand and gravel are natural

aggregates resulting from rock erosion. Natural aggregates can also be produced from

crushed rock

recycled aggregates, produced from processing material previously used in construction

secondary aggregates, produced from industrial processes

However, as far as all the potential sources of unconventional aggregates covered in SARMa were

concerned, this classification was found to be not fully comprehensive or, in some cases,

potentially misleading.

For instance, it was found to be unclear in which category would fall excavated rock/soils, recycled

mining waste and, finally, quarry/mine co-products.

A discussion among SARMa partners took place during the Bucharest meeting on 05-07.10.2010,

where it was agreed that the definition of aggregates would be covered in the SARMa Glossary.

This said, to carry on with the Activity 3.3, a classification of recycling activities was proposed

instead, as this approach seemed to be more straightforward and comprehensive.

The following 4 types of recycling were therefore considered as potential sources of

unconventional aggregates:

R1: Recycling of by-products, waste and residues from extractive activities

R2: Recycling of Construction and Demolition Waste (CDW)

R3: Recycling of excavated soils/rock from civil works

R4: Recycling of industrial waste (e.g. slags from civil ferrous metal production, bottom ash

from Municipal Solid Waste (MSW) incineration, ashes from coal combustion)

The above listed recycling activities fall within the legal framework of one or more of the EU

Directives and Communications mentioned in par. 1.2.

Moreover, it has to be stressed that some of the input materials that can be recycled into

aggregates are (legally) considered waste while other input materials are not.

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According to the definitions adopted in the SARMa Glossary, it is possible to classify aggregates

obtained from recycling activities R1 to R4.

Regardless of the origin and classification of aggregates, it is recommended to consider their

technical quality, which affects the potential end-uses.

As the SARMa project is concerned, the following types of recycled aggregates (more in general

alternative aggregates) are considered:

Type A: high quality RA for concrete and road construction (road sub grade);

Type B: medium quality RA for road, airport and harbour construction;

Type C: low quality RA for environmental filling and rehabilitation of depleted quarries and

landfill sites.

The following parameters should also be considered:

Recycled aggregates type A B C

Saturated surface dried specific gravity ssd (kg/m3)

Los Angeles Index LA (%)

Shape Index SI (%)

Flakiness index FI (%)

Sand equivalent SE (%)

Fineness modulus Mf -

Impurity level - (%)

The following information should be provided, as well:

Eco-compatibility of recycled aggregates (leaching test)

Availability of codes of practice to achieve technical excellence

Availability of CE Marking

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2. METHODOLOGY AND SYNTHESIS OF BASELINE STUDY REPORTS (BSR-R)

This chapter provides first a preliminary introduction to the Case Studies (Table 1 and

accompanying text) as reported in the Baseline Study Reports (BSR-R), followed by a tabular

(vertical format) brief description of each.

Table 1.

SARMa Partner

Case study Type of

recycling Associated

extractive activity

Status of associated

extractive activity

AL (METE) 1 Bulqiza R1 Chromium mine Active

GR (IGME) 2 Gerakini R1 Magnesite Active

IT (RER/Parma)

3 Madregolo -Collecchio

R2 Sand & gravel Abandoned

4 Castellarano R1+R2+R3+R4 Sand & gravel Abandoned

RO (IGR/FGG) 5 Deva-

Ruschita R1 Marble quarry Active/Abandoned

SI (GeoZS)

6 Velica

Pirešica R2 + R3 Dolomite Active/Abandoned

7 Sežana R2 + R3 Limestone Active/Abandoned

8 Dogoše R2 + R3 Sand & gravel Active/Abandoned

9 Smarje-Sap R2 + R3 Dolomite Active/Abandoned

Table 1 shows an overview of the case studies considered within the Activity 3.3, with the

indication of the responsible Partner, the type of recycling (see par. 1.3) and the status of the

associated extractive activity

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Three case studies specifically deal with recycling of by-products, waste and residues from

extractive activities (R1).

In particular:

the Chromium Dressing Plant of Bulqiza (case study 1, Albania (METE)) treats 240.000 t/y

of low grade chromium ore. Moreover, tailings are deposited in a dam close to the plant

(2Mt with grade variable from 13 to 15% Cr2O3) and are currently recycled as mining waste

in the dressing plant (about 200.000 t/y). The recycled products are a marketable chromium

concentrate (38-42% Cr2O3), for chemical industry and metallurgy, and a sand suitable for

concrete and civil construction;

the Magnesite mine of Gerakini (case study 2, Greece (IGME)) treated 326.000 tonnes of

magnesite in 2009 and produced 57.000 tonnes of caustic calcined magnesia and 22.400

tonnes of dead-burned magnesia. The feed of the recycling plant comprises both by-

products from the sorter unit plant of the mill and waste material from the quarry as well.

The feed mixture to the crushing grinding plant depends on the main production schedule.

Feed usually contains magnesite and serpentine in small quantities, but mainly dunite.

Recycled aggregates are used mainly for road construction.

in the Deva-Ruschita active marble quarry (case study 5, Romania (IGR/FGG)),

MARMOSIM company utilizes about 190.000 t/y of marble as dimension stone (about 50%

of excavated material), while the highly fractured rock is sent to the Omya plant, located

near the Deva area. Moreover, the white to yellow white marble, deriving from the small

fraction of the residual material by MARMOSIM plant, is preliminary crushed in order to be

sent to the Omya plant as raw material. In this way, approx. 50% of marble blocks with an

inadequate size are recovered, as well. In the Omya plant marble varieties with a calcium

carbonate contents greater than 96% are milled to the micron dimensions, while the

MARMOSIM employs all marble types, even those with brownish colours even if for these

last varieties the market is decreasing;

The rest of the case studies deal with recycling of Construction and Demolition Waste (CDW) (R2),

but also recycling of excavated soils/rock from civil works (R3), and, in one case, recycling of

industrial waste (R4).

In particular:

the recycling plant of Collecchio/Madregolo (case study 3, Italy (RER/PARMA)) is an

example of evolution from "traditional quarrying" to "integrated quarrying and recycling". In

particular, the plant re-processes the recycled aggregates resulting from milling of road

asphalt pavements (R2) in addition with natural aggregates. Hot-process and cold-process

are the two recycling techniques adopted: in the first method recycled aggregates are

added with a percentage lower than 20% of the total mixture, in the second the recycled

aggregates are employed with percentages up to 50%. Medium grade recycled aggregates

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(type B) for road, airport and harbour construction are produced according to the CE

marking requirements. Recycled asphalt concrete is also manufactured;

the recycling plant of Castellarano (case study 4, Italy (RER/PARMA)), deploying the

R.O.S.E. technology, is located within a quarry site, where the recycling plant is located

beside a natural aggregates quarry and nearby the ceramic district of Sassuolo -

Scandiano, one of the most important Italian industrial districts. This plant mainly processes

waste from the ceramic industry (R4). In the BSR-R another R.O.S.E. plant treating

Construction and Demolition Waste (CDW) (R2) and excavated soils/rock from civil works

(R3) is also presented. High grade recycled aggregates (type A) for concrete and road sub

grade, medium grade recycled aggregates (type B) for road, airport and harbour

construction and low grade recycled aggregates (type C) for environmental filling and

rehabilitation of depleted quarries are produced in this plant with respect to the CE marking

requirements (UNI EN 12620:2008 and UNI EN 13242:2008);

the recycling plant of Velica Piresica (case study 6, Slovenia (GeoZS)) is located in the

abandoned part of an active dolomite quarry. In this plant Construction and Demolition

Waste (CDW) (R2) and excavated soils/rock from civil works (R3) are treated in order to

obtain recycled aggregates. In particular high grade recycled aggregates (type A) and

medium grade recycled aggregates (type B) are produced and employed in road and

railways constructions;

the recycling plant of Sežana (case study 7, Slovenia (GeoZS)) is located in the abandoned

part of a limestone quarry. In this plant Construction and Demolition Waste (CDW) (R2) and

excavated soils/rock from civil works (R3) are treated in order to produce recycled

aggregates. In particular high grade recycled aggregates (type A), medium grade recycled

aggregates (type B) and low grade recycled aggregates (type C) for environmental filling

are produced;

the recycling plant of Dogoše (case study 8, Slovenia (GeoZS)) is located in the exhausted

Sand and Gravel quarry, not completely remediated. The quarry is located near the Drava

river. In this area there are also a processing plant for natural aggregates and a mixing

concrete plant. In this plant Construction and Demolition Waste (CDW) (R2) and excavated

soils/rock from civil works (R3) are treated in order to obtain recycled aggregates. In

particular medium grade recycled aggregates (type B) for road construction and low grade

recycled aggregates (type C) for environmental filling are produced and employed for

concrete, bituminous mixtures, mixed materials;

the last recycling plant is located in the abandoned part of the active Dolomite quarry of

Smarje-Sap (case study 9, Slovenia (GeoZS)). The recycling treatment is performed only

once a year by renting a crusher. In this plant Construction and Demolition Waste (CDW)

(R2) and excavated soils/rock from civil works (R3) are treated in order to produce low

grade recycled aggregates (type C) for environmental filling.

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2.1 Case study 1 - Albania (METE): the Chromium Dressing Plant of Bulqiza

About 240.000 t low grade chromium ore are treated every year in the plant. The content of Cr2O3 in the input material ranges from 20% to 26%.

Production capacity is about 110.000 t/y of chromium concentrate with 48-50 % Cr2O3 content.

Tailings are deposited in a dam close to the plant. The material collected in the amount of about 2 Mt and quality 13-15% Cr2O3, is currently being recycled in the dressing plant.

The loss of Cr2O3 component during operation of the plant has been about 25-35% of its quantity in raw material.

The possibilities to recover 50% of Cr2O3 quantity from tailings of Bulqiza chromium dressing plant exist since 25% of lost are in liberated chromium particles over 0.1 mm and 50% are in slimes (fine particles under 100 microns).

Recycling plant

Type R1.

Daily amount of raw material: 500 - 600 t/d

Yearly amount of raw material: 180.000 – 200.000 t/y

Direct collection: from work site to treatment plant (trucks with the capacity of 25 t/each)

Technical information on recycling treatment description

unit Machines description

Feed Different depositsPrimary crushing Jaw crusher Pre-screening Vibrating screen Secondary crushing Conic crusherScreening Vibrating screen - different belts, Wet classification Spirals classifiers -hydraulic classifiers Grinding Bar millsGravity separation Jigs - shaking table - in every stage, wet operations

Water treatment Spiral classifiers for concentrate solid-liquid separation. Decantation in dam, for sand tailings

Recycled products

Recycled aggregates

Production Selling price

Employment Transportation costs

Average delivery distance

(t/h) (t/y) (€/t)

Chromium concentrate

38% -42% Cr2O3

4 - 5 20.000

150-250

Good quality chromium

concentrate for chemical industry and metallurgy

for export transportation costs are 30-

60 €/ton. Within the Albanian territory

transportation cost is 0.1 € per ton-km

The main

countries are Italy, Sweden,

and China.

Sand (6-7% Cr2O3) 30 -

35 160.000

t/year

high quality sand for concrete and civil

construction

0.12 € per t-km

20-30 km

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2.2 Case study 2 – Greece (IGME): the Magnesite mine of Gerakini

Magnesite extraction site

Stockpiles of by-products

Recycling plant - Aggregates production unit

Gerakini Mine is located in the Chalkidiki Prefecture of the Region of Central Macedonia in Greece. It belongs to the municipality of Polygyros.

Gerakini mine site belongs to the state and is legally operated by the Grecian Magnesite S.A. The mine site is not close to nature protected areas or national heritage sites.

The main product of the production unit (kilns) are caustic calcined and dead - burned magnesia. A range of gangue as well as by-products stem out within the framework of the extraction and processing procedures that take place at Gerakini mine for the exploitation of the magnesite deposit.

The mine tailings left over and stockpiled after magnesite extraction and used currently for production of aggregates, is a composite material, comprising dunites and harzburgites of varying grade of alteration, and remaining fragments of magnesite.

In order to reduce disposal area needs and exploit part of the aforementioned disposed off materials, the company has established a crushing grinding plant unit for the production of secondary aggregates. This plant unit is located close to the grizzly installation of the production circuit (250-500 m). The feed of this crushing –grinding plant comprises both by-products from the sorter unit plant of the mill and waste material from the quarry as well. The feed mixture to the crushing grinding plant depends on the main production schedule. Feed usually contains magnesite and serpentine in small quantities, but mainly dunite.

Thus, the specific input material belongs to the R1 category (R1: Recycling of by-products, waste and residues from extractive activities).

Raw input material for the aggregate production unit is transferred by lorries, as all the transportations within the quarry.

The average quantity processed yearly is 150.000 tones (1 shift per day).

Wastewater of the recycling plant goes to the thickeners which are part of the sorter unit. Clear water produced by the thickeners is useful for other uses in the mine.

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Flowchart of the recycling plant

Recycled aggregates

Recycling plant

Type: R1 (R1: Recycling of by-products, waste and residues from extractive activities)

Number of raw input waste accepted: 150.000 t/y

Classification of raw input waste (EWC): 01 01 02, 01 04 12

Direct collection of raw input waste: Within the mine site, input raw feed is transferred by trucks to the crushing unit

Technical information on recycled treatment

Occupied average surface: 400 m2

Paved areas: NO

Stationary plant: Flowchart is shown

Plant processing throughput: 600 t/d

Recycled aggregates

Grade of recycled aggregates: Medium grade recycled aggregates (type B) for road, airport and harbour construction are produced in this plant with respect to the CE marking requirements (UNI EN 12620:2008 and UNI EN 13242:2008);

Production quantity and selling price: Approximately 150.000 tonnes of aggregates (mainly 0-30mm, 3A) are produced annually. Cost: 1,5 – 5,2 €/t at mine

Transportation cost: According to the delivery distance 0,15 €/t/km

Employment of recycled aggregates: Used mainly for road construction

Uses and present market destinations: Average transport distance 45 km, maximum transport distance 60 km

LCA: Not accomplished

SILO

FEEDER

CONVEYOR BELT

CONE CRUSHER

SIEVES (WET SIEVING)

‐6 mm +6 mm – 30 mm +30 mm

SCREW FINAL PRODUCT ROTOR

MUD

THICKENERS

WASHER

‐6 mm

17

2.3 Case study 3 – Italy (RER/PARMA): the recycling plant of Collecchio/Madregolo

This case study is an example of evolution from "traditional quarrying " to “integrated quarrying and recycling” co-existing with an environmentally protected area.

In an earlier stage, the site was a conventional quarry (quarrying and treatment of natural aggregates). Later, the quarry became part of an environmentally protected area, with consequent re-organisation of quarrying and processing.

When the mineral deposit was exhausted, the excavation activity moved to another site, while the treatment plant remained in the same location. Subsequently, recycling of C&DW (from highway maintenance operations) started to be a source of integration of primary raw materials, partially extracted in quarries owned by the plant operator (SIP) and partially purchased on the free market. Both hot-process and cold-process recycling of asphalt concrete are used.

Collecchio/Madregolo can be regarded as a meaningful example of evolution from traditional quarrying towards Sustainable Quarrying for at least 2 reasons:

- It shows that extractive industry and environmentally protected areas can co-exist

- It shows how depletion of non-renewable resources can be an incentive to search for alternative sources, including recycling, within the context of an economically viable industrial production

Recycling plant

Type R2.

The plant uses milled material resulting from the milling of road surfaces that are mixed to natural raw materials.

Quantity of raw input material: 15.000 t/y (100% milled material from road surfaces)

Raw input waste (EWC): 17 03 02 – 01 04 10

Direct collection: from work site to treatment plant (lorry mean capacity 30-45 t)

Average distance: provincial scale


Occupied average surface(including a mill, the recycling plant itself and ancillary infrastructures such as waste storage areas, offices, etc.): 260.000 m2

Dimensions of the storage of the different raw input waste: 3.100 m2. The same area is used for both the fine waste material (0-15 mm) and for the coarser waste material (0-40 mm) that are divided in individual piles.

Paved areas 10.000 m2

Stationary plant

Two recycling techniques are deployed: (1) hot-process and (2) cold-process. For both methods, the material must be crushed and screened before entering recycling.

18

Hot-process recycling refers to the addition of recycled material with a percentage not exceeding 20% of the total mixture, at the downloading in the elevator of the aggregates coming from the dryer, where the recycled material is heated (through contact) by virgin aggregates before entering the mixer.

Cold-process recycling use percentages up to 50%, and consists in mixing of virgin aggregates, recycled material, water, emulsion and cement, all at room temperature.

Plant processing capacity for each product: 300 t/h

Plant processing throughput: 161.000 t/y

Recycled aggregates

Grade of recycled aggregates: medium grade (recycled asphalt concrete for road, airport and harbour construction)

Production quantity and selling price:

recycled aggregates: 40 t/h - 25.000 t/y - 11 €/t

recycled asphalt concrete “RA” 300 t/h - 32.000 t/y - 40 €/t

The recycled bituminous aggregates are produced according to the standards UNI EN 13108, Bituminous mixtures - Material specifications - part 8 “Reclaimed asphalt”, for bituminous aggregates with CE marking

Transportation cost according to the delivery distance (€ per ton-km) on average 4.00 €/t average of 20 km. Maximum delivery distance 30 km

Life Cycle Assessment

Data for LCA analysis

Raw input materials

Quantity processed t About

161.000Land use

Occupied area m2 about

260.000 Materials/fuels Hammers/jaws kg - Water kg 0 Lube oil kg - Polyurethane screen kg - Steel screen kg - Synthetic rubber kg - Diesel l 53820 Electricity Kwh 705791 Natural gas MC 1681937 Outputs Recycled aggregate type A t - Recycled aggregate type B t 57.000 Recycled aggregate type C t - Steel scrap t -

19

2.4 Case study 4 – Italy (RER): the recycling plant of Castellarano

The company “Pescale” holds the R.O.S.E. patent which represents a BAT in the field of CDW recycling. The BSR-R is based on information retrieved from the authorization documents of the Castellarano plant, whereas the technical data correspond to a medium-sized R.O.S.E. plant operated by Varia Versilia Ambiente S.r.l. di Pietrasanta (Lucca).

The recycling plant is located in the context of an extractive activity, nearby a natural aggregates plant.

The area is part of the “Ceramico di Sassuolo – Scandiano District”, one of the most important Italian industrial districts. Over the last decades the area evolved from the traditional farming economy to an industrial productive reality, especially in small and medium sized companies.

The R.O.S.E. plant is equipped with engineered systems for the separation of the unwanted fractions, the control of dust and the collection of fine material.

The quality of the products recycled with the R.O.S.E technology has been certified not only by many years of experience but also by specific scientific researches carried out by several universities, Public Administrations and private companies.

Recycling plant

Type R1+R2+R3+R4

Quantity of raw input material: 600 t/d (576 t/d effectively treated) – potentially 150.000 t/y, authorised 124.300 t/y

Classification of raw input waste (EWC): 010102 - 010408 - 010409 - 010410 - 010412 - 010413 - 101103 - 101112 - 100201 - 100202 - 100809 - 100811 - 100906 - 100908 - 100903 - 100999 - 101008 - 101003 - 101099 - 101201 - 101299 - 101311 - 101314 - 101208 - 101399 - 120199 - - 161102 - 161104 - 161106 - 170101 - 170102 - 170103 - 170107 - 170202 - 170302 – 170504- 170508 - 170802 - 170904 - 191209 - 200202

The plant is situated near the ceramic district Sassuolo – Scandiano. For this reason, Castellarano plant treats mainly industrial waste from the ceramic industry:

17% are waste from working operations of gravel and stone (EWC 010408, 010410, 010413)

76% are waste of ceramic products (EWC 101201, 101208);

7% are crushed stone for railway foundations (EWC 170508).

20

According to ANPAR (National Association of Recycled Aggregates Producers) R.O.S.E. plants treat on average:

41.9% of “C&D mixed waste” (EWC 17 09 04);

18.5% of “Excavated rock and soils” (EWC 17 05 04);

22.7% of “Mixtures of cement, brick, tile and ceramic slag” (EWC 17 01 07);

6.9% of “Bituminous mixtures” (EWC 17 03 02)

10% of the other EWC.

Direct collection: from work site to treatment plant (lorry average payload 12 t)

Average distance: provincial scale


Occupied average surface (including the recycling plant itself and ancillary infrastructures such as waste storage areas, offices, etc.): 77.000 m2

Acceptance procedures for the raw input material: camera to verify the material present on the truck

Dimensions of the storage of the different raw input waste: lower than 1/12 of the overall authorized quantity

Paved areas: no

Stationary plant: load, pre screening, grinding, magnetic separation, screening and separation.

Description Unit Machines description x Secondary demolition x Feedx Scalpingx Pre-screeningx Manual sifting

x Primary crushing x jaw crusher impact crusher others: hammer mill

x Magnetic separation Secondary crushing jaw crusher impact crusher othersx Screening x Sorting x dry wet Water treatment

Plant processing capacity for each product : 75 t/h

Plant processing throughput for each product: 150.000 t/y

Recycled aggregates

Grade of recycled aggregates: high quality (type A, for concrete and road sub grade), medium quality (type B for road, airport and harbour construction), low quality (type C, for environmental filling and rehabilitation of depleted quarries and landfill sites)

Production quantity and selling price Production Selling price

(t/h) (t/y) (€/t)

Type A 13.30 26.595 From Euro 9 to Euro 15

Type B 94.61 189.208 Euro 4.70

Type C 5.09 10.089 From Euro 5.50 to Euro 6.50

Impianto R.O.S.E.[Recupero Omogeneizzato Scarti Edilizia]

+ −+ −

Ciclo di funzionamento impianto I.R.M.E.L.

21

Grade of recycled aggregates

Recycled aggregates type A (UNI EN 12620:2008)

B (EN 13242:2008)

Sand R.O.S.E.

0/6

Crushed Stone R.O.S.E.

6/15

Crushed stone R.O.S.E.

15/30

Stabilizing R.O.S.E.

0/70

Stabilizing R.O.S.E. 0/30

Saturated surface dried specific gravity

ssd (kg/m3) - - -

Los Angeles Index LA (%) - 25 25 25 25 Shape Index SI (%) - 15 40 20 40 Flakiness index FI (%) - 15 55 35 50 Sand equivalent SE (%) 61 - - 26 28 Fineness modulus Mf - f11 f 1.5 f 1.5 f 3 f 5 Impurity level - (%) - - - - - …

The eco-compatibility of recycled aggregates is provided according to D.M. 05/02/1998 and subsequent amendments and additions.

The recycled aggregates have been certified through declaration of conformity in compliance with the UNI EN 12620:2008 norm concerning materials of type A and with the EN 13242:2008 norm for the materials of type B.

According to the technical specifications of the above European norm, sand and crushed stone produced by the plant are suitable to be used in concrete manufacturing and high quality mixes, whilst the stabilized aggregate is suitable for unbound and bound (with hydraulic binders) civil engineering applications and, in particular, for foundations in roads building. Screened earth is suitable for the recovering of dumping grounds and environmental recovery.



No LCA data were provided concerning the Castellarano plant. Instead, data were provided relevant the plant of Varia Versilia Ambiente, Pietrasanta in Lucca (year 2009).

Raw input materials

Quantity processed t About

230.000Land use Occupied area m2 23.125Materials/fuels Hammers/jaws kg 2.5 serieWater kg 0Lube oil kg 685.44Polyurethane screen kg 0Steel screen kg Number 4 Synthetic rubber kg 0Diesel l 67.416Electricity MJ 548.697,6... ... Outputs Recycled aggregate type A t 26.595Recycled aggregate type B t 189.208Recycled aggregate type C t 10.089Steel scrap t Not supplied ...

22

2.5 Case study 5 – Romania (IGR/FGG): the Deva-Ruschita marble quarry

At Ruschita site there are two quarries:

the “Old Quarry” is abandoned and partially filled with the waste material coming from the newer mining works;

the second one, “Paraul cu Raci Quarry”, is active. Traditional methods for dimension stone exploitation (open pit and underground) are employed.

Reserve calculations estimate that the volume of marble in this area is about 1.8 Mm3.

The MARMOSIM company (a Romanian private company which is specialized in blocks processing and is located 80 km away from the quarry) utilizes about 190.000 t/y of marble from Ruşchiţa quarry, which means about 50% of excavated material. The residual materials are mining waste.

Ruşchiţa marble quarry mostly sells light-coloured marble (white marble to yellow marble), the waste rock after sorting is stocked in the dumps. One of the main drawbacks that lowers the recovery of high value marketable ornamental stone is presence of cleavage which decrease the maximum size of the final products (slabs).

The quarry outputs that do not meet the technical specification of the MARMOSIM plant because of cleavage is approx. 40% while 50% cannot easily be sold due to the dark colour (see annex).

The Omya plant near Deva area (to Voislova) represents a multiple solution in terms of recycling. On the one hand, the area with the fissured ores was purchased directly by Omya company, and on the other hand, at least section of white to yellow white marble derived from the small fraction of the material which was considered residual material by MARMOSIM plant is connected by a line parallel processing where this material is crushed and preliminary prepared for transportation to the Omya plant as raw material. In this way, approx. 50% of marble blocks with an inadequate size are used too.

Recycling plant

Type R1.

Direct collection: from work site to the treatment plant (average distance 20 km)

Technical information on recycling treatment

Crushed to get size micron materials, marble which has contents over 96% calcium carbonate, derive from the varieties of marble with very low and lowest colour index, is used in many fields as paint industry, construction materials industry, paper industry, etc.

23

Depending on the variety of marble, the percentage content of calcium carbonate is different: the highest percentage (reaching up to 99%) belongs to white pure marble.

Omya plant collects the white waste marble, regardless of size aggregates (sometimes it is including fissured blocks marbles, abandoned for processing in the marble plates) and crushes it up to the micron dimensions.

While Omya plant uses only varieties with calcium carbonate contents more than 96%, the MARMOSIM company uses all marble types, even those who have brownish colours. However, market demand has recently decreased for brownish or blackish varieties, and thus for export they are usually rejected.

This means that full recovery of MARMOSIM waste cannot be carried out by Omya factory and thus it remains a problem to be solved in future.

24

2.6 Case study 6 – Slovenia (GeoZS): the Dolomite quarry of Velica Piresica

Recycling plant is located in active quarry Velika Piresica in east Slovenia.

The location is placed in an active dolomite and limestone quarry Velika Piresica.

The recycling plant is located in the abandoned part of the quarry.

Quarry is visible, being located alongside the road Celje – Velenje.

Recycling plant

Type R2 + R3

Daily amount of raw material: 145 t/d

Yearly amount of raw material: 29.000 t/y

Classification of raw input waste (EWC): 17 01 01, 17 01 02, 17 01 03, 17 01 07, 17 03 02, 17 05 04, 17 05 06, 17 05 08, 17 06 04, 17 08 02, 17 09 04

Direct collection of raw input waste: dump truck (tipper) engine - average distance up to 50 km


Occupied average surface: 5.000 m2

Dimensions of the storage of the different raw input waste and of the produced recycled aggregates: 2.500 m2 and 2.500 m2

Paved areas: 5.000 m2

Stationary plant description

unit Machines description

Secondary demolition Feed Scalping Pre-screening x Manual sifting x Primary crushing jaw crusher x impact crusher others Magnetic separation Secondary crushing jaw crusher impact crusher others x Screening x Sorting dry wet Water treatment

Plant processing throughput (t/h and t/y) 20.000 t/y

Energetic consumptions crusher – 2.500 l/y and screening – 1.500 l/y

25

Recycled aggregates

Grade of recycled aggregates: high grade recycled aggregates (type A); medium grade recycled aggregates (type B)


(t/h) (t/y) (€/t)

Type A 10.000 6.26

Type B 19.000 3.05

Type C

Aggregates are used for road and railways construction. CM Celje is a Construction Company and it uses recycled aggregates partially for asphalt production Maximum delivery distance 60 km, average delivery distance 40 km



Raw input materials Quantity processed t 29.000Land use Occupied area m2 5.000Materials/fuels Hammers/jaws kg 150Water kg 50 m3

Lube oil kg 150 lPolyurethane screen kg Steel screen kg 160Synthetic rubber kg Diesel l 15.256 Electricity MJ 4.300 kWh... ... Outputs Recycled aggregate type A t 10.000Recycled aggregate type B t 19.000Recycled aggregate type C t Steel scrap t 18.5...

26

2.7 Case study 7 – Slovenia (GeoZS): the Limestone quarry of Sežana

At first there was limestone quarry with mining right. Since September 2009 they have permission for recycling. Quarry and recycling centre own the same company.

They located recycling centre in the abandoned part of quarry, which is still active

Recycling plant

Type R2 + R3


Classification of raw input waste (EWC): 17 01 01, 17 01 02, 17 01 03, 17 01 07, 17 02 01, 17 02 02, 17 02 03, 17 03 02, 17 05 04, 17 05 06, 17 08 02, 17 09 04

Direct collection: from work site to treatment plant


Dimensions of the storage of the different raw input waste: 4550 m2

Dimensions of the storage of the produced recycled aggregates: 2100 m2

Paved areas: 4550 m2

Stationary plant


Recycled aggregates

Grade of recycled aggregates high grade recycled aggregates for concrete (type A), medium grade recycled aggregates for road construction (type B); low grade recycled aggregates for environmental filling (type C)


(t/h) (t/y) (€/t)

Type A 15.000 2.80

Type B 25.000 2.60

Type C 10.000 2.20

Employment of recycled aggregates: environmental filling

They use majority of recycled aggregates in their own construction sites

27

2.8 Case study 8 – Slovenia (GeoZS): the Sand and Gravel quarry of Dogoše

The location is an exhausted sand and gravel pit, not completely remediated.

The quarry is near the Drava river.

Next to centre there is also a separation and crushing facility for aggregates and concrete plant.

Recycling plant

Type R2 + R3


Classification of raw input waste (EWC): 17 01, 17 03, 17 05, 17 08, 17 09

Indirect collection of raw input waste


Occupied average surface 5.0 ha

Dimensions of the storage of the different raw input waste and of the produced recycled aggregates 3.0 ha

Paved areas 0.5 ha

Stationary plant

Plant processing throughput (t/h and t/y) 80 t/h, 100.000 t/y

Recycled aggregates

Grade of recycled aggregates: medium grade recycled aggregates for road construction (type B); low grade recycled aggregates for environmental filling (type C)


(t/h) (t/y) (€/t)

Type B 50 30.000 8.00

Type C 100 70.000 4.00

Employment of recycled aggregates: concrete, bituminous, mixed

28

2.9 Case study 9 – Slovenia (GeoZS): the Dolomite quarry of Smarje-Sap

The location is at the active dolomite quarry Smarje-Sap.

The recycling plant is small and it is located in the abandoned part of quarry.

Quarry is hidden from near village, because it is located in side of a hill and surrounded with forest.

The recycling treatment is performed only once a year. They have contract with another company and once a year they rent a crusher.

Every day waste is collected from the construction sites and transported to the recycling plant (2-3 trucks/day).

Recycling plant

Type R2 + R3


Classification of raw input waste (EWC): 17 01 01, 17 01 07, 17 05 04, 17 05 06, 17 08 02, 17 09 04

Direct collection of raw input waste


Occupied average surface 2-3.000 m2

Dimensions of the storage of the different raw input waste and of the produced recycled aggregates 2-3.000 m2

Paved areas no

Stationary plant


Recycled aggregates

Grade of recycled aggregates: low grade recycled aggregates for environmental filling (type C)

Production quantity and selling price:


(t/h) (t/y) (€/t)

Type C 5.000 3.00

Employment of recycled aggregates: environmental filling

Uses and present market destinations Rentable transport radius is up to 15 km

29

3. DISCUSSION AND RECOMMENDATIONS

According to the experience gathered through the SARMa project case studies, the overall attitude

to recycle, and the way recycling activities are conceived and managed in order to become source

of unconventional, appears to be sensibly different from one country to another.

As a consequence, giving a comprehensive picture of aggregate recycling in South East Europe

appeared to be nearly impossible, while it was considered more meaningful to the SARMa project

to pick up examples of meaningful recycling operations that, even though sensibly different in

terms of context and technologies, might be used in order to exchange know-how and promote

recycling among partner countries.

Recycling activities covered in SARMa are in fact extremely heterogeneous, varying from

processing of mining waste to treatment of C&DW, excavated soils/rock from civil works and

industrial waste.

Table 2 shows an overview of the case studies, with emphasis on the amount of input material,

the typologies and the amounts of the different recycled products and the market price.

According to the SARMa experience, mining waste can be re-processed in the same mineral

processing plant that is used for primary raw materials, as in the case of the Chromium Dressing

Plant of Bulqiza (case study 1, Albania (METE)), where the tailings deposited in a dam nearby the

plant are recycled. The processing/recycling plant of Bulqiza shows an high level of complexity,

being composed of several subsystems such as primary jaw crushing, secondary conic crushing,

vibrating screening, wet classification through spiral classifiers and hydraulic classifiers, grinding by

a bar mill, jigging, shaking table, water treatment by mean of spiral classifiers and decantation.

A different experience of mining waste recycling is that relevant to the Deva-Ruschita marble

quarry (case study 5, Romania (IGR/FGG)), where the processing plants is comparably less

complex with respect to Bulqiza, and the treatment is focused on the comminution of the different

materials and classification by size.

In both cases, the potential amount of waste to be treated has been estimated: in the Chromium

Dressing Plant of Bulqiza the tailings are deposited in a dam of about 2 Mt with 13-15% Cr2O3,

while in the Deva-Ruschita marble quarry the marble reserve is about 1.8 Mm3.

A different context is that relevant to recycling of C&DW, excavated soils/rock from civil works and

industrial waste, where a jeopardised situation has been pointed out. In these cases, typically, the

poor quality of input materials and the low market value of potential outputs represent a heavy

constraint to the deployment of technologies and the optimisation of the recycling plant. For this

reason, design and operation of the recycling chain is more difficult with respect to mining waste

recycling.

All the SARMa case studies concerning the recycling of C&DW, excavated soils/rock from civil

works and industrial waste are evolutions of traditional extractive activities. The recycling plant of

30

Collecchio/Madregolo (case study 3, Italy (RER/PARMA)) is located in an exhausted sand and

gravel quarry and the recycling plant of Castellarano (case study 4, Italy (RER/PARMA)) is located

within a quarry activity as well. Moreover, also in Slovenia, the recycling plants are located in the

abandoned part of active quarries: a dolomite quarry for Velica Piresica plant (case study 6,

Slovenia (GeoZS)), a limestone for the plant of Sežana (case study 7, Slovenia (GeoZS)), an

exhausted sand and gravel quarry for the plant of Dogoše (case study 8, Slovenia (GeoZS)) and a

dolomite quarry for the plant of Smarje-Sap (case study 9, Slovenia (GeoZS)).

The Italian case studies deal with the recycling of two different C&DW: in the plant of

Collecchio/Madregolo the input material is bituminous conglomerates, while in the plant of

Castellarano the input material is C&DW from civil demolition or industrial waste from the ceramic

industry. It has to be noticed that different input materials have to be kept separated in order to

optimise the treatment and obtain high grade aggregates. The treatment plants are technologically

advanced and produce high, medium and low grade recycled aggregates.

Besides, also the Slovenian case studies appear as evolution of traditional extractive activities. In

such a context, it can be noticed that natural aggregates producers own the technical know-how on

natural aggregates processing that can be usefully applied in the recycled aggregates production.

Similarly, natural aggregates producers hold knowledge on market issues that might be exploited

in order to incentive demand for recycled aggregates.

All this considered, according to the experience gathered in SARMa, the potential sources of

aggregates other than conventional natural aggregates are quite inhomogeneous.

Keeping in mind that conventional natural aggregates and aggregates from unconventional

sources (recycling) are not in competition (see par 1.1), but rather their joint utilisation is strategic

to SSM, it is advisable to stress more on the technical quality of aggregates rather than on their

origin.

In this sense, it must be remarked that the Directive on Construction Products takes into account

the chemical-physical characteristics of products, regardless to their origin, while recycling and

waste management Directives are mostly focused on the origin of the unconventional aggregates.

Consistently, the CE marking, which was introduced by the Directive on Construction Materials and

that is presently mandatory for aggregates, but not fully operational yet, is in fact unique for natural

and alternative aggregates and thus it might represents a very important tool for removing

obstacles to the use of recycled aggregates for several end-uses.

Making CE marking fully operational in the aggregate industry would mean shifting the focus from

the origin of aggregates (natural or alternative) to the technical quality of the aggregate itself. This

would likely be a powerful tool in order to increase both the recycling rate and the efficiency of the

recycling chain.

31

Table 2.

SARMa Partner

Case study Type of

recycling

Amount of input

material (t/y)

Type of recycled products

Amount of recycled products

(t/y)

Price / cost

AL (METE) 1 Bulqiza R1 180 000

chromium concentrate 38-

42% Cr2O3 20 000

30-60 €/t (for export)

0.1 €/t*km (in the Albanian

territory)

recycled aggregates

sand 6-7% of Cr2O3

160 000 0.12 €/t *km (20-30 km)

GR (IGME) 2 Gerakini R1 150 000 recycled

aggregates Type B

150 000

1.5-5.2 €/t at mine

Transp.cost: 0.15 €/t*km

IT (RER/Parma)

3 Madregolo

-Collecchio

R2

recycled aggregates

25 000

11 €/t

4 €/t (average 20 km

Max 30 km)

recycled asphalt concrete

32 000 40 €/t

4 Castellarano R1 + R2 + R3 + R4

150 000

recycled aggregates

Type A 26 595 9-15 €/t

recycled aggregates

Type B 189 208 4.70 €/t

recycled aggregates

Type C 10 089 5.50-6.50 €/t

RO (IGR/FGG)

5 Deva-

Ruschita R1

SI (GeoZS)

6 Velica

Pirešica R2 + R3 29 000

recycled aggregates

Type A 10 000 6.26 €/t

recycled aggregates

Type B 19 000 3.05 €/t

7 Sežana R2 + R3 55 000

recycled aggregates

Type A 15 000 2.80 €/t

recycled aggregates

Type B 25 000 2.60 €/t

recycled aggregates

Type C 10 000 2.20 €/t

8 Dogoše R2 + R3 100 000

recycled aggregates

Type B 30 000 8.00 €/t

recycled aggregates

Type C 70 000 4.00 €/t

9 Smarje-Sap R2 + R3 5 000 recycled

aggregates Type C

5 000 3.00 €/m3

32

3.1 Recommendations

Recycling activities covered in the SARMa project are extremely heterogeneous, varying from

processing of mining waste to treatment of C&DW, excavated soils/rock from civil works and

industrial waste. It is therefore difficult to draw general recommendations. Nevertheless, some

preliminary recommendations that might be used as background for the final outputs of the SARMa

project are listed below.

In order to put into practise the EU strategies, a strong synergy between mining, traditional

mineral processing and recycling has to be promoted. To this aim, it is important to consider

that mineral dressing principles are the same for both natural and for recycled/manufactured

aggregates. Moreover, the equipment employed in the beneficiation of primary mineral

materials can be successfully adapted for recycling.

Because natural aggregates producers own the technical know-how on natural aggregates

processing, they can usefully apply it in recycling of aggregates. Similarly, natural aggregates

producers hold knowledge on market issues that might be exploited in order to boost demand

for recycled aggregates.

Conventional natural aggregates and aggregates from unconventional sources (recycling)

should not be considered competitors, but rather their joint utilisation is strategic to SSM.

It is not always necessary to develop new technologies for recycling; rather innovation in

recycling can be regarded as extension and adaptation of already available and well-accepted

technologies.

Cooperation between mining and recycling has to be encouraged to maximise economic and

environmental benefits.

Where possible, recycling should be an evolution of traditional extractive or mining activities.

For example, recycling plants should be located in exhausted quarries or in the abandoned part

of active quarries.

Recycled/manufactured aggregates can replace natural aggregates in applications such as

road construction and concrete production, always with respect to the required quality

standards.

It is advisable to shift the focus from the origin of aggregates (natural, recycled or

manufactured) to the technical quality of the aggregate itself, as foreseen by the 80/106/EEC

Directive on construction products. This Directive requires the respect of technical

specifications imposed by the CE marking harmonised standards (for example: EN 12620

aggregates for concrete; EN 13242 aggregates for road construction; etc.), without

consideration of the raw materials’ sources.

CE marking is mandatory for aggregates. This represents a very important tool for removing

obstacles to the use of recycled/manufactured aggregates for several end-uses and it’s an

incentive for producing high quality aggregates.

33

To avoid decay of end-products technical performance, high-grade recycled aggregates must

be produced using advanced technologies. The aim of these technologies is the production of

recycled materials with homogeneous characteristics and with physical-mechanical

characteristics comparable with those of natural aggregates. Unwanted components, that can

adversely affect the grade of recycled aggregate, must be removed.

Life Cycle Assessment (LCA) can be used to enhance environmental efficiency of aggregates

quarrying, as well as recycling, and help understanding the role of natural and recycled

aggregates in the SSM.

34

4. CASE STUDIES –FULL TEXT BASELINE STUDY REPORT (BSR-R)

Table 3.

CASE STUDY BASELINE STUDY REPORT (BSR-R)

CASE STUDY 1 BSR-R OF ALBANIA (METE): THE CHROMIUM DRESSING PLANT OF BULQIZA

CASE STUDY 2 BSR-R OF GREECE (IGME): THE MAGNESITE MINE OF GERAKINI

CASE STUDY 3 BSR-R OF ITALY (RER/PARMA): THE RECYCLING PLANT OF COLLECCHIO/MADREGOLO

CASE STUDY 4 BSR-R OF ITALY (RER): THE RECYCLING PLANT OF CASTELLARANO

CASE STUDY 5 BSR-R OF ROMANIA (IGR/FGG): THE MARBLE QUARRY OF DEVA-RUSCHITA

CASE STUDY 6 BSR-R OF SLOVENIA (GEOZS): THE DOLOMITE QUARRY OF VELICA PIRESICA

CASE STUDY 7 BSR-R OF SLOVENIA (GEOZS): THE LIMESTONE QUARRY OF SEŽANA

CASE STUDY 8 BSR-R OF SLOVENIA (GEOZS): THE SAND AND GRAVEL QUARRY OF DOGOŠE

CASE STUDY 9 BSR-R OF SLOVENIA (GEOZS): THE DOLOMITE QUARRY OF SMARJE-SAP

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CASE STUDY1 - ALBANIA (METE): THE CHROMIUM DRESSING PLANT OF BULQIZA

Case study of:

Bulqiza Country: Albania

SARMa Partner: Author of the report: e-mail: Date of submission to WP3.3 leader:

10% partner 2 METE/AGS

Gjovalin Lekaj, Sokol Mati; Lavdie Moisiu; Edlira Plaku

[email protected]

05.05.2010

Introduction

Chromium dressing plant of Bulqiza is in operation since 1970 year. About 240 000 tones poor chromium ore are treated every year in the plant. The content of Cr2O3 in the raw material ranges from 20% to 26%. Production capacity is about 110 000 tons per year chromium concentrate with 48-50 % Cr2O3 content. Tailings are deposited in a dam close to the plant. The quantity is about 2 million tones and Cr2O3 content ranges from 12 to 15% with an average 12.5%. The lost of Cr2O3 component during operation of the plant has been about 25-35% of its quantity in raw material. The analysis of technological process and tailings performed last years has shown the reasons of the lost. About 50% of Cr2O3 component in the tailings are in fraction under 0.1mm. It means a big slime production in the grinding cycle, bad classification and low figures of slime concentration. The analysis in process has shown that after grinding of raw material under 1.5 mm, the quantity of -74 micron fraction is 40%. These fine particles are concentrated with low figures in existing shaking tables. About 25% of lost are in tailings regarding low separation sharpness of existing equipment produced in home. The possibilities to recover 50% of Cr2O3 quantity from tailings of Bulqiza dam exist since 25% of lost are in liberated chromium particles over 0.1mm and 50% are in slimes (fine particles under 100 microns). The concentration of tailings would be with advantage and from economical point of view, because the raw material in this case is ground and it is free of charge. For this reason was carried out the study for possibilities of chromium concentration from tailings of Bulqiza chromium dressing plant.

1. Description of location

Geographical data/coordinates Chromium Dressing Plant of Bulqiza takes places in the north part of Albanian. It is situated near Bulqiza town (Bulqiza district) in Peshkopi region. The coordinates of dressing Plant are as follow: X= 4433900; Y= 4594600; Z= 820 m The distance from Tirana to Bulqiza is about 130 km.

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Fig. 1

Fig. 2

Administrative and legal framework (e.g. permit of the treatment plant) The Dressing plant is part of the concession given through the law nr 8791, date 10.05.2001 “For the approval of concession agreement of the form “R O T” of the chromium mine of Bulqiza, chromium dressing plant of Bulqiza, selection implant of Klos and the ferrochromium plant of Burrel, between METE and the Italian company DARFO s.p.a and the delivering of the guaranties for the concession of this agreement” DCM nr.82, date. 26.02.2001 “ For the approval of the concession agreement of the chromium mine of Bulqiza, chromium dressing plant of Bulqiza, selection implant of Klos and the ferrochromium plant of Burrel,”

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The Company “Fabrika e Pasurimit te Kromit, Bulqize” sh.p.k.(“Enrichment Chromium Plant, Bulqiza“ ltd) owns the mining exploitation licence no. 892, dated 27/07/2005, for the enrichment (recycling) of fine sterile.

Municipality name / name of the region Bulqiza city, Bulqiza District, Peshkopia Region

Description, type and status of the location Both, the dam and the Mineral Processing Plant (Dressing Plant) are located near a mining site. Dressing Plant (for recycling) of chromium tailing is under operation. The area is located next to the national road Tirana-Peshkopi, about 3 km from Bulqiza city. It is almost the degraded area; does not contain any most important water sources. Although located close to the electrical substation, there is not any problem in the areas with high voltage lines.

Fig. 3-4

Fig. 5-6

Demographic issues City of Bulqiza 5 000 inhabitants

Land use planning (e.g. spatial relation to protected areas) The zone is not a protected area and there is not forestry on that.

Infrastructure The area is located next to the national road, Tirana-Bishop; about 3 km from Bulqiza city.

Biodiversity features In the hill side, ultrabasic rocks, flora is very rare such as grass, bushes, etc.

The dam and

Dressing Plant

location

Bulqiza City

location

Buildings of

Dressing Plant

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2. Recycling plant

Types of raw input material:

- Type R1. Recycling of by-products, waste and residues from extractive activities

All the tailing (waste technology) of enrichment factory are deposited, from more than 30 years in the stock that is shown in the figure below. The material collected in the amount of about 2 million tons and quality 13-15% Cr2O3, is currently being recycled in Dressing Plant

Mineralogical characteristics of the tailings

Composed minerals are chromspinelide, serpentine, pyroxene and small quantities of olivine. Valuable mineral is chromium-iron-spinel (CrMg, Fe)(Cr,Al,Fe)2O4). It is disseminated in tailings particles in from of grains ranging from 1.5 to 0.5mm locked in gangue mass, and under 0.5mm sometimes in form of liberated particles and sometimes in form of unliberated particles. A big quantity of valuable mineral (about 80% by weight) was found in the particles under 0.3mm size. Content of Cr2O3 in the mono mineral of chromites is about 60%, while s.g-about 4.1 gr/cm3. Chromite grains are irregular but contact with gangue minerals is clear. The main gangue mineral is serpentine, about 60% by weight. Cr2O3 content in serpentine is about 2%. The overwhelming majority of serpentine is liberated in all the tailing mass under 2.5mm. s.g of serpentine is about 2.7gr/cm3 under 2.5mm.

Pyroxene is another gangue mineral about 20% by weight. Olivine with s.g. 3.25 gr/cm3 occurs in smaller quantity

Actually Dressing Plant is adapted for the treatment of these wastes.

The sterile material has a composition under 0.5 mm (500 micron). The following table shows the full composition of granules and the content of Cr2O3 for each fraction. The sampling procedures of the materials is realised under a sampling process for the whole surface of the dam in a quadratic forms. Each sample is taken in the centre of each square of 3x3 m a depth of 2 m. The quantity of each sample is 10 kg. The number of points is 96. The whole material is transported to the laboratory and is analysed through different processes for size distribution, chemical composition , treatment, etc. Particle size distribution of tailings is shown in tab. Nr.1

Tab.1 Size distribution

Size (mm) quantity % Assay (% Cr2O3)

Recovery of Cr2O3

Progressive (%)

- 2.50 + 1.0 9.40 8.85 5.67

- 1.0 + 0.50 21.97 8.44 12.64 47.06

- 0.50 + 0.25 15.39 8.28 8.69 57.25

- 0.25 + 0.12 12.98 8.36 7.40 67.54

- 0.12 + 0.05 14.53 23.59 23.37 86.39

- 0.05 25.73 24.07 42.23 100.00

total 100.00 14.66 100.00

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From this table is revealed that 1- the quantity of fines is in a level of 25 % with a grade of 24 % Cr2O3, 2- the un-liberated particles are in a quantity of 30 %. We can give recommendation

that this part should be grind under 0.5 mm. Tab.2 Chemical composition of tailings

Oxides Content (%)

SiO2 28.30

MgO 36.18

Al2O3 2.44

CaO 0.64

Cr2O3 12.60

Ni 0.14

FeO 2.21

Fe2O3 5.72

MnO 0.11

Co 0.01

TiO2 -

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Fig. 7

Fig. 8

Quantity of raw input material (specify per each type of raw input material R1-R2-R3-R4) - Type R1. - daily amount (t/d) about 500 - 600 t/d of raw material - yearly amount (t/y) about 180 000 – 200 000 t/y of raw material

Chromium tailing from chromium dressing plant

of Bulqiza

Chromium tailing from chromium dressing

plant of Bulqiza

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Classification of raw input material: Raw input material: R1. (Recycling of by-products, waste and residues from extractive activities) and is classified like non hazardous, 100% mining waste.

Collection of raw input material Direct collection: from work site to treatment plant. The material it is uploaded in trucks with the capacity of 25 t/each. The material is almost incoherent. (See the figure 8); Hence it can be easily uploaded with autoloaders on trucks with capacity of 25 t/each. The distance from the dam to the plant’s yard is about 300 meters, following the paved (asphalted) road. While the processed tailing deposited again on the dam in a specific place, come in as a pulp form and has been transported by pipelines using the inclination of the terrain which is more than satisfactory. (See the fig. 9). The dam serves in the same time even for the separation solids-liquids and the most of the water is recycled.

Fig. 9

The dug part for recycling effects in the

Dressing Plant

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Fig. 10

Technical information on recycling facility - occupied average surface

The enrichment factory of chromium mineral was built in 1972. The aim of this factory has been the enrichment of about 240-250 thousands ton/year chromium poor mineral with 24-40% Cr2O3 content. Dressing Plant, in total covers an area of 120 000 m2. The factory consists of three independent sections from each other. The first and second sections are identical according to the project and thus have worked until 1990-1991, when it was finished reconstruction of the first section. While the third section has the technological scheme that differs from that of other sections, but it use the same principles and methods of enrichment. In this factory are processed around 240.000 t/y; this mineral comes from Batra, Bulqiza, Ternoves and Klos, etc.deposits.

- acceptance procedure for the raw input material The procedures for the entrance of the material are through a big weight of 40 tons and the material after is deposited in the entrance of the plant. With loaded trucks material go to the first bin of a capacity of 60 tons after with a chain transporter and belts is deposited in the main bin of the plants of a capacity 200 tons each. The plants has 3 of them one for each section.

- dimensions of the storage of the different raw input material and of the produced recycled aggregates The raw material comes from the dam and is deposited in the deposit of raw material at the entrance of the plant. The capacity of the deposit is 20 thousand tons, and is divided in two steps. Dam of tailings covers an area of about 60,000 m2. The dam is in

Tailings Pulp coming down in a pipe line

from the dressing plant and depositing in the

dam.

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the same time even the place where the new tailings produced through the recycling process are deposited. Thus, one of the final recycling products, SAND, is deposited at any specific place of the dam.

The concentrate produced by recycling process is deposed in the concentrate room (area) with a surface of about 8.000 m2.

- paved areas Paved area is composed from the first step of the deposit of the material at the entrance of the plant in a surface of 10.000 m2 and all the area of the plant which in total has a surface of 6.000 m2. All the paved area has it collection system of the water. The water collected through different channels is directed to the main flow of the waste helping movement of the solid in the waste channel.

- areas equipped with a wastewater gathering system The dam is equipped with a recycling system of water which goes at the dam together with the tailings in the pulp form. Even the water which goes together with the recycled chromium concentrate succeeds to be recycled through a spiral classifier. Both quantities of the recycled water are gathered by pumps in a cylindrical deposit at the highest quota of the Dressing plant.

- energy sources (diesel, electricity from grid, diesel generator, The energy used it is the electrical one, supplied from the national distribution network. Near the Dressing plant there is an electric substation. The plant has its own transformers.

- environmental controls and monitoring - There is a monitoring point from the National Agency of Natural Resources which is

monitored during the year and the results are presented in the final report of the AKBN.

Technical information on recycling treatment - hybrid plant for the production of natural and recycled aggregates

In this plant are located some sections which are used by occasion for the recycling of the tailing dam materials or for processing of the mineral of size under 300 mm, which is extracted directly at the Bulqiza mine (3 km far from Dressing plant) either. In the last case enters into function the fracturing machinery up to the size 12 mm and after that occurs the grinding of the mineral up to the size 1.5 mm. This plant works for both minerals from the mine and from the dam. When is used the material of the dam the crushing section does not work just the belts for the transport of the material at the main bins.

- process units (please provide flowcharts with indication of mass flows and equipment description including treatment capacity and installed power) The plant consists of the equipment as by the following table:

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description unit

Machines description

Feed different deposits Primary crushing jaw crusher Pre-screening Vibrating screen Secondary crushing conic crusher Screening vibrating screen different belts, wet classification spirals classifiers hydraulic classifiers grinding Bar mills

gravity separation Jigs, shaking table in every stage, wet operations

Water treatment Spiral classifiers for concentrate solid-liquid separation. decantation in dam, for sand tailings

At the present, since the entire dam’s material has been grinded less than 2.5 mm, it is not necessary the fracturing process and it goes directly at the sieving process, and after that at grinding and enrichment process and water separation one.

- Plant processing capacity for each product (t/h):

for chromium concentrate 7-8 t/h,

for recycling sand 45-55 t/h

- Plant processing throughput for each product (t/y)

for chromium concentrate 4-5 t/h,

for recycling sand 30-35 t/h

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Fig. 11

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3. Recycled aggregates

Type of recycled aggregates. - There are not any aggregates in the products. In this case we are dealing with recycle

products. - Good quality chromium concentrate for chemical industry and metallurgy - high quality sand for concrete and civil construction;

Production quantity (t/h and t/y). Selling price (€/t)


(t/h) (t/y) (€/t)

Chromium concentrate 38% -42% Cr2O3

4 - 5 20,000 150-250

Sand (6-7% Cr2O3) 30 - 35 160.000 ton/year


Recycled sand Saturated surface dried specific gravity ssd (kg/m3) Los Angeles Index LA (%) Shape Index SI (%) Flakiness index FI (%) Sand equivalent SE (%) Fineness modulus Mf - Impurity level - (%) …

It emerges clearly from the experimental results that in the case of the ore the compression strength Õc is greater than the shear strength Õs which, in turn, is higher than the tensile strength Õt, the relationship being as follows: Õc = 4-6.5 Õt = 2.5 Õs.

Eco-compatibility of recycled aggregates (leaching test - please provide the certificate) There is not any evaluation for the eco-compatibility, but any treatment plant makes a environment permission in which is the EIA

Existence of codes of practice to achieve technical excellence

Existence of CE Marking (please provide the certificate)

Description of use of recycled aggregates 1. Recycled chromium concentrate:

- chemical industry - ferrochromium production/special steel production

2. Recycled sand: - Construction: partly for concrete / civil construction the sand used for the construction

has a grade of max 1 % of Cr2O3. This sand is mostly used form the villagers for purpose of walls for land, roads, etc. The impact on the quality of concrete or for other uses is zero, because these values are almost the same as in the ultra basic rocks used for construction. The impact on environment concerning leaching etc, is not

47

studied because the period of study for such experiments it will be for years, but the experience of using these kind of rocks in the past reveals there is not impact on environment by using them.

Transportation of recycled aggregates - Transportation cost according to the delivery distance; - The whole amount of production of recycled chromium concentrate is for export. The

main countries are Italy, Sweden, and China. Transportation costs are 30-60 €/ton. Within the Albanian territory transportation cost is 0.1 € per ton-km

The cost for the sand transportation is 0.12 € per ton-km. Average delivery distance is 20-30 km

4. LCA

Regarding the life time of this activity, it will depend on the capacity for the treatment of the wastes. The quantity of the waste has a value and from the calculation based on the treatment capacity of the plant today these waste will be finished to be treated after 6 years. In the future years all the sand which is not commercialised will be deposited in the same dam. For the moment it is deposited in the new dam near the old one. In the future months based on the way of exploitation of the old dam the sand with a low grade percentage of Cr2O3 will be deposited in the old dam, and will be commercialised from there. In this case life cycle assessment will concern on treatment of waters and rehabilitation of the dam. The recycle of the water will continue until the level of the solid will be at zero vale. The plan for the future as is showed in the rehabilitation plan this dam will be cover by soil and planted by trees which are trees of the region. During discussion with the local authorities there is an idea to convert the area in a park but there are not further discussions on this issue

5. Environmental impact assessment

Geomorphologic exposure and visibility aspects (e.g. landscape change) visible in local area / visible in broad area

Taking into consideration the very smashed terrain at that zone, there are not problems related with the change and/or ruining of the landscape. Location visibility in that zone can be classified like poorly visible

Protected areas status There is not a protected area

Water (surface and groundwater), soil and air quality conditions Water, soil and air quality are in normal values, because the activity of the recycling plant has a very limited impact on them.

Existence of codes of practice to achieve environmental excellence There are codes for the norms and standards of the pollution derived from the processing plant of this kind. There are part of the environment legislation and mining legislation.

Systematic operation of environmental monitoring and control program There is a monitoring point from the National Agency of Natural Resources

Noise, visual impacts, dust and emissions The values of those kinds of pollution are within the norms and standards.

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6. Socioeconomic impacts assessment Local/regional employment situation

50-70 employees are in the dressing plant, the rate of unemployment in the area is high 12 %

Health and safety aspects (on- and off-site) The health and safety aspects in the processing plant are under monitoring and supervision of two institutions National Agency of Natural Resources and Inspection Salvation Body. Actually they reports on this issue reveals a comprehensive level for the health and safety problems.

Capacity building (e.g. training courses and plant visits) This plant serves as a site visit for all the students of Mining faculty in the branch of mineral processing

Relevant vulnerability issues (e.g. human health risk assessment) In the EIA are treated also the human health risk assessment which are more connected with working area like humidity, etc.

Local communities engagement and involvement in decision making By law is taken the opinion of local authorities

Benefits of improving the knowledge base at a local level should be mentioned and highlighted Transparency and knowledge base at a local level in the area is well known because this area is a mining area and the population have mining as a main source for their economy and the population of the area is mostly involved in mining activity.

Presence of effective and regular dissemination of information to particular stakeholder groups There is not a regular dissemination of the communication within the population, but by regulation the company every three months gives the information to the central authorities for its activity.

Available mechanisms to increase communication and discussion between stakeholders. Media, participation in local authorities meeting and vice versa, NGO, participation of civil society.

7. Best practices approach Possibilities for new technology applications Yes there are some new possibilities for further

improvements in technology, In metal recovery, combined method by treating also mineral.

Optimising the efficiency of recycled aggregates production e.g. water & energy consumption, transport. Must be increased the effectivity at each equipment of the technological scheme and must be invested as well at the technological water recycling plant.

Determine impediments to best practice, e.g. lack of knowledge, regulatory blocks

Prepare recommendations for industry and government actions to encourage best practice By making a new policy for the cleaning products, and especially for recycle products by incentive for such investments, using financial instruments

Way forward e.g. LCA study approaches (understanding of the balance between benefits and impacts)

49

CASE STUDY 2 - GREECE (IGME): THE MAGNESITE MINE OF GERAKINI

Case study of:

GERAKINI Country: GREECE

SARMa Partner: Authors of the report: e-mail:

Date of submission to WP3.3 leader:

IGME

Fotini Chalkiopoulou Kiki Hatzilazaridou John Hatzipanagis Chara Papantoni

[email protected] [email protected]


1.1. Geographical data/coordinates

Gerakini Mine (blue triangle in Figure 1) is located in the Chalkidiki Prefecture of the Region of Central Macedonia in Greece. It belongs to the municipality of Polygyros.

Figure 1 Gerakini Chalkidiki, Central Macedonia, Greece

It is located in a distance of:

570 km north of Athens 85 km east-southeast of Salonica 800 m away from Gerakini settlement >1,5 km from coastal line

Coordinates of location using WGS84 system:

400 17΄ 48,53΄΄ Ν 230 27΄ 59,74΄΄ Ε h = 132 m s.I.m.

Gerakini region

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1.2. Administrative and legal framework Mining in Greece (including ores, industrial minerals, marbles and aggregates) is ruled by a series of laws, regulations, etc. The Greek legislation separates mineral resources into two major groups, on the basis of the difference in ownership rights:

Ores, the exploitation of which is governed by the Mining Code (MC) 210/1973 and by definition (Articles 1-3) do not belong to the owner of the land and their exploration and exploitation right should always be concessed

“Quarrying minerals”, including industrial minerals, marbles and aggregates that belong to the landowner of the occurrence and are exploited principally according to L. 669/1977.

Mining Code (MC) 210/1973 and its amendments (Law 274/1976) contain all the essential issues related to the extraction of ores, such as: exploitation rights, licensing process related to mining, installment and operation of machinery, obligations of the mine operator, authorization process, treatment of illegal mining, process for exploitation of public mines, etc.

Further and above specific legislative framework for exploitation of aggregates, as far as environmental issues are concerned, mining activity is ruled by L. 1650/1986 “ For environmental protection”, as amended by L. 3010/2002, and all related laws, regulations, decisions, etc. All projects and activities that require environmental licensing are grouped and classified into categories (A, B) and subcategories (A1, A2, B3, B4). Depending on the subcategory, different type of environmental study needs to be submitted for evaluation and approval. For project/activity of subcategories A1 and A2 that are located in a protected area, such as Natura 2000, the following procedure is the one of subcategory A1. The approval of Environmental Conditions is given either by the Ministry of Environment, Energy and Climate Change or by Joint Ministerial Decisions (JMDs) of the latter and other ministries or by the General Secretary of the relevant Region (regional level) or by the relevant Prefecture (local level) depending mainly on the subcategory of the activity in question. The submission of an Environmental Impact Assessment Study (EIAS) or Environmental Report (ER) is obligatory and the exploitation license is granted after the approval of the Environmental Conditions (EC). The latter is usually valid for 5 years.

The Greek market needs in aggregates are covered mainly with crushed rock aggregates and occasionally by sand mining, due to plenty of carbonate rocks appropriate for aggregates production.

Secondary aggregates are mainly produced from mining waste (i.e. waste from magnesite mining and processing or slags). Also, marble waste fines are normally used for the production of marble dust.

According to the Greek legal framework (Article 3 L. 1428/1984 as amended by article 2 L. 2115/1993), aggregates excavated during exploitation of all kinds of minerals may be supplied by the operator under the condition that the relevant fiscal terms are applied (i.e. payment of the proportional rent). In this case study, aggregates production unit is considered as essential part of the processing procedure of the main product.

As far as the magnesite exploitation waste is concerned, approximately 150.000 tonnes of aggregates (mainly 0-30mm, 3A) are produced annually. These aggregates are used mainly for road construction as well as for restoration works within the mine.

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1.3. Demographic issues The Prefecture of Chalkidiki (White region in Figure 2) covers an area of 2.886 km2 and has a population of 108.000 inhabitants (data 2001). It is divided into 14 municipalities and has the longest coastline amongst all the prefectures of the mainland. The municipality of Polygyros (red area in Figure 2), where the Gerakini mine is located, covers an area 471 km2. Its population is 11.000 inhabitants (data 2001).

Figure 2 Prefecture of Chalkidiki (White region), Municipality of Polygyros (Red region)

1.4. Description, type and status of the location / Geological features

Gerakini mine site belongs to the state and is legally operated by the Grecian Magnesite S.A. Its operation has not caused inconvenience to the inhabitants, as there is only visual contact to the nearest settlement. Gerakini settlement is 300 m away from the treatment plant and 800 m away from the extraction site. Overview of the area is shown in Figure 3.

Gerakini mine

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Figure 3 Overview of the mine site

Figure 4 An overview of the Gerakini mine installations

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The geological setting of Gerakini area is part of an overthrusted ocean floor ophiolite slab of Mesozoic age ultrabasic rocks comprising dunites, harzburgites, peridotites along with subordinate presence of partly lherzolitic wehrlites and meta-peridotites. The eastern part of the Gerakini mine area is dominated by pyroxenite whereas in the south an outcropping gabbro suite is well exposed. (Figure 4)

Figure 5 Geological map

Lenses and schlieren‐type of chromite mineralisations occur in dunites whereas feasible magnesite deposition is associated with extensive alteration. Stock‐work veins of magnesite form exploitable resources hosted by dunites, more or less serpentinized, and harzburgites. Dunites get to become more “fresh” with depth (Figure 5).

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Figure 6 Mine site

Figure7 Mrs Hatzilazaridou (IGME Geologist) and Mrs Zafeiriadou (Mining Engineer of the company) in the mine site

However, the mine tailings left over and stockpiled after magnesite extraction and used currently for production of aggregates, is a composite material, comprising dunites and harzburgites of varying grade of alteration, and remaining fragments of magnesite.

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Figure 7 Fronts of the mine, where magnesite veins are visible

1.5. Land use planning The mine site is not close to nature protected areas or national heritage sites. Additionally, as can be seen in the land use map of Figure 5, the mine site is mainly surrounded by olive groves and crop areas and as a result, there are no protests by the inhabitants because of mine operation. Natural lakes or rivers do not exist nearby, and the water quality is not affected at all. A lake has been formed in the mine site and keeps water after raining, so as to be used in the treatment plant procedures. The company intends to keep this lake for local/agricultural use when reclamation is held.

Figure 8 Land use map of the region

Extraction

Olive groves

Crops

Urban areas

Vegetation

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Figure 9 Views of the artificial lake in the mine site

1.6. Infrastructure The closest settlement to the mine site is Gerakini (<1 km away) and the coast line is not more than 1,5 km away. Most important roads can be seen in Figure 5 (Red lines). The mine site has been developed in an area very well supported by primary and secondary asphalt roads. A network of asphalt roads connects the mine site with the coastline, facilitating the transportation of the mine products to the ships. Figure 6 shows the loading bay for the shipping of the products.

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Figure 10 Loading bay for the shipping of the products

1.7. Biodiversity features The area around the mine site is characterized by high biodiversity. Vegetation varies depending on the soil, the grazing that took place during the previous season and land farming in previous years. The main species of flora and fauna of the region are referred in Table 1. None of them is protected by law.

Table 1 Flora and fauna of the region Fauna Flora

Animals Olea Oleaster

Lepus europeus Quercus cocifera

Vulpes vulpes Ardutus Unedo

Meles meles Erica verticillata

Mustela nivalis Smilax asperta

Erinaceus concolor Rubia peregrina

Rattus norvegicus

Mus musculus

Myotis ssp

Birds

Pica pica

Cuculus canorus

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Accipiter ssp

Turdus merula

Amphibia

Bufo bufo

Reptiles

Testudo graeca, marginata

Hemydactylus turcicus

Podarcis ssp

2. Recycling plant A range of gangue as well as by-products stem out within the framework of the extraction and processing procedures that take place at Gerakini mine for the exploitation of the magnesite deposit.

Figure 11 The caustic calcined and dead - burned magnesia production unit (kilns) – Main product

Figure 12 Optical separation (sorters) - I. Hatzipanagis (IGME Geologist) and F. Chalkiopoulou (IGME Mining Engineer) visiting the sorter processing unit of Gerakini mines mill

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Figure 13 Reject product deriving during treatment of fines with sorter technology

Figure 14 Stockpiles of by-products

In order to reduce disposal area needs and exploit part of the aforementioned disposed off materials, the company has established a crushing grinding plant unit for the production of secondary aggregates. This plant unit is located close to the grizzly installation of the production circuit (250-500 m). The feed of this crushing –grinding plant comprises both by-products from the sorter unit plant of the mill and waste material from the quarry as well. The feed mixture to the crushing grinding plant depends on the main production schedule. Feed usually contains magnesite and serpentine in small quantities, but mainly dunite.

Thus, the specific input material belongs to the R1 category (R1: Recycling of by-products, waste and residues from extractive activities). Raw input material for the aggregate production unit is transferred by lorries, as all the transportations within the quarry. The average quantity processed yearly is 150.000 tonnes (1 shift per day).

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Figure 15 Recycling plant - Aggregates production unit

Figure 16 Production of aggregates unit/recycling plant

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Figure 17 Aggregates

Wastewater of the recycling plant goes to the thickeners which are part of the sorter unit. Clear water produced by the thickeners is useful for other uses in the mine.

Figure 18 Thickeners

Medium grade recycled aggregates (type B) for road, airport and harbor construction are produced in this plant with respect to the CE marking requirements (UNI EN 12620:2008 and UNI EN 13242:2008)

Production cost is 1.5-5.2 €/t and transportation cost according to the delivery distance is 0.15 €/t*km

Average transport distance is 45 km and maximum transport distance is 60 km.

A flowchart of the recycling plant, which occupies 400 m2 is shown in Figure 20.

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Figure 19 Flowchart of the recycling plant

SILO

FEEDER

CONVEYOR BELT

CONE CRUSHER

SIEVES (WET SIEVING)

‐6 mm +6 mm – 30 mm +30 mm

SCREW FINAL PRODUCT ROTOR

MUD

THICKENERS

WASHER

‐6 mm

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CASE STUDY 3 - ITALY (RER/PARMA): THE RECYCLING PLANT OF MADREGOLO

Case study of:

Madregolo (Collecchio) Country: ITALY


RER

Segadelli Stefano Ratta Manuela With helps of: P. Boggio, S. Galloni, A. Pelosio, SIP company holders


Introduction

The plant is a good example of evolution from "traditional quarrying" to sustainable quarrying and it is therefore in line with the SARMa project. Indeed, at the beginning the site was a "conventional" quarrying activity: quarry and relative treatment plant of natural aggregates. Subsequently the Taro Regional Park (an environmentally protected area) was established and the “cohabitation” started between the quarrying activities and the park entity.

When the gravel and sand deposit was exhausted, the quarrying activities moved to another place, but the treatment plant remained in the same area and the site managers started purchasing raw (natural) materials from other companies: the suppliers were several in number and by typology of aggregates and, at the same time, the recycling of milled materials (from highway maintenance operations) started, integrating sources of raw materials with secondary raw materials.

This said, the recycling plant owned by SIP deploys both hot-processing and cold-processing technologies for the recycling asphalt concrete. The recycling facility works in a continuous cycle in the sense that the asphalt concrete plant can work with both recovery materials and with natural raw materials. Moreover the company works independently because it has all the necessary raw materials and the facilities for their treatment, from the quarry to the crusher for the production of asphalt concretes, from the bitumen plant to the production of the asphalt concrete; for these reasons the plant is considered a system that works with a "continuous cycle”.

This activity takes place within a regional park which is also SIC/ZPS and therefore they must comply with the current environmental regulations.

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Geographical data/coordinates:

Y 961282.01331 X 596063.56270 Z (medium) – only meters (a.s.l.) = 70m

Administrative and legal framework (e.g., permit of the treatment plant):

The plant, located in an area included in the Interregional Plan for Extractive Activities (PIAE) developed by Parma Province.

This is a plant for the recovery of non-hazardous waste with a capacity exceeding 10 t/day, subject to notice of commencement activities under national legislation on waste management.

Scale about 1:190.000

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The project has undergone an environmental assessment procedure under the juridical authority of the Province of Parma, as the site is located in a protected natural area.

The recovery activities must be undertaken in compliance with regulations regarding:

- town planning and building;

- air pollution;

- fire prevention;

- sewage disposal;

- noise pollution;

- safety and health of workers at work.

Municipality name / name of the region

Collecchio, Emilia-Romagna Region

Description, type and status of the location

- Quarrying activity in a rural site

Except for land which exploited for infrastructures, manufactures and other buildings, this area is devoted to extensive agriculture (tomatoes and cereals, arable and lasting fields).

- Status of location: active

- Description of infrastructure

Most important roads: motorway A15 Parma – La Spezia (about 1.5 km);

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Secondary roads: near the northern edge there is the National Road N° 9 Via Emilia, while in the south east there is the Cisa N° 62National Road, which represent two arterial roads of regional significance.

There are also many roads of the provincial network (S.P. N° 357R Fornovo, S.P. N° 89, S.P. N° 49 Collecchio), and a dense network of municipal roads linking the municipal offices and the many hamlets in the area.

The crossing of the Taro River is ensured by three bridges (along the Via Emilia in Ponte Taro, between Collecchio and Medesano, and between Fornovo Taro and Ramiola), which are essential for the connection of roadway networks on the left and right hydraulic sides of the river and its territories.

At the edge of the study area there are also three important rail networks: the Milan-Rome-Naples line (downstream of the Via Emilia), the Parma-La Spezia line (on the right bank of the Taro) and the Fidenza-Fornovo line (on the left bank of the Taro).

As the highway network, also the rail network has an important role for inter-regional and national transport, since it links the major industrial centres of northern Italy (and of Central Europe) with the major ports on the Tyrrhenian Sea (La Spezia, Genoa, Livorno).

high voltage lines (about 1km)

low voltage lines: no

Demographic issues: The Parma Province is highly populated (the residents as at 1/1/2010 were 437.308 on a surface of 3.449 km² ) and wealthy, with low rates of unemployment. The surroundings of the Taro River alluvial fan, however, are still mostly agricultural. On a wider scale (in the radius of a few tens of km) the area is interested by manufacturing and commercial activities, with some excellences in tertiary sector, like tourism, wine and food. This require great effort to preserve existing/remaining natural features.

For more information: http://www.statistica.parma.it/

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Land use planning (e.g., spatial relation to protected areas)

- Description of the land use (e.g.: urban / sub-urban / meadow / pasture / forest / degraded land, also covered by plants - overgrown / nature protected area / national heritage site (archeological, technical, historical, etc.) / other...)

The case study is part of an area with a predominantly agricultural nature and, above all in the past, widely used for quarrying. The recycling facility (including waste storage yards) is in Band C.

In terms of planning, in the area of the Taro fan there are numerous territorial constraints defined by the Provincial Territorial Coordination Plan (PTCP) and its Technical Standards for Implementation. The PTCP is the planning tool that incorporates and specifies the contents of the regional plans (Regional Territorial Plan – PTR, Regional Landscape Territorial Plan - PTPR, Regional Plan for Water Protection – PTA, Integrated Regional Transport Plan - PRIT, the Natura 2000 network sites, etc.) and is the mandatory reference for the municipal town planning. The PTCP also incorporates on a provincial scale the indications and the supra-regional constraints (in particular the plan to extract the Hydro-geological Arrangement Plan – PAI, developed by the River Po Basin Authority, approved by Decree of the President of the Council of Ministers on the 24th May 2001). Such constraints involve almost exclusively the agronomic use of the fluvial and peri-fluvial areas of the Taro River, mostly in the form of extensive and intensive arable crops, of a rotational character (tomatoes, wheat and maize, fodder grass, etc.).

The central part of the fan coincides with the Taro River Regional Park and with the Natura 2000 network IT 4020021 “Middle Taro”, while just to the east there is the Carrega Woods Regional Park and its SIC IT4020001 “Boschi di Carrega”. The two regional parks border with each other for a short distance.

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Infrastructure - Distance to nearby settlement (in km), in settlement, or on the edge of the settlement

This part of the Taro fan is characterized by numerous anthropic interferences, including a number of road infrastructures (provincial and municipal roads), productive activities (crushers, concrete and asphalt production plants, food industries, crafts, etc.), several quarries and major towns.

Madregolo: 1 km S-E Noceto: 3 km W Parma: 8 km E Collecchio: 6 km S

Biodiversity features: Because of relevant anthropic presences, few natural sites are connected to Taro riverbed and its banks: in the “Taro river” Regional park, however, several endemic mammal and bird species are still present and reproduce. Recently, the Taro Regional Park has been designated as the SIC – ZPS Middle Taro (IT4020021) and is therefore one of the Sites of European Importance of the NATURA 2000 NETWORK. This recognition is due to the rare river habitats that it still encloses (such as Myricaria germanica riparian shrubs) and to the important animal species housed (among them the rare Occhione, Burhinus oedicnemus, breeds there, in the

picture).

It is also important as an ecological corridor linking the continental plains and hills: moreover the whole valley is one of the main migration directions between the Tyrrhenian and the Po Valley.

The part of the site which falls within the protected area was involved in some regional LIFE Nature projects, including the "Redevelopment of the Taro river habitats for avifauna”.

Below, Burhinus oedicnemus from the side, geographical classification of the SIC-ZPS Middle Taro and of the examined area.

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2. Recycling plant

Types of raw input material:

- R1: Recycling of by-products, waste and residues from extractive activities: no

- R2: Recycling of Construction and Demolition Waste (CDW). In particular, the plant recycles milled material resulting from the maintenance of road asphalt pavements.

- R3: Recycling of excavated soils/rock from civil works: no

- R4: Recycling of industrial waste (e.g., slags from civil ferrous metal production, bottom ash from Municipal Solid Waste (MSW) incineration, ashes from coal combustion processes etc.): no

- Others

Quantity of raw input material (specify per each type of raw input material R1-R2-R3-R4)

- daily amount (t/d):

- yearly amount (t/y): about 15.000 (t/y) of material type R2

Classification of raw input material*:

- EWC code (European Waste Catalogue 2000/532/EC) : 17 03 02 – 01 04 10

- by-products: no

- mining waste: no

- others (specify)

(provide the input material average composition, i.e. % of different EWC)

100% milled material from road surfaces.

Collection of raw input material

- direct collection: from work site to treatment plant: yes

- lorry type: transported by authorized lorries called "operating means" and therefore subject to specific dispositions of the Highway Code. The new Highway Code defines the operating means as “vehicles or groups of vehicles equipped with special equipment for the loading and transporting of material that is used in or is debris of construction works, as well as road and mineral extracting works and similar materials, that complete, during the transport, the production cycle of specific materials for the building construction”. The transfer is free for lorries with a payload between 30 and 45 t.

- average distance: provincial

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Technical information on recycling facility

- occupied average surface about 260.000 m2 (including a mill, the recycling plant itself and ancillary infrastructures such as waste storage areas, offices, etc.)

- acceptance procedure for the raw input material: before accepting the waste material it is required a leaching test (sample required from every single construction site that originated the waste material) according to the D.M. 05/02/1998 and to its modifications. A leaching test and an hazardous test is carried out yearly on a sample taken from the plant storage area. The plant recycles the following types of waste: CER 170302 and CER 010410.

- dimensions of the storage of the different raw input material: about 3.100 m2 , the same area is used for both the fine waste material (0-15 mm) and for the coarser waste material (0-40 mm) that are divided in individual piles; dimensions of the produced recycled aggregates: according to European standards (UNI EN 13108-8, UNI EN 13242) 0/40 mm

- paved areas: about 10000 m2

- areas equipped with a wastewater gathering system: waste storage area with impermeable basin

- energy sources (diesel, electricity from grid, diesel generator, …):

diesel, electricity and natural gas.

- environmental controls and monitoring ARPA (the Environmental Protection Agency) is responsible for the environmental control of the activity

management standards (environment/safety/quality): UNI EN ISO 9001:2008

Technical information on recycling treatment

- stationary or mobile plant for the production of recycled aggregates: stationary plant

- hybrid plant for the production of natural and recycled aggregates: yes

- process units (please provide flowcharts with indication of mass flows and equipment description including treatment capacity and installed power)

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The plants are divided into two types: a Discontinuous Plant (CB 160) and a Continuous Plant (MEC 140). In general discontinuous and continuous plants can be divided into the following main parts:

pre-dosing units;

bitumen tanks and filler silos;

dryer;

methane burner;

mixing tower;

finished product silo;

management cabin.

The aggregates are transported from the heaps and then put into the appropriate pre-dosing units. Here the aggregates are separately measured under different particle size classifications, depending on the required type of asphalt and with a conveyor belt are brought into a rotary drum dryer.

The dryer is a steel cylinder with blades placed inside.

When the drum rotates, the blades lift the material and drop it through the hot air of the drum. At the same time, the aggregates advance due to a slight slope of the drum. In the plant the drying follows the counter flow process (where the direction of the hot air flow is opposite to the direction of the material flow).

Important control parameters for the drum are: the slope angle, the rotational speed and the blade design. At the end of the drum there is a gas burner for drying and heating the aggregates. The heat is thus transferred by radiation (from the hot spot – flame – to everything around, at lower temperatures). For dust control, the steam passes through a bag filter as well as the inlet air from the end of the drum. Clean air is then released into the atmosphere through a chimney. The dust collected in the bag filter (filler) by pressure exchange, is constantly being re-inserted in the mixing process.

When hot aggregates (temperature 135-180ºC) leave the dryer, they fall into an elevator and are transported up the tower mixing.

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Discontinuous Plants: CB 160

Here the aggregates are transferred into a vibrating screen and separated into storage silos. Alternatively they can be stored in a by-pass silo for direct use. From here they feed the weighing hopper, according to the mix design that is produced. Aggregates moves from the weighing hopper to the blades shaft mixer where they are mixed with the bitumen that is downloaded from a weighing small tank; bitumen, in turn, is pumped from a heated storage tank. A weighing silo can be used to change the quantity of filler. The mixing time varies from 30 to 60 seconds, depending on the recipe type.

The finished asphalt is transferred directly into the truck waiting for immediate delivery on site or stored in insulated finished product silos.

Continuous Plants: plant 1 – MEC 140

Here the aggregates are directly fed into the rotary type mixer (with specific slope, speed and blading) together with the bitumen and filler, both measured continuously according to the aggregate flow (quantity / speed) entering into the dryer cylinder. The mixing time is constant and potentially proportional to the drying flow of the plant. The finished asphalt is transferred directly into the truck waiting for immediate delivery on site or stored in insulated finished product silos.

Recycling of milled material from asphalt concrete

The used recycling techniques are the hot-working conduction (heat transferred between two solids at different temperatures) and the cold-working. For both methods, the material must be crushed and screened before being determined. The hot-working conduction methods refer to the addition of recycled material with a percentage not exceeding 20% of the total mixture, at the downloading in the elevator of the aggregates coming from the dryer, where the recycled material is heated (through contact) by virgin aggregates before entering the mixer.

The cold-working methods use recycling percentages up to 50%, and they consist in the simple mixing of virgin aggregates, recycled material, water, emulsion and cement, all at room temperature.

- Plant processing capacity for each product (t/h) 300 t/h

- Plant processing throughput for each product (t/y) about 161.000 t/y

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Type of recycled aggregates.

- Type B: “RA” recycled asphalt concrete for road, airport and harbour construction



(t/h) (t/y) (€/t)

Type A - - -

Type B -recycled aggregates -recycled asphalt concrete “RA”

40 300

25 000 about 32 000

11.00 40.00 asphalt concrete cost

Type C - - -


Recycled aggregates type A B C Saturated surface dried specific gravity ssd (kg/m3) n.a. n.a. n.a. Los Angeles Index UNI EN 1097-2

LA (%) n.a. n.a. n.a.

Shape Index UNI EN 933 - 3

SI (%) n.a. n.a. n.a.

Flakiness index UNI EN 933 - 4

FI (%) n.a. n.a. n.a.

Sand equivalent UNI EN 933 - 8

SE (%) n.a. n.a. n.a.

Fineness modulus UNI EN -1

Mf - n.a. n.a. n.a.

Impurity level - (%) n.a. n.a. n.a. n.a. : not applicable

The type A, B and C aggregates are originated from building demolition, soil excavation, etc. not used in the plant to produce bituminous aggregates.

The recycled bituminous aggregates are produced according to the dedicate standards UNI EN 13108, Bituminous mixtures - Material specifications - part 8 “Reclaimed asphalt”, for bituminous aggregates with CE mark

Eco-compatibility of recycled aggregates (leaching test - please provide the certificate) A leaching test is carried out on the inlet material that is given (attached there is an example of the leaching test certificate).

Existence of codes of practice to achieve technical excellence: no

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Existence of CE Marking (please provide the certificate): yes; aggregates and bituminous mixtures (reference: UNI EN 13108 standard – Bituminous mixtures – specifications – Item 8)

Description of use of recycled aggregates

- road and railways construction

Transportation of recycled aggregates

- Transportation cost according to the delivery distance (€ per ton-km) on average 4,00 €/t average of 20 km

- Maximum delivery distance km 30,00

- Average delivery distance km 20,00

4. Life Cycle Assessment (LCA)*


Inventory data for recycling (data with reference to 1 year of activity)

Raw input materials

Quantity processed t About 161.000

Land use

Occupied area m2 about 260.000

Materials/fuels Hammers/jaws kg - Water kg 0 Lube oil kg - Polyurethane screen kg - Steel screen kg - Synthetic rubber kg - Diesel l 53.820 Electricity Kwh 705.791 Natural gas MC 1.681.937 Outputs Recycled aggregate type A t - Recycled aggregate type B t 57.000 Recycled aggregate type C t - Steel scrap t -

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Geomorphologic exposure and visibility aspects (e.g., landscape change):

Investigation area is a context characterized by shapes testifying the passage from hilly to plain morphologies trough quaternaries alluvial terraces ‘surfaces.

Shapes and deposits typical of alluvial terraces are identified as flat area, originated by depositional and/or erosive processes, delimited by river escarpments.

This portion of territory is characterized by wide riverbeds, xerophitic terraces, wet depressions and riparian woods, agricultural surfaces but even industrial settlements, basins of disused quarries and active extraction poles.

- Location visibility (can be) determined by visibility from settlement or local road(s): poorly visible

Protected areas status:

This area is mainly included in the area of Regional Park “Taro river” and it is partially interested by action planned in the context of Life Nature project “Re-development of bird habitats in Taro river “.

Several zones of the investigated area are subject to severe impacts coming from several economical activities and increasing urban expansion.

Most relevant menaces come from banks and riverbed morphology changes, from access, even by motorized vehicles, to floodplain, riverbed and shingle of swimmers, fishers, hikers and other vehicles linked to quarry activities. Other relevant menaces in this area come from realization of new infrastructure, such as roads.

Water (surface and groundwater), soil and air quality conditions:

Elements such as water (surface and subterranean), soil and air present excellent features.

Taro riverbed has a mobile base with braided canals flowing on sediments and realizing morphological adaptation in terms of dimensions, shapes, track and slopes. Alluvial riverbed shaping derives from natural process of riverbed and banks erosion and sediments’ transportation and deposition. Considering the whole XX century, investigated river section has been significantly transformed as a consequence of strong urbanization started in the ‘50s and identifiable as extraction of materials from riverbed, canalization and urbanization of the river dependencies.

Investigated area plays a relevant role in recharging aquifer structure in Parma plain. The presence of alluvial deposits characterised by rough and high permeability constitute a relevant body for water system recharging. Supply of aquifers is composed by sub-riverbed flow and by local contributions coming from surface infiltration. Considering particular hydrological and litho-stratigraphical conditions, the investigated area is subject to hydro-geological vulnerability with high sensitivity related to possible diffusion of polluting elements. Aquifer is subject to seasonal variability in line with hydrometric stratus of the surface water network. In correspondence with intensive and prolonged meteoric events, with consequent increase of the hydrometric height, the water-table depth up to current campaign level.

From pedological point of view, most valuable soils are in late Pleistocene terraces where gravel and sand with clay-slime origin are covered by lime and slime altered horizon thicker than 1,5 meter

Air is highly conditioned by anthropic activities.

Existence of codes of practice to achieve environmental excellence:

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Several guidelines published by Emilia-Romagna Region exists.

Systematic operation of environmental monitoring and control program:

During cultivation and final settlement phases it is foreseen to have continuous subterranean water monitoring to be realized trough two piezometers. These instruments will provide qualitative measurements of the aquifers pressure (every three months) and a monthly assessment of the water-table depth.

Noise, visual impacts, dust and emissions:

The plant is equipped with work and environmental impact mitigation works such as acoustic barriers, speed bumps, waterproofing of the squares by means of a "closed" type asphalt.

Quantitative studies are not yet available.

6. Socioeconomic impacts assessment

Local/regional employment situation:

Local main economical vocations are agriculture and industries (large companies and SMEs) linked to food production. Recreational and tourist activities are mainly linked to “Taro River” regional park.

Existing extractive activities located in Taro river fan in order to exploit gravel are active since decades and have a relevant role in local economy.

This area is wealthy, showing low un-employment rates.

Health and safety aspects (on- and off-site):

Quarry respects European laws regulating working place safety and health. Significant impacts come from means of transport leaving from mills and joining public road systems; in order to mitigate them, specific mitigation measures (panels, cartels, visual signalers and velocity road bollards) have been realized.

Capacity building (e.g., training courses and plant visits):

Population can find qualified information over the Internet, provided by local agencies and administration. Furthermore, during the authorizative process all the stakeholders are invited to participate and provide comments to the future extractive activities. Both at regional and provincial scale conferences and workshops are organised.

Relevant vulnerability issues (e.g., human health risk assessment):

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Relevant anthropic presence mean risks for human health mainly referred to road safety and to noise and dusts/powders production (local impacts and deriving from existing plants).

Local communities engagement and involvement in decision making:

The site localization provided by Provincial Quarrying Activities Plan 2008 is previously submitted to vision and evaluation of local social (citizens, local authorities and environmental associations) and economical (companies and entrepreneurs) stakeholders.

This area is located in a protected natural area (Regional Park “Taro river” and Natura 2000 network) and extractive methods are agreed with Park managing authority.

Benefits of improving the knowledge base at a local level should be mentioned and highlighted:

Any improvement of the knowledge base at local level is recognised as a benefit. Region and Province promote stakeholders’ involvement during planning and when authorising/renewing permissions to extractive activities. Stakeholders includes environmental associations, local committees for public safety and for landscape preservation.

Presence of effective and regular dissemination of information to particular stakeholder groups:

The project have been evaluated, debated and approved with provincial and local stakeholders.

Available mechanisms to increase communication and discussion between stakeholders:

Mostly conferences, spontaneous debates may start over the Internet.

7. Best practices approach

The company has launched a research (Spinner Project) with the University of Parma to increase the percentage of recycled materials in road surfaces: the Supply Mix moves smoothly from only natural to natural and recycled and the company tries to diversify the products. In particular, the Spinner Project entails a field and a laboratory testing to increase the proportion of recycled milled materials from 20% (a range that is now generally required) to 70%, with the possibility of reusing the remainder to produce stabilized materials (for cycling, pedestrian, etc., which would be of remarkable excellence in terms of recycling). The implications of this testing will not only lead to interesting evaluations on technology to be used in future to try to reduce the problem of milled materials, but it will also face many political, administrative and regulatory implications (compliance to UNI standards, contract specifications, technical standards for buildings, good practice guidelines, etc.). Lastly, the company is getting the permissions to begin the recycling of debris (C&DW).

Furthermore, a problem that was highlighted by the interviewed company is the bureaucracy, that in theory is the best way to control and manage the waste stream and the recycling cycle, but in practice is difficult to manage because the modules require too much time to be filled in and they are often complicated and therefore not immediate.

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CASE STUDY 4 - ITALY (RER/PARMA): THE RECYCLING PLANT OF CASTELLARANO

Case study of:

Castellarano (Reggio Emilia) Country: ITALY


RER

Manuela Ratta Stefano Segadelli


Introduction This site was chosen because Castellarano is the head office of the company “Pescale” which holds the R.O.S.E. patent (Homogenized Recovery of Construction Waste) representing one of the best technological expressions (BAT) in the field of recycling non hazardous special waste such as C&DW. The authorization data shown in this form concern the Castellarano plant, whereas the technical data correspond to a medium-sized R.O.S.E. plant managed by Varia Versilia Ambiente S.r.l. di Pietrasanta (Lucca).

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1. Description of location Geographical data/coordinates

Latitude: 44°29'32,154"N Longitude: 10°42'33,277"E

Location map of the pilot site

Administrative and legal framework (e.g., permit of the treatment plant):

The recycling plant is located within an active extractive facility with 2 plants, one dedicated to processing of natural aggregates and one dedicated to recycling. In the area two recovery operations of non-hazardous special waste keep on working: one authorized according to art. 210 of the Legislative Decree 152/2006 and the other is subject to notification of activity commencement according to art. 216 of the same decree which controls the handling of waste. The recovery activity is carried out also in compliance with the norms concerning: - Town-planning and construction; - Atmospheric pollution; - Fire prevention;

Scale about 1:190.000

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- Sewage disposal; - Acoustic pollution; - Workers’ safety and health on the work place.

Municipality name / name of the region:

Castellarano / Emilia-Romagna Region

Description, type and status of the location

- Location type can be: industrial / agricultural / mining/quarrying site / other (specify): Agriculture is unimportant, whereas industries and service sectors are highly developed.

- Status of location: active - Description of infrastructure (e.g., near by: most important roads / secondary roads / high

voltage lines / low voltage lines / electric wire / telephone wire / waterworks / water tower / permanent or temporary water protected areas / other (specify): An important way (S.P. 486) is located on the west side of the area; the highway (A1) is located about 23 km on the north-west of the area. An important railway, of national relevance, is locate about 19 km on the north-west of the area and another railway, of local relevance, is locate near Sassuolo country, about 8 km on the north-east.

Demographic issues

The area is considerably populated with low employment rates and fits into the wider context of the “Ceramico di Sassuolo – Scandiano District”, the most important Italian industrial district as far as turnover is concerned. This district is situated along the administrative between the provinces of Reggio-Emilia and Modena, and in particular the municipalities involved are:

Municipality Residents as at 2009 (source

www.comuni-italiani.it) Surface in km 2

Casalgrande (Reggio Emilia) 18.639 37,4 Castellarano (RE) 14.985 57,5 Rubiera (RE) 14.527 25,2 Scandiano (RE) 24.822 49,8 Viano (RE) 3.420 45,2 Castelvetro di Modena (Modena) 10.933 49,7 Fiorano modenese (MO) 16.990 26,3 Formigine (MO) 33.440 47,0 Maranello (MO) 16.865 32,7 Sassuolo (MO) 41.586 38,7 Total 196.207 409.5

Over the last decades the district has undergone a progressive modification of its economical and social structure, evolving from the traditional farming economy to an industrial productive reality, especially in small and medium sized companies, many of which are tied to the ceramic field and to its industries which make this district one of the most competitive on a national level.

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This sudden change in the productive structure and in the demand in the workforce, has defined demographic volumes that have registered a continuous and incessant increase of the inhabitants; an increase which in the 1970s and 1980s was characterized by Italian immigrants hailing mainly from south Italy and from Italian mountain areas and provinces, followed by a flow of foreign immigrants from abroad, particularly North Africans. For further information consult the website www.comuni-italiani.it

Figure 1 Parks Sic and ZPS (Natura Network 2000) Ceramic District of Sassuolo - Scandiano

Pescale S.p.A. Site

Land use planning (e.g., spatial relation to protected areas)

- Description of the land use (e.g.: urban / sub-urban / meadow / pasture / forest / degraded land, also covered by plants - overgrown / nature protected area / national heritage site (archeological, technical, historical, etc.) / other...)

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This case study takes place in an area which is mainly industrial, yet the plant stands on a land classified by the current town planning scheme as “agricultural area for the extraction of aggregate materials outside of the PAE (art. 19.12). From a planning point of view, there are several territorial restrictions in the area, defined by the Provincial Territorial Coordination Plan (PTCP – Piano Territoriale di Coordinamento Provinciale) and its Technical Implementation Norms. The PTCP (Provincial Territorial Coordination Plan) is the planning instrument that adopts and specifies the contents of the regional plans (Regional Territorial Plan – PTR, Regional Landscape Territorial Plan – PTPR, Water Protection Regional Plan – PTA, Transportation Regional Integrated Plan – PRIT, sites of the Natura 2000 Networks, etc.) and establishes mandatory reference for the municipal town planning- the PTCP also adopts on a provincial scale the inter-regional guidelines and restrictions (particularly the extracting Plan for Hydrogeological Layout – PAI, drawn up by the Authorities of the River Po Basin, approved by the Decree of the President of the Council of Ministers on the 24th May 2001. This area is found in the C area (flooding area caused by catastrophic floods) according to the PAI which does not provide for any particular precaution or restrictions for the operations therein, delegating the allowed operations to the town planning instruments.

Infrastructure

Distance to nearby settlement (in km), in settlement, or on the edge of the settlement The area is distinguished by numerous anthropic interferences, among which several road infrastructures (provincial and town roads), productive activities, numerous quarries and important built-up areas such as:

Sassuolo: about 8 km N-E Castellarano: about 4 km N-E Roteglia: about 2 km S-W

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Figure 2 – Main infrastructures and their typology

The drawn road map is not representative of the entire road network, but it only includes the main infrastructures of the Ceramic District Municipalities, and it excludes local arterial roads, as can be seen in figure 2. The railway infrastructures present in the Ceramic District, apart from the FS line which passes through the Municipality of Rubiera consist of lines that are mainly used for the commuting of people from the neighbouring towns to the Provincial capital (the Sassuolo – Reggio Emilia and Sassuolo – Modena line), under the jurisdiction of the managers of the town commuting (ATCM for the Province of Modena and ACT for that of Reggio Emilia). The infrastructures which pass through the municipal territories are mainly provincial and town roads . The maximum development of the road infrastructures has been registered in the Municipalities of Formigine and Sassuolo; whereas, the railway network has been more developed on the Reggiano territory, in which the Municipalities of Scandiano and Casalgrande stand out. The infrastructural density data (the length compared to the town surface) shows the prevailing of the Municipalities of Sassuolo, Formigine e Fiorano with values that are higher than those of the District Municipalities in the Modena territory (which is higher than the Reggiano value). The situation is reversed for the railway infrastructures: the maximum density is found in the Municipalities of Casalgrande and Scandiano; the data value of the District Municipalities in the Reggiano territory is higher this time than the Modena data.

Biodiversity features

The Index of Territorial Biopotentiality almost totally highlights the municipalities which belong to the ceramic district, an impoverishment of the territory with the trivialization of the landscape due to the development of clusters of settlements and extensive cultivation.

Key to symbols Municipal limits

Railway

Types of roads Motorway

Municipal roads Provincial roads

Main roads Bypasses of municipal authority

Roads in project

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2. Recycling plant The R.O.S.E. plant deploys some of the best available technologies for C&DW recycling, some of which have been patented and which have special engineered solutions for specific operations such as the separation of the unwanted fractions, the containment of dust and the collection of fine material. Furthermore, it is pointed out that the entire conveyor belt system is dust controlled. The quality of the products recycled with the R.O.S.E technology (Homogenized Recovery of Construction Waste) used by the company, has been certified not only by many years of experience but also by specific research carried out by Italferr, Experimental Institute for the Environment and Territory of the Italian railway network, by C.N.R., by Public Administrations, by several universities, as well as by the co-ordinated norms concerning the various aggregate categories which acknowledge the validity of the recycled materials in the making of road, civil engineering and industrial works. Types of raw input material:

According to the technical document attached to the request for the authorization of the recycling facility, the plant deals with various types of material belonging to the categories R1, R2, and R4. Here follows an example of the main ones are specified:

R1: Recycling of by-products, waste and residues from extractive activities. This is waste that can be traced back to chapter 01 of the list of waste by definition of the CER code: in particular this is the case of mining waste as well as the residue of the washing and cleaning treatment of the mined materials.

R2: Recycling of Construction and Demolition Waste (CDW). Belonging to chapter 17 of the waste list such as construction and demolition made up of cement, bricks, tiles and ceramic, crushed stone for the railway foundations.

R3: Recycling of excavated soils/rock from civil works made up of earth and rocks classifiable as not hazardous (code CER 170504).

R4: Recycling of industrial waste: such as waste made up of glass, scrap and waste of ceramic products, slags, foundry moulds and cores, refractory lining and material coming from metallurgic and non-metallurgic workings, metallic materials coming from the mechanic treatment of urban waste etc.

Quantity of raw input material (specify per each type of raw input material R1-R2-R3-R4)

- The plant has an overall nominal potential for the treatment of waste of 600 t/d, whereas the quantity of waste effectively treated adds up to 576 t/d.

- yearly amount (t/y) foreseeing 250 working days per year, the plant potential is 150000 t/y; the authorized recovery operations provide for the overall treatment of 124300 t/y of waste.

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Classification of raw input material*:

- EWC code (European Waste Catalogue 2000/532/EC) The technical-administrative documentation sent by the Province refers to the follow types of waste: 010102 Non-metalliferous mineral mining waste 010408 Gravel and crushed stone waste, different from those specified under entry 010407 010409 Sand and clay waste 010410 Dust and similar residues, different from those specified under the entry 010407 010412 Waste and other residues from the washing and cleaning of minerals different from

those under the entries 010407 and 010411i 010413 Waste produced from the working of stone, different from those under the

entry 010407 101103 Glass-based fibre material waste 101112 Glass waste different from those specified under the entry 101111 100201 Slag treatment waste 100202 Non-treated slags 100809 Other slags 100811 Impurities and skimming, different from those specified under the entry 100810 100906 Unused foundry moulds and cores, different from those specified under the

entry 100905 100908 Used foundry moulds and cores, different from those specified under the

entry 100907 100903 Slags 100999 Waste not otherwise specified (ferrous metal earth and casting sand) 101006 Unused foundry moulds and cores, different from those specified under the

entry 101005 101008 Used foundry moulds and cores, different from those specified under the

entry 101003 Casting slags 101099 Waste not otherwise specified (Non ferrous metal earth and casting sand

casting sand) 101201 Compund waste not subjected to thermal treatment 101299 Waste not otherwise specified (waste or fragments of baked ceramic

materials and grinding wheels of the ceramic industry) 101311 Waste from the production of cement-based composite materials, different

from those specified under the entries 101309 e 101310 101314 Cement mud and waste 101208 Waste of ceramic, bricks, tiles and construction materials (subjected to

thermal treatment) 101399 Waste not otherwise specified (mixed waste from production operations of

cement, lime and chalk without hazardous substances) 120199 Waste not otherwise specified (polishing grindstones and sands) 161102 Coal-based refractory materials and lining coming from metallurgical working

operations, different from 161101 161104 Other coal-based refractory materials and lining coming from metallurgical

working operations, different from 161103 161106 Refractory materials and lining coming from non-metallurgical working operations,

different from those specified under the entry 161105 170101 Cement

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170102 Bricks 170103 Tiles and ceramic 170107 Cement mixtures and slags, different from those specified under the entry

170106 170202 Glass 170302 Bituminous mixtures, different from those specified under the entry 170301 170504 Earth and rocks, different from those specified under the entry 170503 170508 Crushed stone for railway foundations, different from those specified under

the entry 170507 170802 Chalk-based construction material, different from those specified under the

entry 170801 170904 Construction and demolition mixed waste, different from those specified

under the entries 170901, 170902 and 170903 191209 Minerals (e.g. sands, rocks) 200202 Earth and rock

(provide the input material average composition, i.e. % of different EWC)

Being situated near the ceramic district Sassuolo – Scandiano, the Castellarano plant works mainly with waste from the ceramic industry; the quantitative ratios among the various categories of waste used, referred only to the recovery operations subjected to communicating the beginning of the works, can be thus summarized:

- 17% is made up of waste from working operations of gravel and stone (codes CER 010408, 010410, 010413)

- 76% from waste of ceramic products (codes CER 101201, 101208); - the remaining 7% from crushed stone for railway foundations (code CER 170508).

Studies in this sector carried out by ANPAR have highlighted that for the types of waste worked by the Castellarano plant differentiate considerably from the other aggregate recovery plants, which according to the processing carried out on the MUD 2006 data, treat on average:

- 41.9% of “Construction and demolition mixed waste, different from those specified under the entries 17 09 01, 17 09 02 and 17 09 03” (code CER 17 09 04);

- 18.5% of “Earth and rocks, different from those specified under the entry 17 05 03” (code CER 17 05 04);

- 22.7% of “Mixtures of cement, brick, tile and ceramic slags, different from those specified under the entry 17 01 06” (code CER 17 01 07);

- 6.9% of “Bituminous mixtures different from those specified under the entry 170301” (code CER 17 03 02)

- The remaining 10% of the other CER codes.

Collection of raw input material

direct collection: from work site to treatment plant - lorry type: authorized trucks with an average payload of 12 tons. - Acceptance fee: free of charge for the private residents thanks to an agreement

between the firm Pescale and the Municipality of Castellarano for quantities lower than a metre cube. In all the other cases, acceptance is subject to a payment according to the following price list:

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Construction aggregates 2.5 euro/ton Tile residues 3.5 – 6 euro/ton Marble polishing dust 15 – 25 euro/ton Glass residues 20 – 25 euro/ton Foundry earth and sands 18 - 25 euro/ton

- average distance: provincial scale

Technical information on recycling facility

- occupied average surface: about 77.000 m2: (including the recycling plant itself and ancillary infrastructures such as waste storage areas, offices, etc.);

- acceptance procedure for the raw input material The waste/material on arrival at the recovery platform are carefully checked, in terms of admissibility for treatment, at the weighing station to which the means on arrival are directed by following a compulsory route.

- The eluate of the collected waste adheres to the law parameters right from the origins. The choice of the feed line between the two found in the plant is made before the arrival of the material. The controlling phase is carried out by means of a colour video camera, connected to a high resolution monitor installed inside the administrative controlling box. This is able to ensure the verifying, through filling from the top, of the product nature of the waste/material present on the truck in arrival at the station. A specific video camera is located at the end of the weighing machine in order to identify afterwards the vehicles being weighed by means of recording the number plate.

- dimensions of the storage of the different raw input material and of the produced recycled aggregates: The material in arrival is stockpiled in heaps situated in stabilizing devices. The storage is situated at a higher altitude compared to the treatment plant to which there is access through a two-way service ramp. There are separate heaps according to the different waste categories and to the chosen recovery procedure, in order to enable any possible checks by the relevant authorities. In accordance with the authorization from the Province, the overall quantity of waste pending treatment must not exceed 1/12 of the overall authorized quantity.

- paved areas: no - areas equipped with a wastewater gathering system: waste storage area with impermeable

basin authorization from the Province determines the carrying out of the recovery operations upon completion of the canalization concerning the sewerage network for the collection of rainwater. Furthermore, it is required that certain types of waste have to be stored in a section of the site that has been equipped for the collection of leachate.

- energy sources: diesel, electricity from grid and natural gas. - environmental controls and monitoring ARPA (the environmental Protection Agency) is

responsible for environmental control of he activity

management standards (environment/safety/quality)

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Technical information on recycling treatment:

- Stationary plant for the production of recycled aggregates - process units (please provide flowcharts with indication of mass flows and equipment

description including treatment capacity and installed power) The layout of a generic R.O.S.E. plant, represented in the picture below, can be thus summarized: Load

the plant feed is carried out by means of a wheel loader. The hopper, made of heavy metal structural work has a capacity of 20 cubic metres and is equipped with an automatic capacity converter. By means of the hopper, the material is transferred from the feeder to the treatment compartment. The passage is controlled by a video camera which frames the outlet and enables the checking of the material and if necessary the action of the operator to block the feed should there be any diversity in the materials. The plant is equipped with two feed lines, one for each of the two waste recovery operations which co-exist in the area (one with ex art. 210 legislative decree 152/06 authorization and the other subject to simple communication ex art. 216 of the above mentioned decree). The grinding campaigns are

carried out separately for the two feed lines by following an established calendar; only at the end of the treatment can the produced secondary materials be homogenized together. Pre-screening

The next treatment phase is a first roughing out/screening: the material is passed on an inclined vibroscreen for the screening of fine fractions and is then directed to the completely closed crushing chamber of the hammer mill.

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Grinding The hammer mill enables a suitable particle size reduction of the debris and a nearly perfect sorting of the metallic elements. The crushing unit is equipped with a particular device that slows down the flow of fine-sized grains and enables the total recovery of fines and dust. After grinding, the treated material is moistened before undergoing the next step. Deferrization

By means of a horizontal extractor, the treated waste is directed to a primary belt deferrization device, which separates the iron and transfers it to a box, where it is stored pending recovery. The material then undergoes a second deferrization operation, after which it is directed to the following selection phase.

Screening and separation The material that has been reduced to particle size and freed from the ferrous fraction, is directed to a multihole double deck vibroscreen (primary vibrating screen that allows the granulometric selections 0/30mm, 30/70mm, >70mm), with the possibility of further recycling of the fractions higher than 30mm. Furthermore, it is possible to subject the 0/30mm fraction to further selection (secondary vibrating screen), by dividing it into 3 flows: 0/6mm, 6/15mm e 15/30, always stockpiled in heaps, to be used for mixes, concrete, self-locking laying and spandrel/pipe covering in general. At the same time during this selection, the separation of the unsuitable light fractions (paper, wood, plastic etc.) is automatically carried out, by means of a specific size floating device, strengthened by three pneumatic action steps (by means of combined systems of vibration and ventilation) for minor granulometric classes. The waste obtained is stockpiled and directed to authorized plants, according to the relative characteristics.

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Impianto R.O.S.E.[Recupero Omogeneizzato Scarti Edilizia]

+ −+ −

Ciclo di funzionamento impianto I.R.M.E.L.

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The plant’s yield mostly depends on the content in light material waste to be sent off for disposal (usually below 1% of weight).

Description Unit Machines description x Secondary demolition x Feed x Scalping x Pre-screening x Manual sifting

x Primary crushing x jaw crusher impact crusher others: hammer mill

x Magnetic separation Secondary crushing jaw crusher impact crusher others x Screening x Sorting x dry wet Water treatment

- Plant processing capacity for each product (t/h) 75 (t/h)

- Plant processing throughput for each product (t/y) 150.000 (t/y)

3. Recycled aggregates Type of recycled aggregates.

The Castellarano plant produces aggregates of types A and B, however we were not sent the quantitative products and the relative sale prices. Thus, in the table below there are the data that refer to the Varia Versilia Ambiente, Pietrasanta of Lucca plant (financial year 2009); - Type A: high quality RA for concrete and road construction (road sub grade):

Yes, various-sized crushed stone and sand; - Type B: medium quality RA for road, airport and harbour construction:

Yes, established various granulometries; - Type C: low quality RA for environmental filling and rehabilitation of depleted quarries and

landfill sites: Yes, screened earth and coarse sand.



(t/h) (t/y) (€/t)

Type A 13.30 26595 From Euro 9 to Euro 15

Type B 94.61 189208 Euro 4.70

Type C 5.09 10089 From Euro 5.50 to Euro 6.50

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Grade of recycled aggregates (data for which the conformity certificate has been supplied in reference to the Castellarano plant, enclosure 1); :

Recycled aggregates type A (UNI EN 12620:2008)

B (EN 13242:2008)

Sand R.O.S.E. 0/6

Crushed Stone R.O.S.E. 6/15

Crushed stone R.O.S.E. 15/30



Saturated surface dried specific gravity

ssd (kg/m3) - - -

Los Angeles Index LA (%) - 25 25 25 25 Shape Index SI (%) - 15 40 20 40 Flakiness index FI (%) - 15 55 35 50 Sand equivalent SE (%) 61 - - 26 28 Fineness modulus Mf - f11 f 1.5 f 1.5 f 3 f 5 Impurity level - (%) - - - - - …

Eco-compatibility of recycled aggregates (leaching test - please provide the certificate) The material in departure undergoes a conformity analysis as provided for by the Ministerial Decree 5/2/1998 and subsequent amendments and additions. The certificates found in enclosure 1 supply solely a conformity declaration of the analytical values resulting from the transfer test in compliance with the norms in force.



The aggregates produced by the R.O.S.E. plant have been certified through declaration of conformity in compliance with the UNI EN 12620:2008 norm concerning materials of type A and with the EN 13242:2008 norm for the materials of type B.

Description of use of recycled aggregates:

According to the technical requisites provided for by the European norm, the sand and crushed stone produced by the plant are suitable to be used for the making of concrete and high quality mixes, whilst the stabilizing type forms an aggregate for unbound materials and bound with hydraulic binders to be used in civil engineering works and for foundations in the building of roads, whereas the screened earth does so fod the recovering of dumping grounds and environmental recovery.


- Transportation cost according to the delivery distance (€ per ton-km) - Maximum delivery distance: specific data were not given from the plants but through

studies carried out by Quasco for the Region of Emilia-Romagna with the result that the maximum transport distance of recycled material is the provincial one in order to maintain a competitive price.

- Average delivery distance

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4. Life Cycle Assessment (LCA)* Data for LCA analysis: since no data were given concerning the Castellarano plant, the plant of Varia Versilia Ambiente, Pietrasanta in Lucca was chosen as a reference (Financial year 2009): Inventory data for recycling (data with reference to 1 year of activity)

Raw input materials

Quantity processed t About 230.000

Land use Occupied area m2 23.125 Materials/fuels Hammers/jaws kg 2.5 serie Water kg 0 Lube oil kg 685.44 Polyurethane screen kg 0 Steel screen kg Number 4 Synthetic rubber kg 0 Diesel l 67.416 Electricity MJ 548.697,6 ... ... Outputs Recycled aggregate type A t 26.595 Recycled aggregate type B t 189.208 Recycled aggregate type C t 10.089 Steel scrap t Not supplied ...

5. Environmental impact assessment Geomorphologic exposure and visibility aspects (e.g., landscape change):

Investigation area is a context characterized by shapes testifying the passage from hilly to plain morphologies trough quaternaries alluvial terraces ‘surfaces. Shapes and deposits typical of alluvial terraces are identified as flat area, originated by depositional and/or erosive processes, delimited by river escarpments. This portion of territory is characterized by wide riverbeds, xerophitic terraces, wet depressions and riparian woods, agricultural surfaces but even industrial settlements, basins of disused quarries and active extraction poles.

- Location visibility (can be) determined by visibility from settlement or local road(s):

poorly visible / visible in local area / visible in broad area

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Protected areas status

In the area there are no parks or natural reserves. The nearest protected area is the SIC “San Valentino, Rio della Rocca” site, at about 5km away in the northerly direction (fig.1).

Water (surface and groundwater), soil and air quality conditions

For the description of the surface and underground water conditions and of the air quality, consult the contents of the study at the following Internet address http://www.arpa.emr.it/pubblicazioni/modena/generale_307.asp.

Existence of codes of practice to achieve environmental excellence:

Several guidelines published by Emilia-Romagna Region exists. Systematic operation of environmental monitoring and control program. Noise, visual impacts,

dust and emissions:

In order to govern a territorial range such as the Ceramic District of Modena and Reggio Emilia, one of the most important district realities on a Regional and National level and a world-wide leader, made up of 5 municipalities in the province of Modena and 5 municipalities in the province of Reggio Emilia, known for having an importance in both the economical and technological development fields, the Agenzia Regionale Prevenzione Ambiente (Regional Agency for Environment Safeguarding) of Emilia Romagna, has organized a series environmental diagnosis – management tools, by planning and creating a computer – informative system for collecting data and information, transferred from local interest and institutional holders that for different reasons rest and act on the territory. This is all aimed at the cataloguing, processing and subsequent circulation – communicating of the data. The environmental themes/problems researched through the indicator System for the environmental analysis of the territory are the following: Water; Air; Soil; Electromagnetism; Noise; Waste; Power consumption; Nature and biodiversity. The contents of this study can be consulted on the Internet at the following address: http://www.arpa.emr.it/pubblicazioni/modena/generale_307.asp.


The site, as already mentioned, is situated in the widest context of the Ceramic District of Sassuolo Scandiano, the most important Italian industrial district for turnover. The district includes part of the areas at the foot of the hills in the provinces of Modena and Reggio Emilia in which there are over 200 factories with more than 21.000 employees and with a production of about 480 million m² per year of tiles. This represents about 80% of the total Italian production and about 20% of world production. The Italian ceramic industry developed in the post-war period, constantly consolidating itself and growing between 1971 and 1980, and underwent a slowdown during the 1980s, only to stabilize from 1990 onwards.

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Health and safety aspects (on- and off-site)

The ceramic district (Sassuolo-Scandiano) forms one of the most important mono-productive centres on a national and international scale. In the 1950s some parts of this geographic area were considered depressed, but starting from the 1960s it underwent a staggering development, which can be explained also because of the presence of raw materials. It passed from 5 ceramic companies in the post-war period to 291 in 1976, with a production of 27.5 million m² in 1959, 214 million in 1973 (with 257 companies), until reaching the current 377 million (188 companies). However the high living density and the mingling with the industrial factories have also represented an important pressure factor on the environment and health in that area. The industry forms a productive sector of global impact on the environment, both indoors, i.e. in work places, and outdoors, in the air, water and soil. In the 1970s, this global impact had reached maximum levels, noticed thanks to the monitoring network for air quality and for the sampling of surface waters. The biological effects of environment pollution emerged with pathologies such as fluorosis and lead poisoning, present in the area also in acute forms. We remember for example that the values of lead found in the 1980s in Sassuolo in the blood of the adult residents in the area, in a remarkable amount of the sample, exceeded the limits indicated by the EEC directive 82/605 and they were considerably higher than the values found in other Italian areas. For all these reasons, this area was declared as being at a high risk of an environmental crisis (Resolution of the Ministers’ Council 3.2.1989) upon request by the region and local entities. Particular attention has been paid to this problem over the last years: apart from the improvement in the pollution control inside the companies (purification plants and waste recycling), also the controlling of the effects has particularly evolved. Thus, apart from noticing the completion of the purification of all the emissions, there has also been the tendency to reduce polluting industries such as paint factories. Another environmental pressure factor is vehicle traffic: the productive activity, besides the direct effects such as atmospheric and water pollution and solid waste disposal, entails an enormous volume of both business and private truck transportation, with repercussions on the environment, on road safety and in short on the quality of life.

Capacity building (e.g., training courses and plant visits): no information about

Relevant vulnerability issues (e.g., human health risk assessment)

The extremely high concentration of ceramic productive units in a restricted area has caused damages to the agricultural livestock wealth and a general alteration of the environmental matrixes connected to the impact of gassy, liquid and solid discharges. The struggle against pollution caused by the ceramic industry was started at the beginning of the 1970s as execution of the national laws, but above all to remedy the serious jeopardizing of the environment concerning this district. From 1978 to 1982, once the installation of gassy emission treatment plants was completed, the one for the water discharge treatment was started up. At the end of that period these discharges practically resulted as being active in 100% of the working factories. However, the Presidential Decree 915, which at the end of 1982 regulated the handling of waste, was not yet in force and consequently there were no rules or suitable technology to manage the increasing quantity of waste coming from the purification, in particular exhausted lime and purification mud. This led to the discarding of these materials in a very risky way for the environment, e.g. burying them in the vicinity of the factories or unloading them in the high-water beds of the rivers and streams. In the 1980s, with the strengthening of environmental sensitivity on a national level, the District companies perfected considerably the productive techniques with a view to save resources and respect the environment, arriving at the recycling of most of the waste produced.

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Today, a large part of the waste dust and tiles, baked and unbaked and the waste/residues deriving from the treatment of waters (mud), are re-used in the ceramic production or, more seldom, in the brickwork industry. The washing water of the plants is treated and reused. The exhausted lime deriving from fume purification still remains today the more difficult waste for re-use. A remarkable contribution to this tendency was given by the intense activity of technological, plant-engineering and productive innovation which characterizes the sector. Furthermore, policies have been applied for the separate collection of waste aimed at the recovery, recycling and /or disposal of other waste that is not directly re-usable in internal production (exhausted oils, water, wooden pallets, plastics, metallic scraps).

Local communities engagement and involvement in decision making:

The study area, as all the areas present inside the PIAE, was subjected to the vision and the assessment of the main social (citizens, public entities and environmental associations) and economical (companies and entrepreneurs of the field) interest holders.

Benefits of improving the knowledge base at a local level should be mentioned and highlighted: no information about

Presence of effective and regular dissemination of information to particular stakeholder groups:

the company took part in several initiatives which aim at improving the communication and discussion mechanisms among the various interest holders on a regional scale.

Available mechanisms to increase communication and discussion between stakeholders: no information about

7. Best practices approach Possibilities for new technology applications

The R.O.S.E (Homogenized Recovery of Construction Waste) plant, planned and designed by Pescale S.p.A. was bestowed in 1990 with the national sector Award for the recycling of materials by ENEA and represents one of the best solutions in the specific field of special aggregate treatment. The main characteristics are: Reduced impact on the workers’ health due to the presence of shut-off devices on all the

selection lines; Reduced impact on the environment due to the contained saving of resources and power,

the minimizing of acoustic pollution and the dissipation of dust, the control of the material quality used and the products;

Simple but efficient plant engineering solutions which allow a good durability and easy maintenance operations.

The R.O.S.E. technology is a registered trademark of Pescale S.p.A. which is also used in other plants distributed on the national territory and in particular:

SINERTI SRL - SPILAMBERTO (MO) ECOTER SPA - MILANO (MI) LEGNANO ECOTER Srl - LEGNANO (MI) NERVIANO ECOTER SRL - NERVIANO (MI)

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DEL DEBBIO SPA - MARLIA (LU) INERT.ECO SRL - LA SPEZIA V.V.A. SRL - PIETRASANTA (LU) NUOVA BETON SPA - S. POLO (BS) A.R.E.A. SRL - NAVACCHIO (PI) I.R.M.E.L. SRL - PONTE BUGGIANESE (PT) BUGNO LUCIANO SRL - VIGONZA (PD) ECO INERTI SRL - VILLA MUSONE (MC) TOP CENTER PORFIDI SRL - CEMBRA (TN) R.A.M.E. SRL - BELLIZZI (SA) in attesa di collaudo CALCESTRUZZI ERICINA SRL - TRAPANI

Optimising the efficiency of recycled aggregates production e.g., water & energy consumption,

transport

The R.O.S.E. plant, in the material recycling field, represents one of the best solutions due to the contained saving of resources and power, , the minimizing of acoustic pollution and the dissipation of dust, the control of the material quality used and the products. In particular, the R.O.S.E plant results as being characterized by an ordinary treatment potential equal to 50 m3/h, corresponding to an average yearly capacity, in the event of a sole working cycle, of 100.000 m3/year (Daily Working Cycle 8 hours/day – Yearly Working Cycle (250 days/year), corresponding to about 140.000t/year, for a total working power of the entire plant engineering complex of 100 KWh. Concerning the volume balance the plant yield is extremely high. In fact for every 1000 kg of debris in arrival are obtained:

2 kg of non suitable light material to dispose of in category 1 dumping ground; 1 kg of wood liable to be reused; 7 kg of non suitable aggregate material to be disposed of in category 2 type a dumping

ground; 5 kg of ferrous material to be sent off for reuse; 985 kg of granulometrically stabilized aggregates.

One of the most interesting aspects of the R.O.S.E. technology, is the perfect plant-engineering automating of the various phases, so much as to enable the handling by three-four operators. The first is assigned to weighing the material in arrival at the plant and the registration of the same in the loading and unloading registers. The second one sees to the plant feed by means of a mechanic wheel and to the loading of the finished products onto the trucks in departure. The third operator manages, by means of a suitable control panel, controlling monitor and a switchboard, all the plant phases, able to stop the functioning in any moment if necessary. The fourth becomes necessary in order to guarantee: holiday shifts, extraordinary maintenance operations, production peaks etc.

Determine impediments to best practice, e.g., lack of knowledge, regulatory blocks:

Following specific studies (e.g. VAMP project), the problem which was mainly highlighted by the interviewed companies which carry out waste collection, transport, recovery and disposal that is both hazardous and non hazardous on the Region of Emilia Romagna scale, is the complex set of forms to produce which in theory is optimal to keep the flow of waste and the recovery cycle under control, but in practice is difficult to manage.

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Prepare recommendations for industry and government actions to encourage best practice: no information about.

Way forward e.g., LCA study approaches (understanding of the balance between benefits and impacts): no information about.

8 – Acknowledgements We would like to thank for their collaboration: - Geom. Angelo Toschi, Sole Director and management reference of all the work carried out by

Pescale S.p.A. of Castellarano; ; - Ing. Giorgio Bressi Technical Director of the Associazione Nazionale Produttori di Aggregati

Riciclati (Producers’ National Association of Recycled Aggregates) Chart page 15: Impianto R.O.S.E.: R.O.S.E. Plant Recupero Omogeneizzato Scarti Edilizi: Homogenized Recovery of Construction Waste Ciclo di funzionamento Impianto I.R.M.E.: I.R.M.E. Plant functioning cycle Ingresso material: Material entrance Controllo Merceologico e Pesatura: Product Controlling and Weighing Allontanamento Materiale non idoneo: Rejection of Unsuitable Material Stoccaggio Materiale a Riserva: Storage of Material Alimentazione material in tramoggia mediante pala gommata: Material feed in hopper by means of a wheel loader Pre-classatura granulometrico (selezione materiale ferroso): Granulometric pre-classifying (selection of ferrous material) Frantumazione (0/100 in uscita): Crushing (0/100 in departure) Cumulo Terre: Earth heaps Abbattimento polveri: Abatement of dust 1° stadio di deferrizzazione mediante elettromagnete a nastro: 1st stage of deferrization by means of electromagnet band 2° stadio di deferrizzazione mediante elettromagnete a nastro: 2nd stage of deferrization by means of electromagnet band Separazione frazioni leggere (carta – legno – plastic 70mm): Separation of light fractions (paper – wood – plastic 70mm) Stoccaggio frazioni leggere (discarica): Storing of light fractions (dumping ground) Stoccaggio ferro (recupero): Storing of Iron (recovery) Classatura granulometrica Frazioni 0/30 30/70 e > di 70mm: Granulometric Fraction Classifying 0/30 30/70 and > than 70mm Ricircolo Aggregato: Aggregate Recirculation Extra standard qualità: Extra quality standard Separazione legno: Separation of wood Classatura granulometrica: Granulometric classifying Stoccaggio legno (recupero): Storing of wood (recovery)

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CASE STUDY 5 - ROMANIA (IGR/FGG): THE MARBLE QUARRY OF DEVA-RUSCHITA

Case study of:

Deva-Ruschita Country: Romania


IGR

Maruntiu Marcel, Bindea Gabriel, Coltoi Octavian


The largest marble quarry in Romania is at Ruschita (Caras – Severin County). Quarry is located about 10 km north of Rusca Montana locality, between Padeş River and Paraul cu Raci (Crayfish Creek) (Fig. 1). Coordinates of location of Ruschita quarry are:

- 450 38’ 43” N - 220 24’ 25” E Elevation ≈ 667 m

Fig. 1 Simplified geological map of the Ruschita Zone (IGR’s geological data).

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Marble deposit is occurring in a west-east oriented isoclinal folded structure, dipping of approx. 80o to the south. The host rocks consist mainly of amphibolite and muscovite-biotite schist, usually retrogressed to sericite, chlorite, epidote bearing assamblages and belonging to Ruschita-Alun Formation of Ghelar Series from Poaina Rusca Massif (Fig 1). At Ruschita are actually two quarries (Fig. 2) successively developed in time. The first one, “Old Quarry”, the most impressive by man-made landscape, is abandoned and partially filled with the waste material coming from the newer mining works. The second one, “Paraul cu Raci Quarry”, is the active part in the quarrying area, using the classic methods for dimension stone exploitation, as well as the underground ones (Fig. 3).

Fig. 2 Aerial view of Ruschita quarries: closed “Old Quarry” at lower altitude and active “Paraul cu Raci Quarry” at higher altitude (source MARMOSIM S.A)

Fig. 3 Exploitation methods in use for marble quarrying in Ruschita zone

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Reserve calculations estimate that the volume of marble in the area is about 1.8 million cubic meters. The main lens have three favorable areas for mining activities, each of them extending over 2 to 3 km2 and over a depth of 100 meters.

White marble, called statuary marble, is found mainly in the central area of the new quarry and is generally exhausted. It was extracted in the past from “Old Quarry” from the surface to a depth of 100 meters. This sort, almost unique in Europe, is intensely searched out by the company, hoping to find it in large quantities also in the new quarry. The largest part of accessible reserves is represented by the pink marble with banded texture due to the iron oxide and silicate impurities. Sometimes, small quantities of striped gray marble with special decorative effects have been exploited.

In the table 1 the chemical contents of oxides of silicon and calcium are presented as mean values determined on three samples of different colored marble.

Table 1. Chemical contents of some sorts of marbles from Ruşchiţa quarry

Components White marble

Pink marble

Grey marble

SiO2 0.25 0.82 0.50 CaO 55.23 53.65 54.70

This marble is generally easy and beautiful to work. The higher technological qualities which possess have made Ruschita marble be much appreciated in the country and abroad.

Ruschita quarry is located in an isolated rural zone where the mining activities started more than 80 years ago. The exploitation permit holder is MARMOSIM S.A, a Romanian private company which is also specialized for processing of blocks to obtain final products in the factory located in Simeria (Hunedoara County), 80 km away from the quarry. They are using the public infrastructure (national and local roads, electric lines, etc) all developed in time for serving the proxy localities and also the mining area. The transport of the blocks to the factory is made by using heavy lorries. The nearest railway station to Ruschita is Voislova at a distance of about 18 km.

Mining works are directly affecting only the forest areas, not integrated into a protection zone as concern natural or national heritage.

2. Recycling plant (Omya plant from Voislova)

Coordinate of location: 450 31’ 98” N 220 26’ 36” E Elevation ≈ 315 m

Fig. 4

103

An example of partial recycling of the mining waste is Voislova-Ruschita (near Deva).

Fig. 5

Ruşchiţa marble quarry sell especially light-colored marble varieties like white marble to yellow marble, the rest resulted after sorting is stocked in the dumps.

Another drawback which appears in the selling marble is presence of cleavage which prevents obtaining after processing of the sufficiently large plates

Usually where the cleavage system don’t allows obtained from monolithic blocks of a form of cubes with side length metric, the exploitation areas are considered outside of interest to the MARMOSIM factory and there are not used.

In this context results a huge volume of material which can be considerate a residual for the marble plant.

Additionally, storage and stabilization activities of this waste imply higher cost, which increase the finished product price.

In terms of percentage, the material result to the exploitation which does not meet the demands of the MARMOSIM plant caused by cleavage is approx. 40% while raw material cannot be selling because of the darkness colour represent approx. 50%.

104

Opening of the Omya plant near by Deva (to Voislova) area has resolved more of problems regarding recycling. On the one hand, the area with the fissured ores was purchased directly by Omya company, and on the other hand, at least section of white to yellow white marble derived from the small fraction of the material which was considered residual material by MARMOSIM plant is connected by a line parallel processing where this material is crushed and preliminary prepared for transportation to the Omya plant as raw material. In this way, approx. 50% of marble blocks with an inadequate size are used, too.

Crushed to get size micron materials, marble which has contents over 96% calcium carbonate, derive from the varieties of marble with very low and lowest color index, is used in many fields as paint industry, construction materials industry, paper industry, plastics industry, for decrease soil acidity, etc..

Depending on the variety of marble, the percentage content of calcium carbonate is different: the highest percentage (reaching up to 99%) belongs to white pure marble. Omya plant obtains the white sterile waste, regardless of size aggregates (sometimes it is including fissured blocks marbles, abandoned for processing in the marble plates) and it crushed to the micron dimensions

While Omya plant uses only varieties with calcium carbonate contents more than 96%, the MARMOSIM company uses all marble types, even those who have brownish colors. Practically, however, market is decreased for brownish or blackish varieties, and for export they are rejected.

This means that full recovery of MARMOSIM waste cannot be fully resolved by Omya factory opening and it remains a problem for future reflection.

As a general data the MARMOSIM company utilization about 190.000 t/y of marble from Ruşchiţa quarry, which means about 50% of excavated material. Result is waste (considering that, in part, from the beginning had been avoided cracked marble sectors) about 60% with a secondary benefit of almost 50% due to varying concentrations of calcium carbonate.

Types of raw input material: R1: Waste from extractive activities

Quantity of raw input material (specify per each type of raw input material R1-R2-R3-R4) - daily amount (t/d) - yearly amount (t/y)

Classification of raw input material: - EWC code (European Waste Catalogue 2000/532/EC) - by-products - mining waste - others (specify)

(provide the input material average composition, i.e. % of different EWC) Mining waste

Collection of raw input material - direct collection: from work site to treatment plant

- lorry type and payload - average distance: 20 km.

- indirect collection: from work site to collection centre and from collection centre to treatment plant

105

- lorry type and payload - average distance

- in situ recycling trough mobile plant: mobile plant transportation - lorry type and payload - average distance

Technical information on recycling facility - occupied average surface - acceptance procedure for the raw input material - dimensions of the storage of the different raw input material and of the produced

recycled aggregates aggregates of marble, max.20 cm

- paved areas - areas equipped with a wastewater gathering system - energy sources (diesel, electricity from grid, diesel generator, …) electricity from grid - environmental controls and monitoring - management standards (environment/safety/quality)

Technical information on recycling treatment - stationary or mobile plant for the production of recycled aggregates Stationary plant - hybrid plant for the production of natural and recycled aggregates - process units (please provide flowcharts with indication of mass flows and equipment

description including treatment capacity and installed power)

description unit


Secondary demolition Feed Scalping Pre-screening Manual sifting Primary crushing jaw crusher impact crusher others Magnetic separation Secondary crushing jaw crusher impact crusher others Screening Sorting dry wet Water treatment

- Plant processing capacity for each product (t/h)

- Plant processing throughput for each product (t/y)

- Best available technologies: possible application of new technologies

106


Type of recycled aggregates. - Type A: high quality RA for concrete and road construction (road sub grade); - Type B: medium quality RA for road, airport and harbour construction; - Type C: low quality RA for environmental filling and rehabilitation of depleted quarries

and landfill sites.



(t/h) (t/y) (€/t)

Type A

Type B

Type C


Recycled aggregates type A B C Saturated surface dried specific gravity ssd (kg/m3) Los Angeles Index LA (%) Shape Index SI (%) Flakiness index FI (%) Sand equivalent SE (%) Fineness modulus Mf - Impurity level - (%) …

Eco-compatibility of recycled aggregates (leaching test - please provide the certificate)



Description of use of recycled aggregates - Construction: structural or not structural concrete / road and railways construction /

environmental filling / other (specify) - chemical industry - Manufactory - Other

Transportation of recycled aggregates - Transportation cost according to the delivery distance (€ per ton-km) - Maximum delivery distance - Average delivery distance

107

4. Life Cycle Assessment (LCA)*


Inventory data for recycling (data with reference to 1 year of activity)

Raw input materials Quantity processed t Land use Occupied area m2 Materials/fuels Hammers/jaws kg Water kg Lube oil kg Polyurethane screen kg Steel screen kg Synthetic rubber kg Diesel l Electricity MJ ... ... Outputs Recycled aggregate type A t Recycled aggregate type B t Recycled aggregate type C t Steel scrap t ...


Geomorphologic exposure and visibility aspects (e.g. landscape change) - Location visibility (can be) determined by visibility from settlement or local road(s):

poorly visible / visible in local area / visible in broad area

Protected areas status

Water (surface and groundwater), soil and air quality conditions

Existence of codes of practice to achieve environmental excellence

Systematic operation of environmental monitoring and control program

Noise, visual impacts, dust and emissions

6. Socioeconomic impacts assessment

Local/regional employment situation 50 local employments


Capacity building (e.g. training courses and plant visits)

Relevant vulnerability issues (e.g. human health risk assessment)

Local communities engagement and involvement in decision making

Benefits of improving the knowledge base at a local level should be mentioned and highlighted

108

Presence of effective and regular dissemination of information to particular stakeholder groups

Available mechanisms to increase communication and discussion between stakeholders.

7. Best practices approach

Possibilities for new technology applications

Optimising the efficiency of recycled aggregates production e.g. water & energy consumption, transport

Determine impediments to best practice, e.g. lack of knowledge, regulatory blocks Lack of knowledge of the properties for the recycled aggregates

Prepare recommendations for industry and government actions to encourage best practice Make restriction concerning the work in the classic location for exploitation of natural aggregates. Way forward e.g. LCA study approaches (understanding of the balance between benefits and

impacts)

109

CASE STUDY 6 - SLOVENIA (GEOZS): THE DOLOMITE QUARRY OF VELICA PIRESICA

Case study of:

Velika Piresica Country:

Slovenia


GeoZS

Ana Burger

[email protected]


Geographical data/coordinates Recycling plant is located in active quarry Velika Piresica in east Slovenia. This is countryside, but near are city Celje and highway Ljubljana-Maribor. Celje is the third biggest town in Slovenia (approximate 50.000 inhabitants). Approximately 21.400 people live in the municipality Zalec. Most of the inhabitants of the municipality live in villages. The total area of municipality Zalec is 117.10 m2.

GKY: 513720

GKX: 127544

AMSL: 286 m

WGS84: LAT 4617’30,70˝ (46,291862) WGS84: LON 1510´23,78˝ (15,173274) For picture please see SDB questionnaire.

Administrative and legal framework (e.g. permit of the treatment plant) Permission for collecting wastes, permission for reprocessing, mining project

Municipality name / name of the region Zalec / Savinjska

Description, type and status of the location - Location: mining/quarrying site - Status of location: active - Description of infrastructure: near by: most important roads / secondary roads / electric wire

/ telephone wire / waterworks

Demographic issues - Demographic issues Municipality Zalec lives 21.400 inhabitants. The largest town is Zalec

with 5.400 inhabitants. Average age of inhabitants is 38,8 years. Most of the inhabitants of the municipality live in villages. The total area of municipality Zalec is 117,10 m2.Near is also Celje which is the third largest city in Slovenia (approximate 50.000 inhabitants).

110

Land use planning (e.g. spatial relation to protected areas) - Recycling plant is located in abandoned part of active quarry.

Infrastructure - Distance to nearby settlement (in km) in settlement or on the edge of the settlement: 200 m


2. Recycling plant Types of raw input material:

- R2: Recycling of Construction and Demolition Waste (CDW)

Quantity of raw input material (specify per each type of raw input material R1-R2-R3-R4) - daily amount (t/d): R2 - 145 t/d - yearly amount (t/y): R2 - 29.000 t/y

Classification of raw input material: - EWC code (European Waste Catalogue 2000/532/EC) 17 01 01, 17 01 02, 17 01 03, 17

01 07, 17 03 02, 17 05 04, 17 05 06, 17 05 08, 17 06 04, 17 08 02, 17 09 04 * (provide the input material average composition, i.e. % of different EWC)


- lorry type and payload dump truck (tipper) engine: D2876 LF, 6 cylinders; volume: 12.816 cm3; engine power: 338/460 1.900 kW/KM; rpm: 2.100, 1.000-1.300

- average distance up to 50 km - indirect collection: from work site to collection centre and from collection centre to

treatment plant - lorry type and payload - average distance

- in situ recycling trough mobile plant: mobile plant transportation - lorry type and payload - average distance

Technical information on recycling facility - occupied average surface 5.000 m2 - acceptance procedure for the raw input material see diagram bellow - dimensions of the storage of the different raw input material and of the produced

recycled aggregates 2.500 m2 and 2.500 m2

111

- paved areas 5.000 m2 - areas equipped with a wastewater gathering system They use water to avoid dusting. - energy sources (diesel, electricity from grid, diesel generator, …)

environmental controls and monitoring - They must report to Environmental Agency of the Republic of Slovenia once a year. - management standards (environment/safety/quality)

Technical information on recycling treatment - stationary or mobile plant for the production of recycled aggregates - hybrid plant for the production of natural and recycled aggregates - process units (please provide flowcharts with indication of mass flows and equipment


description unit


Secondary demolition Feed Scalping Pre-screening x Manual sifting x Primary crushing jaw crusher x impact crusher others Magnetic separation Secondary crushing jaw crusher impact crusher others x Screening x Sorting dry wet Water treatment


- Plant processing throughput for each product (t/y) high grade recycled 10.000 t/y 3,05 €/m3+ VAT ; medium grade 19.000 t/y 2 €/m3+ VAT

- Best available technologies: possible application of new technologies


- Type A: high quality RA for concrete and road construction (road sub grade); - Type B: medium quality RA for road, airport and harbour construction; - Type C: low quality RA for environmental filling and rehabilitation of depleted quarries

and landfill sites.

112



(t/h) (t/y) (€/t)

Type A 10.000 6.26

Type B 19.000 3.05

Type C


Recycled aggregates type A B C Saturated surface dried specific gravity ssd (kg/m3) 1.3 1.25 Los Angeles Index LA (%) Shape Index SI (%) Flakiness index FI (%) Sand equivalent SE (%) Fineness modulus Mf - Impurity level - (%) …

Eco-compatibility of recycled aggregates (leaching test - please provide the certificate)



Description of use of recycled aggregates - Aggregates are used for road and railways construction. CM Celje is Construction

Company and they use recycled aggregates – one part is used in asphalt production.

Transportation of recycled aggregates - Transportation cost according to the delivery distance (€ per ton-km)

- Maximum delivery distance 60 km - Average delivery distance 40 km

113

4. Life Cycle Assessment (LCA)* Data for LCA analysis Inventory data for recycling (data with reference to 1 year of activity)

Raw input materials Quantity processed t 29.000 Land use Occupied area m2 5.000 Materials/fuels Hammers/jaws kg 150 Water kg 50 m3 Lube oil kg 150 l Polyurethane screen kg Steel screen kg 160 Synthetic rubber kg Diesel l 15.256 Electricity MJ 4.300 kWh ... ... Outputs Recycled aggregate type A t 10.000 Recycled aggregate type B t 19.000 Recycled aggregate type C t Steel scrap t 18.5 ...

5. Environmental impact assessment Geomorphologic exposure and visibility aspects (e.g. landscape change)

- Location visibility (can be) determined by visibility from settlement or local road(s): visible in broad area (but only the quarry, the recycling plant is poorly visible)

Protected areas status No.

Water (surface and groundwater), soil and air quality conditions Measurements are always below the regulations.

Existence of codes of practice to achieve environmental excellence No.

Systematic operation of environmental monitoring and control program No.

114

Noise, visual impacts, dust and emissions Noise and dust are below regulations. They spill material with water, just to avoid dusting.


This municipality has 10 % unemployment rate.


Capacity building (e.g. training courses and plant visits) Yes.

Relevant vulnerability issues (e.g. human health risk assessment) No.

Local communities engagement and involvement in decision making Yes.

Benefits of improving the knowledge base at a local level should be mentioned and highlighted They accept up to 750 kg wastes from local people free of charge, so that waste don’t end on illegal deposits. Company fixes roads.


Available mechanisms to increase communication and discussion between stakeholders. Company organized lectures for inspectors and civil servants.

7. Best practices approach Possibilities for new technology applications In case of larger amounts, company will use new technologies.



Prepare recommendations for industry and government actions to encourage best practice


115

Diagram

116

CASE STUDY 7 - SLOVENIA (GEOZS): THE LIMESTONE QUARRY OF SEŽANA

Case study of:

Sezana Country:

Slovenia


GeoZS

Ana Burger

[email protected]


Geographical data/coordinates LON 13º50'43,26'' ; LAT 45º42'57,68''

Administrative and legal framework (e.g. permit of the treatment plant) permission for collection, environmental permission for manufacturing, environmental concordance, construction permission, permission for serviceability

Municipality name / name of the region Sezana / Obala-Kras region

Description, type and status of the location CERGO Mali Medvejk is located northerly from Sezana. At first there was limestone quarry with mining right. Since September 2009 they have permission for recycling. Quarry and recycling centre own the same company. They located recycling centre in the abandoned part of quarry, which is still active. Recycling centre is one of the steps of sanitation process for this quarry and it is covered with asphalt in a part where deposit is. They have two different process units. One is used for recycling and the other units are used in quarrying. / active

Demographic issues Sezana is small city (6.500 inhabitants) and it is economic, industrial and cultural center of Karst (Kras) region. The city is located by the roar and railway Ljubljana – Trieste. In Sezana are primary and secondary schools. Villager from surrounding villages work in Sezana. In the municipality Sezana lives 12.583 people. Average age is 39,2 years.

Land use planning (e.g. spatial relation to protected areas) Mining area / Natura 2000, Ecological important area, Special Protected Area

Infrastructure Electricity, telephone, road and highway

117

Biodiversity features - The company had at first problems with permission. At the edge of the quarry are European

Scops Owl’s (Otus scops) nests and because of that they couldn’t get permission. When the project were changed that now is zone between birds area and recycling plant, they get permission


- R2: Recycling of Construction and Demolition Waste (CDW) - R3: rockwaste and soils from civil works

Quantity of raw input material (specify per each type of raw input material R1-R2-R3-R4) - yearly amount (t/y): 55.000t/y

Classification of raw input material: - EWC code (European Waste Catalogue 2000/532/EC) 17 01 01, 17 01 02, 17 01 03, 17 01

07, 17 02 01, 17 02 02, 17 02 03, 17 03 02, 17 05 04, 17 05 06, 17 08 02, 17 09 04 * (provide the input material average composition, i.e. % of different EWC)


Technical information on recycling facility - occupied average surface - acceptance procedure for the raw input material see diagram - dimensions of the storage of the different raw input material and of the produced

recycled aggregates: 4.550 m2 (40.000 t momentarily) / 2.100 m2

- paved areas 4.550 m2 - areas equipped with a water gathering system - energetic consumptions

environmental controls and monitoring - They use water to avoid dusting

Technical information on recycling treatment - stationary or mobile plant for the production of recycled aggregates: stationary - hybrid plant for the production of natural and recycled aggregates: no - process units (please provide flowcharts with indication of mass flows and equipment


118

description unit


Secondary demolition Feed Scalping Pre-screening Manual sifting Primary crushing jaw crusher impact crusher others Magnetic separation Secondary crushing jaw crusher impact crusher others

(Screening

(Sorting ( dry ( wet

( Water treatment


- Plant processing throughput: 55.000 t/y (this are expected numbers, because they have permission since October 2009. At recycling plant is now 4.000 t wastes)


Type of recycled aggregates.

- high grade recycled aggregates for concrete (type A), medium grade recycled aggregates for road construction (type B); low grade recycled aggregates for environmental filling (type C)



(t/h) (t/y) (€/t)

Type A 15.000 2.80

Type B 25.000 2.60

Type C 10.000 2.20



Eco-compatibility of recycled aggregates (leaching test - please provide the certificate) no

119

Existence of codes of practice to achieve technical excellence no

Existence of CE Marking (please provide the certificate) no

Description of use of recycled aggregates - They use recycled aggregates for environmental filling. - They use majority of recycled aggregates in their own construction sites

Transportation of recycled aggregates - Transportation cost according to the delivery distance (€ per ton-km)

120




- When they placed recycling centre they didn’t changed landscape, because plant is in quarry

Protected areas status Natura 2000, Ecological important area, Special Protected Area

Water (surface and groundwater), soil and air quality conditions Because of karst there is lack of surface water. They must have monitoring for dust and noise


Systematic operation of environmental monitoring and control program No.

121

Noise, visual impacts, dust and emissions They are below the regulatory.


8 % unemployment, there are small companies, where people work.

Health and safety aspects (on- and off-site) They use water to avoid dusting. In a quarry is always safety engineer

Capacity building (e.g. training courses and plant visits) They have training courses.


Local communities engagement and involvement in decision making The company always inform local community.

Benefits of improving the knowledge base at a local level should be mentioned and highlighted Hopefully the local people wouldn’t put waste on illegal deposits anymore. But trust in recycled aggregates is not high enough.

Presence of effective and regular dissemination of information to particular stakeholder groups The stakeholders are not inform enough.

Available mechanisms to increase communication and discussion between stakeholders. Maybe with courses.






122

Diagram Sezana – Slovenia

CONSTRUCTION SITE

TRUCK

RECYCLING PLANT

VISUAL CONTROL

WEIGHING

SORTING

DEPOSITING ON SUITABLE PLACE

(SEPARETLY ACCORDING TO TYPE OF WASTE:

ASPHALT, CERAMICS, BRICKS, WOOD, …)

TRANSPORT WITH TRUCKS

FROM DEPOSIT TO CRUSHER

CRUSHING (+LAYING THE

DUST, AS NECESSARY)

SEPARATION

STORAGE

WEIGHIN

USE

123

CASE STUDY 8 - SLOVENIA (GEOZS): THE SAND AND GRAVEL QUARRY OF DOGOŠE

Case study of:

Dogose Country:

Slovenia


GeoZS

Ana Burger

[email protected]


Geographical data/coordinates Dogose is village in Urban Municipality of Maribor with 900 inhabitants. It lies on the river Drava. There is predominate rural population. LON 46 55.90770000 E ; LAT 46 245.409596 N

Administrative and legal framework (e.g. permit of the treatment plant) Buildings have operating permission issued according to Construction Act, Recycling Centre has Environmental permission for aggregate recycling according to Environmental protection Act.

Municipality name / name of the region Urban Municipality of Maribor / Podravska

Description, type and status of the location Location of the Centre, 5,0 ha large, is place at SE part of Maribor next to water channel SD-1. Location is past sand and gravel pit that is not completely remediated yet. Transportation network je close, exit to highway A1 je 1 km away. Next to Centre je also separation and crushing facility for aggregates and concrete plant. / exhausted quarry / active

Demographic issues In Urban Municipality of Maribor leves 140.000 citizens, but village Dogose has only 900 inhabitants. Average age is 40,81 years. Village is about 8-9 km far from Maribor (Slovenian 2nd largest city), but population is mostly rural.

Land use planning (e.g. spatial relation to protected areas): Mining area.

Infrastructure highway, most important roads, electric and telephone wires


124



Quantity of raw input material (specify per each type of raw input material R1-R2-R3-R4) - yearly amount (t/y): 100.000 t/y

Classification of raw input material: - EWC code (European Waste Catalogue 2000/532/EC) 17 01, 17 03, 17 05, 17 08, 17

09 * (provide the input material average composition, i.e. % of different EWC)

Collection of raw input material - indirect collection

Technical information on recycling facility - occupied average surface: 5,0 ha - acceptance procedure for the raw input material see diagram - dimensions of the storage of the different raw input material and of the produced

recycled aggregates: 3,0 ha

- paved areas: 0,5 ha - areas equipped with a water gathering system - energetic consumptions

Technical information on recycling treatment - stationary or mobile plant for the production of recycled aggregates: stationary - hybrid plant for the production of natural and recycled aggregates - process units (please provide the flowsheet and the equipments descriptions)

description unit



- Plant processing throughput: 80 t/h

125

- Plant processing throughput: 100.000 t/y


- medium grade recycled aggregates for road construction; low grade recycled aggregates for environmental filling (type C)



(t/h) (t/y) (€/t)

Type B 50 30.000 8.00

Type C 100 70.000 4.00


Recycled aggregates type A B C

Saturated surface dried specific gravity (ssd (kg/m3)

Los Angeles Index LA (%)

Shape Index SI (%)

Flakiness index FI (%)

Sand equivalent SE (%)

Fineness modulus Mf ‐

Impurity level ‐ (%)

…

Eco‐compatibility of recycled aggregates (leaching test ‐ please provide the certificate)

no

126


no


no

Description of use of recycled aggregates

Construction.




127


Visible in local area.

Protected areas status No.

Water (surface and groundwater), soil and air quality conditions Location is near river Drava.

Existence of codes of practice to achieve environmental excellence

Systematic operation of environmental monitoring and control program

Noise, visual impacts, dust and emissions


Local unemployment is large.

Health and safety aspects (on- and off-site) No particularities, everything is in accordance with construction material industry standards.

Capacity building (e.g. training courses and plant visits) Visitors can see the Centre based on previous announcement, there are no constant tours.

Relevant vulnerability issues (e.g. human health risk assessment) No extra risks are recognized.

Local communities engagement and involvement in decision making Local community is not deeply involved and it not included in decision–making.

128

Benefits of improving the knowledge base at a local level should be mentioned and highlighted Useful improvements are not presented to local community or general public.

Presence of effective and regular dissemination of information to particular stakeholder groups There is no special reporting to certain stakeholder groups, only mandatory reporting is performed.



Applications: opportunities and needs are present, also knowledge; decision making in this direction is needed (missing).

Sought operational improvements : They are carried out in very limited.

Expected impacts towards sustainability : No special changes are foreseen.

Optimising the efficiency of recycled aggregates production e.g. water & energy consumption, transport : Costs and normative use are monitored. Overused and ineffective equipment is being replaced with modern, effective and economical one.

Targeting better practises that can help achieve a better relationship between protected areas and other land uses, such as how to incorporate areas of known aggregates potential into decision-making about new protected areas : Not under the consideration.

Collect information on best practices and failures for aggregates production, e.g. environmental management: YES, Information from EU and world is collected.

Determine impediments to best practice, e.g. lack of knowledge, regulatory blocks: There are no specific (performance) protocols in the recycling of aggregates, and lack of regulation related to recycled aggregates.

Prepare recommendations for industry and government actions to encourage best practice :

o Preparation on renewed Operational programme of CDW management on national level.

o Protocols on performance in the aggregates recycling management (on demolition site, transport, CDW collecting, recycling, re-use and use),

o Preparation a regulation on recycled aggregates use, o Introducing “mandatory” use of recycled aggregates in public construction works

and after also in all construction works.

129

Diagram Dogose - Slovenia

CONSTRUCTION SITE

TRUCK

RECYCLING PLANT

VISUAL CONTROL

WEIGHING

SORTING

DEPOSITING ON SUITABLE PLACE

(SEPARETLY ACCORDING TO TYPE OF WASTE: ASPHALT, CERAMICS, BRICKS, WOOD, …)

TRANSPORT WITH TRUCKS FROM DEPOSIT TO CRUSHER

CRUSHING

SEPARATION

STORAGE

WEIGHIN

USE

COLECTING CENTRE

TRUCK

130

CASE STUDY 9 - SLOVENIA (GEOZS): THE DOLOMITE QUARRY OF SMARJE-SAP

Case study of:

Smarje-Sap Country:

Slovenia


GeoZS

Ana Burger

[email protected]


Geographical data/coordinates Recycling plant is located in quarry in central Slovenia, near city Grosuplje. The quarry is near village Smarje-Sap. Location is about 25 km SE from Ljubljana. Nearby is highway. / LON 14 36 25.80433200 E ; LAT 45 58 28.32067200 N

Administrative and legal framework (e.g. permit of the treatment plant) environmental permission

Municipality name / name of the region Grosuplje / Osrednjeslovenska

Description, type and status of the location This is location of active dolomite quarry Smarje-Sap. Recycling plant is small and it is located in the abandoned part of quarry. Quarry is hidden from near village, because it is located in side of a hill and surrounded with forest. / in the quarry / active

Demographic issues Grosuplje is medium large municipality. The largest town is Grosuplje (6.600 inhabitants), then follow Smarje-Sap (1.400 inhabitants). Average age of inhabitants is 37,6 years.

Land use planning (e.g. spatial relation to protected areas) Mineral resources area. The quarry isn’t located in protected area

Infrastructure Nearby is highway and secondary roads

Biodiversity features In this area lives bear (Ursus arctos)

131



Quantity of raw input material (specify per each type of raw input material R1-R2-R3-R4) - yearly amount (t/y): 55.000t/y

Classification of raw input material: - EWC code (European Waste Catalogue 2000/532/EC) 17 01 01, 17 01 07, 17 05 04, 17

05 06, 17 08 02, 17 09 04 * (provide the input material average composition, i.e. % of different EWC)


Technical information on recycling facility - occupied average surface: 2-3.000 m2 (this is small recycling plant) - acceptance procedure for the raw input material see diagram - dimensions of the storage of the different raw input material and of the produced

recycled aggregates: 2-3.000 m2 (this is small recycling plant) - paved areas: no - areas equipped with a water gathering system - energetic consumptions

environmental controls and monitoring - They use water to avoid dusting

Technical information on recycling treatment - stationary or mobile plant for the production of recycled aggregates: stationary - hybrid plant for the production of natural and recycled aggregates: They separate this

two productions - process units (please provide flowcharts with indication of mass flows and equipment

description including treatment capacity and installed power): see attached diagram Because of small amount of waste, they recycled only once a year. They have contract with another company and once a year they rent crusher. Wastes are transport from construction site to recycling plant every day (2-3 trucks/day).

132

description unit




- Plant processing throughput: 5.000 t/y


- low grade recycled aggregates for environmental filling (type C)



(t/h) (t/y) (€/t)

Type C 5.000 3.00



Eco-compatibility of recycled aggregates (leaching test - please provide the certificate) no

133

Existence of codes of practice to achieve technical excellence no

Existence of CE Marking (please provide the certificate) no

Description of use of recycled aggregates - They use recycled aggregates for environmental filling.

Transportation of recycled aggregates - Transportation cost according to the delivery distance (€ per ton-km): rentable transport

radius is up to 15 km



134


This is location of active dolomite quarry Smarje-Sap. Recycling plant is small and it is located in the abandoned part of quarry. Quarry is hidden from near village, because it is located in side of a hill and surrounded with forest.

Protected areas status No

Water (surface and groundwater), soil and air quality conditions Measurements are always below the regulations.


Systematic operation of environmental monitoring and control program They must report to Environmental Agency of the Republic of Slovenia once a year.

Noise, visual impacts, dust and emissions Noise and dust are below regulations. They spill material with water, just to avoid dusting. There are no visual impacts because site is located at hill slope and in a forest.


Grosuplje municipality has 8 % unemployment rate

Health and safety aspects (on- and off-site) They use water to avoid dusting.

Capacity building (e.g. training courses and plant visits) No.


Local communities engagement and involvement in decision making No.

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Benefits of improving the knowledge base at a local level should be mentioned and highlighted Less of waste end up on illegal deposits. They fixed a road.




The quantity of wastes is too small to invest in new technologies





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Diagram Smarje - Sap – Slovenia

CONSTRUCTION SITE

TRUCK

RECYCLING PLANT

VISUAL CONTROL

WEIGHING

DEPOSITING

CRUSHING (+LAYING THE DUST,

AS NECESSARY) – once a year

STORAGE

WEIGHIN

USE

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5. REFERENCES

ALSF ‘Sustainable Utilisation of Quarry By-Products’, ed. by Abbie Drew, MIRO; Neil Roberts

http://www.sustainableaggregates.com/topics/topics_sustainablebp.htm

Austrian Construction Materials Recycling Association (2007): Guideline for recycled building materials, 7th Edition

Bleischwitz R. and Bahn-Walkowiak B. (2007) 'Aggregates and Construction Markets in Europe: Towards a Sectoral Action Plan on Sustainable Resource Management',Minerals & Energy - Raw Materials Report,22:3,159 — 176

Bleischwitz R. and Fuhrmann K. (2007) 'Sustainable Resource Management: A New Research Agenda', Minerals & Energy - Raw Materials Report,22:1,1 - 6

Blengini, G.A. and Garbarino, E. (2010 a) ‘Resources and Waste Management in Turin (Italy): the role of recycled aggregates the Sustainable Supply Mix’, Journal of cleaner production, Vol. 18, n. 10-11, pp. 1021-1030

Blengini, G.A. and Garbarino, E. (2010 b) ‘Integration of the three inter-dependent life cycles in the mining/quarrying industry: proposed LCA methodology within the EU SARMa Project’. Paper presented at the International Symposium on Mineral Resources and Mine Development AIMS 2010, Aachen (Germany), pp. 457-471, 2010, Vol. 1, ISBN: 978-3-86797-100-3

Blengini, G.A. and Shields, D.J. (2010) ‘Green labels and sustainability reporting. Overview of the building products supply chain in Italy’, Management of Environmental Quality: An International Journal, Vol. 2, n. 4, pp. 477-493

Blengini, G.A. and Garbarino, E. ‘Integrated life cycle management of aggregates quarrying, processing and recycling: definition of a common LCA methodology in the SARMa Project’, International Journal of Sustainable Society, paper accepted

Blum A. and Stutzriemer S. (2007) 'Recycled Construction Minerals for Urban Infrastructure in Germany: Non-technical Issues', Minerals & Energy - Raw Materials Report,22:3,148 - 158

Böhmer, S., Moser, G., Neubauer, C., Peltoniemi, M., Schachermayer, E., Tesar, M., Walter, B. and Winter, B. (2008) Aggregates Case Study, Final Report to contract no 150787-2007 F1SC-AT, Commissioned by the Institute for Prospective Technological Studies of European Commission’s Joint Research Centre, Obtained through the Internet: http://susproc.jrc.ec.europa.eu/activities/waste/documents/Aggregates_Case_Study_Final_Report_UBA_080331.pdf [accessed 01.11.2010].

Christmann P., Arvanitidis N., Martins L., Recoché G. and Solar S. (2007) 'Towards the Sustainable Use of Mineral Resources: A European Geological Surveys Perspective', Minerals & Energy - Raw Materials Report,22:3,88 - 104

ECO-SERVE Network, Cluster 3: Aggregate and Concrete Production (2004) Baseline Report for the Aggregate and Concrete Industries in Europe

EUROPEAN COMMISSION (1999): ‘Construction and Demolition Waste Management Practices, and their Economic Impacts’, final Report, report by Symonds, in association with ARGUS, COWI and PRC Bouwcentrum

EUROPEAN COMMISSION (2001): Reference Document on BAT in the Cement and Lime Manufacturing Industries

EUROPEAN COMMISSION (2003): Reference Document on the General Principles of Monitoring

EUROPEAN COMMISSION (2004): BAT Reference Document for Management of Tailings and Waste-Rock in Mining Activities

EUROPEAN COMMISSION (2005): Communication from the Commission to the Council, the European Parliament, the European Economic and Social Committee and The Committee of the Regions of 21 December 2005: “Taking sustainable use of resources forward - A Thematic Strategy on the prevention and recycling of waste”, COM (2005) 666 final

EUROPEAN COMMISSION (2006): BAT Reference Document on Emissions from Storage

EUROPEAN COMMISSION (2007a): Communication from the Commission to the Council and the European Parliament of 21 February 2007 on the Interpretative Communication on waste and by-products, COM (2007) 59

EUROPEAN COMMISSION (2007b): Mandate to CEN/CENELEC concerning the execution of standardisation work for the development of horizontal standardised assessment methods for harmonised approaches relating to dangerous substances under the Construction Products Directive.

EUROPEAN COMMISSION (2008): End-of-waste criteria. Final Report - JRC Scientific and Technical Reports

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EUROPEAN COMMISSION (2010): ‘General Guide for Life Cycle Assessment. Detailed Guidance. First Edition’, ILCD (International Reference Life Cycle Data System) Handbook – JRC, IES Institute for Environment and Sustainability

EUROPEAN COUNCIL (1988): Council Directive 89/106/EEC of 21st of December 1988 on the approximation of laws, regulations and administrative provisions of the Member States relating to construction products (89/106/EEC) as amended.

EUROPEAN COUNCIL (2006): Council Directive 2006/21/EC of the European Parliament and of the Council of 15 March 2006 on the management of waste from extractive industries and amending Directive 2004/35/EC/

EUROPEAN COUNCIL (2008): Council Directive 2008/98/EC of the European Parliament and of the Council of 19 November 2008 on waste and repealing certain Directives

Garbarino, E. (2010) ‘Similarities and synergies between mineral processing and recycling of Construction and Demolition Waste’, Int. J. Mining and Mineral Engineering, Vol. 2, No. 3, pp.253–275

Meiling P., Rosvall J. and Panas I. (2007) 'Conservation and Maintenance of Modern Urban Architecture: The Need for Long-term Maintenance and Sustainable Management of Metropolitan Housing Areas', Minerals & Energy - Raw Materials Report,22:1,72 - 82

WEB

alsf Sustainable Aggregates http://www.sustainableaggregates.com/

AggRegain http://aggregain.wrap.org.uk/

ECO-SERVE www.eco-serve.net/

EEA European Environmental Agency http://www.eea.europa.eu/

EIONET European Topic Centre on Resource and Waste Management http://waste.eionet.europa.eu

UEPG European Aggregates Association http://www.uepg.eu/

WRAP http://www.wrap.org.uk/construction/

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