update on european carpet recycling activities and experiences · 2019-12-06 · update on european...
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Update on European Carpet Recycling Activities and Experiences
CARE 3rd Annual ConferenceMay 10-12, 2005
Southern Pine Conference Center Callaway Gardens, Pine Mountain, Georgia
Dr. Edmund Vankann
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One Challenge - Two Approaches
One Solution ?
technicaltechnical
economicaleconomicalEUROPE
UNITED STATES
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Timetable of the European Carpet Industry
1993 GUT put Recycling on its agenda as a priority actioneconomical and ecological viable disposal and recycling systems for carpets
landfill is not a solution
development of strategies for the recycling of “Post Consumer Carpet Waste”
Initiation of several research projectsTamara-project (MWI) Carpet as solid fuel in moving bed reactor energy recoveryCOCARE Coding for Carpet Recycling
1996 set up of RECAM-project Closed loop recycling of carpet materials
1998 – 2002 Carpet Recycling Europe (CRE) 2002- 2004 Carpet Recycling Nederland (CRN)
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Incineration of carpet waste in MWI
Questions to be answered:
What is the environmental fate of heavy metals ?
Does PA lead to higher NO-emissions ?
Are Dioxins formed or emitted when carpets are incinerated ?
Do ashes contain harmful substances ?
Forschungszentrum Karlsruhe
COCOCO---COMBUSTION OF CARPET WASTE COMBUSTION OF CARPET WASTE COMBUSTION OF CARPET WASTE WITH TYPICAL HOUSEHOLD WASTEWITH TYPICAL HOUSEHOLD WASTEWITH TYPICAL HOUSEHOLD WASTE
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Results
the addition of carpet waste did not lead to instabilities in the plant, the higher calorific value of the carpet waste caused no problems, the CaCO3 content of the carpets (filler) resulted in a reduction of SO2and HCl emissions due to the formation of CaSO4 and CaCl2 in the ashes, the heavy metal content of the ashes showed only the typical distribution and there was no effect registered that could be ascribed to the carpet waste,the same was true for dioxin and furane emissions in the off-gases,the polyamide content in the carpet waste caused only a very small increase of the NO concentrations in the off-gases.
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The RECAM Project
SUSTAINABLE CLOSED LOOP
SYSTEM FOR RECYCLING OF
CARPET MATERIALS
Partners: DSM ENICHEM TFIGUT
1996-1999
project funded by the EC (Brite Euram)
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The RECAM System
CollectionIdentification
Sorting
fibresnonwovens
textilerecycling
mech. Treatment
energeticrecycling
ashes
materialand chemical
recycling
monomers,polymers
yarns
textilefloorcoverings
simplified structure
■ identification and sorting■ key technologies for successful carpet
recycling
■ CRE pilot project
■ financed by GUT members
■ supported by RECAM partners
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The principle idea of the CRE-project
Sorting Plant
PA 6carpetsPA 6
carpetsPA 66carpetsPA 66carpets
PEScarpets
PPcarpets
Others
Woolcarpets
Carpet waste
Recycling Energy recovery or recycling
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Automatic sorting at CRE
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The practical results of Carpet Recycling Europe
CRE-Sorting Plant
PA 6CarpetsPA 6
CarpetsPA 66CarpetsPA 66Carpets
PESCarpets
PPCarpets
otherCarpets
WoolCarpets
CarpetWaste
17% to (20%)
PA 6 content~27%
4,6 % to (5,4%) PA 6based on input
4,6 % to (5,4%) PA 6based on input
400 to 450 gPA6/m²
based on 1,57 kg/m²
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Comparison with published figures by PA 2000
10.000 t of virgin PA-6 from120.000 t of carpet wasteCalculation without any losses during processing !PA-6 content in PCCW 8,3 %8,3 %
with minimum losses ! 9,25%9,25%
Theoretical available: 6,5 %Theoretical collectable: 4,5 %Practical results 4,6 %4,6 %
Prediction by PA 2000
Realistic figures by CRE
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Carpet Recycling Netherlands
Feasibility study of introducing carpet waste recycling in the NetherlandsMinistry of Economic Affairs/Novem Initiator of projectMinistry of Spatial Planning, Housing and the Environment:
CRN Potential stakeholders (including raw material suppliers and retail
trade)
Waste management branch
Consumer
VNTF/ECA/CRE/GUT
Econ. AffairsEnergy Policy
MJA2-scope enlargement
VROMProduct Policy /Waste Policy
authority
industry
consumer
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It is recommendable to use as much as possible carpet waste as secondary fuel, as this will lead to substantial environmental and economic gains. As stated above, this implies that the carpet waste should be collected as mono stream. Especially with regard to the domestic market for carpet (waste), (additional) possibilities should be created for collecting carpet waste as mono stream, for instance via separate containers for carpet waste at municipal domestic waste transfer stations. Perhaps NVRD (the waste management branch organization in the Netherlands) may also play a role here. However, the realisation of such facilities lies beyond the scope of the VNTF and the remaining Dutch carpet industry
The result of CRN-Project
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The facts behind the recommendation
“Simple” comparison of energy consumption and energy savings with the software LESS , developed by NOVEM
More complex LCA-Calculation by GUT, based on the RECAM-Project
identical results
www.novem.org
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complex LCA Scope
Raw MaterialRaw Material
Raw MaterialRaw Material
Raw MaterialRaw Material
Productionof CarpetsProductionof Carpets Use of carpetsUse of carpets
Disposal of
Carpets
Disposal of
Carpets
existing inventaries ?
different typesof carpets
the question of lifetime
differentscenarios
CARPETCARPET
part 1 part 2 part 3
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Different scenarios
32,7 %37,3 %30 %0 %2005
2,2 %0 %15,7 %82,1 %1998
0 %0 %16 %84 %1995
Recycling Cementindustry
material, textile,chemical and thermal
recycling
RECAMMunicipalWaste
IncinerationLandfillSzenario
Basis for the RECAM –LCA always with energy recovery!
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The RECAM-LCA (CML)
Based on the recycling scenario, described by the RECAM report, a LCA–study comes to the conclusion that the environmental impact of carpet waste can be reduced by factor 2
0%
25%
50%
75%
100%
Ressourcen-verbrauch
Treibhaus-effekt
Humantoxizität Ökotoxizität Versauerung Nährstoff-überschuß
Oxidantien-bildung
Flächen-verbrauch
1998
RECAM
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The modified scenario for NL
0 %0 %100 %20124D1
0 %17 %83 %20123C10 %38 %62 %20062B1
0 %43 %57 %20061A1
14 %33 %53 %2003ZeroLESS
LandfillMWICementkillnsYearScenarios
Basis for the CRN –LCA
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Dutch basic Scenario
Production easte
Transport20 km, 16t LKW, 50 %
Carpet Waste
Domestic
Transport10 km, Auto
LandfillMWI
21 % 53 %26 %
Transport20 km, 16t LKW, 50 %
Contract
Transport100km, 16t LKW, 50%
Transport75 km, 16t LKW, 50 %
Transport50 km, 16t LKW, 50 %
Aufbereitung(Schreddern, Pelletieren)
Transport300 km, 16t LKW, 80 %
Cement industry
Collection viaRecycling station
Containersystem
Transport100km, 16t LKW, 50%
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Energy savings
(95kt/a in NL) MWI + Cement kilns versus 100% Landfill
0
993,6
1111,21163,7
1384
1562,4
0
200
400
600
800
1000
1200
1400
1600
100% landfillreference point
ZERO2003
Szenario 1(2006)
Szenario 2(2006)
Szenario 3(2012)
Szenario 4(2012)
Ener
giee
insp
arun
g[T
J/a] status quo 2004
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Overall Comparison
ZERO scenario (2003) ---- Scenario 4 (2012)
-100% -80% -60% -40% -20% 0% 20% 40% 60% 80%
Use of resources
climate change
Ozone layer depletion
acidification (soil/water)
Nutrification
human toxicity
eco toxicity
formation of photo oxidants
land use
noise
Environmental burdonEnvironmental release
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The situation in 2004
No “recycling” facilities available !No separate collection system No landfill from 2005 on
Comparison of different scenarios with the optimal recycling scenario “RECAM”
0307070E
04060D
06040C
08020B
01000A
Landfill[%]
MWI [%]
Cement kilns[%]
Why 70% - 30% ?
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Collection of carpet waste in Germany
Practical results from PCC-waste collections
Frankfurt (RECAM-project)6,25 kg/inh. (opt. conditions)5,00 kg/inh. as average
Bavaria1,4 to 3 kg/inh.
Assumptions4 kg/inh. collectable mass (realistic scenario)5 kg/inh. maximum collectable mass (optimized collection systems)
6,8 kg/inh.theoretic available
max. mass
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Collectable amount of PCCW
Based on realistic assumptions 4 kg to 5 kg of carpet waste can be collected per inhabitant in GermanyThis means:328 kt of PCC-waste (realistic scenario)
58% of the theoretical available mass
410 kt of PCC-waste (optimized scenario)73% of the theoretical available mass
All further calculations are based on the assumption, that it will be possible to collect 70% of the carpets sold .
391 kt in 2005, based on 559 kt sold in 1995 (325 mill.. m²)in Germany
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The basic system for the LCA calculations
Transport30 km, 16t LKW, 40 %
BereitstellungContainer
Alt-Teppichboden
Objektbereich Privatbereich
Sammlung ingemischten Containern
Transport30 km, 16t LKW, 40 %
Transport25 km, 16t LKW, 40 %
Transport50 km, 16t LKW, 40 %
Transport10 km, 16t LKW, 40%
Sperrmüllsammlung
Transport7 km, Auto
Sammlung auf demRecyclinghof
Sortierung in Sperr-müllsortieranlage
Transport75 km, 16t LKW, 40 %
Aufbereitung(Schreddern, Pelletieren)
Transport50 km, 16t LKW, 80 %
Verwertung in derZementindustrie(maximal 70 %)
Verwertung in der Müll-verbrennungsanlage(mindestens 30 %)
50 % 50 %
36,5 %13,5 %
Sammlung ingetrennten Containern
Sortierung in Sperr-müllsortieranlage
Holsystem Bringsystem
35 % 15 %
BereitstellungContainer
Transport75 km, 16t LKW, 40 %
Transport75 km, 16t LKW, 40 %
BereitstellungContainer
Transport25 km, 16t LKW, 40 %
33 % 2 %
15 % 18 %
Transport7 km, 7,5t LKW
Transport75 km, 16t LKW, 40 %
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011.300
46610.834
2.9198.381
3.9147.386
4.9076.393
5.9025.398
6.3974.903
5.7315.569
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
landfill 1998 A B C D E Recam
Energy gains based on LCA- calculations
Energy lossesEnergy losses(Transportation and processing)
Energy gainsEnergy gains
1.130
5.650
11.300
[TJ]
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LCA : impact assessment
Impact categories Comparison of impact categories for different scenarios
(A,B,C,D,E, RECAM) is complex.
Impact of categories is differentNoise PollutionGreen House PotentialHuman ToxicityEco ToxicityOzone layer depletionAquatic toxicityEnergy consumptionConsumption of recourses AcidificationLand consumptionFormation of photo oxidants
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Impact assessment for noise pollution
■ Situation 1998
■ Cement 0 %,
■ RIP 100 %
■ Cement 20 %,
■ RIP 80 %
■ Cement 40 %,
■ RIP 60 %
■ Cement 60 %,
■ RIP 40 %■ Cement 70 %,■ RIP 30 %
■ RECAM 2005
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Impact assessment for human toxicity (HC)
Differences <20% are not relevant
80%
Situation 1998 Cement 0 %,
RIP 100 %
Cement 20 %,
RIP 80 %
Cement 40 %,
RIP 60 %
Cement 60 %,
RIP 40 %Cement 70 %,
RIP 30 %RECAM 2005
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Impact assessment for eco toxicity (ECA)
50%
60%
70%
80%
90%
100%
Situation 1998 Cement 0 %,
RIP 100 %
Cement 20 %,
RIP 80 %
Cement 40 %,
RIP 60 %
Cement 60 %,
RIP 40 %
Cement 70 %,
RIP 30 %
RECAM 2005
Env
ironm
enta
l bur
den
(per
cent
)
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ECO-Indicator Points
2/3
75%
80%
85%
90%
95%
100%
Situation 1998 Cement 0 %,MVA 100 %
Cement 20 %,MVA 80 %
Cement 40 %,MVA 60 %
Cement 60 %,MVA 40 %
Cement 70 %,MVA 30 %
RECAM 2005
Eco-
Indi
cato
r poi
nts
[Pro
zent
]
Ecological optimisation
potential
With the help of Eco-Points the complex system can be compared and illustrated in a simpler way
Fully aggregated final result of the life cycle interpretation by means of ECO-Indicator 95
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Lets have a look over the carpet horizon
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Waste in Germany (in kt)
Bulky Waste; 3003; 0,8%
Compost; 2413; 0,6%
Glass; Paper; Plastics; Elektronic Devices; 9938; 2,5%
Domestic Waste; 19316; 4,9%
other Municipal Waste; 9262; 2,4%
Carpet Waste; 559; 0,1%
Hazardous Waste; 18281; 4,7%
Mining; 54308; 13,9%
Other ; 44491; 11,4%
Production Waste; 43012; 11,0%
Construction Waste; 231480; 59,1%
■ 391.572 kt in total
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0
1000
2000
3000
4000
5000
6000
7000
8000
9000
LDPE
HDPE
PP PVC
PS/EPSPET
ABS/SANPMMA
ACETALsPolycarbonatesPolyamidesAcrylicsOthers
Consumption of thermoplastics in the EU , 2003Th
erm
opla
stic
s in
[kt] Plastics application
Non-Plastics applicationincluding textiles and carpets2,9 % of all thermoplastics
total: 38.148 kt carpet: ~660 kt
Carpet application 1,7% of all
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The next steps (1)
Use carpet waste as Refuse Derived Fuel (RDF)See EU Report:
EUROPEAN COMMISSION – DG ENVIRONMENT
REFUSE DERIVED FUEL, REFUSE DERIVED FUEL,
CURRENT PRACTICE AND PERSPECTIVESCURRENT PRACTICE AND PERSPECTIVES
(B4-3040/2000/306517/MAR/E3)
FINAL REPORT; WRc Ref: CO5087-4; JULY 2003
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What are the benefits ?(See “conclusions” in EU report)
Refuse Derived Fuels (RDF) from MSW can be a be a strategic component of an strategic component of an integrated waste management system to reach the recycling and reintegrated waste management system to reach the recycling and reduction duction targetstargets for biodegradable materials going to landfill as specified under the 1999 Landfill Directive.Use of RDF in industrial processes offers more flexibility than incineration as it it leaves the door open for future recycling programmes as this canleaves the door open for future recycling programmes as this can be made be made modularmodular, it does not need to be fed with a constant amount of waste and it does not require the need to invest in capital intense dedicated incineration facilities.Co-incineration of RDF in coal power plants and cement works shows cement works shows ecological advantages when compared with incineration in a MSW ecological advantages when compared with incineration in a MSW incinerator primarily due to the effective substitution of fossiincinerator primarily due to the effective substitution of fossil fuelsl fuels, as long as the plants comply with the New Waste Incineration Directive 2000/76.
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The next steps (2)
Separate “High Calorific Wastes” like carpets from other waste streams Use them as RDFThis will help to install collection systemBesides ecological benefits economic efficiency is givenInstall suitable recycling programs for selected materials like PA 6Carpets should not be the only source for PA 6 recycling programs
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Step by Step
High Calorific WasteWas
te
Waste reduction Step 1
RDFWaste reduction Step 2
Material Recycling
Step 1
Step 2
■ Ecological and economical approach
■ Step 1: Energy recovery
■ Step 2: Material recycling
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EU is supporting Research Projects
SEFCOSolid recovered fuel (SRF) in large scale energy production
RECOFUELDemonstration of SRF-cofiring-Method in a 600 megawatt power station
COBURN Co-combustion of separated high calorific household waste in power stations.
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What happened to PA2000
Moving bed reactor used for energy production
Moving bed reactor Moving bed reactor used for energy productionused for energy production
Polymerization sold to DOMOPolymerization sold to DOMOPolymerization sold to DOMO
Plastics recycling (Regranulation)Sold to Vogt-Plastics GmbH
Plastics recycling (Plastics recycling (RegranulationRegranulation))Sold to VogtSold to Vogt--Plastics GmbH Plastics GmbH
No carpets are recycled anymore. No plans exist to start this operation
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Railroad ties in Europe ?