design considerations for advanced ......conduct a waste characterization study following astm...

DESIGN CONSIDERATIONS FOR ADVANCED RECYCLING FACILITIES

FEDERATION OF NEW YORK SOLID WASTE ASSOCIATIONS SOLID WASTE & RECYCLING CONFERENCE AND TRADE SHOW MAY 4, 2015

Prepared By:

THEODORE S. PYTLAR, JR. VICE PRESIDENT – SOLID WASTE GROUP

ADVANCED RECYCLING SYSTEMS BEING DEVELOPED TO SORT A RANGE OF INCOMING UNSORTED AND PRE-SEGREGATED STREAMS AND FOR THE RECOVERY OF A VARIETY OF RECYCLABLE COMMODITIES AND PROCESSABLE ORGANICS

Recent D&B Recycling Facility Projects Have Addressed the Processing Source Separated - Dual Stream Source Separated - Single Stream Mixed Refuse - Post Source Separation Mixed Refuse - No Source Separation

And the Recovery of: Standard Fiber and Container Recyclables Mixed Rigid Plastics Cartons Film Plastics Tubs/Lids 1 - 7 Plastics Organics

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PROCESSING SYSTEM SUPPLIERS INNOVATE TO DEVELOP NEW PROCESSING EQUIPMENT AND SYSTEM CONFIGURATIONS TO MEET THE CHALLENGES POSED BY VARIOUS WASTESTREAMS AND RECOVERY TARGETS

Important to accurately specify the goals and requirements of the community or company that will use the system in order to attain a successful match between the processing system and the user’s objectives.

This will ensure that the processing system is designed to meet the user’s need rather than to sell the supplier’s equipment.

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KEY CONSIDERATIONS TO BE ADDRESSED IN THIS PRESENTATION

1. Acquiring accurate quantity, composition and waste delivery information

2. Automated vs. manual sorting

3. Trade-offs between system capital and operating costs and recovery/diversion goals.

4. Productive utilization of residuals.

5. Accurate sizing of receiving, stockpiling, infeed, product storage, baling capability, bale storage and trailer loading.

6. Realistic expectations for product quality and recovery rates based upon incoming materials and processing system design.

7. Odor Control

8. Use of Procurement Procedures and Contractual Features to Enforce the Intent of the Design.

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1. ACQUIRING ACCURATE QUANTITY, COMPOSITION AND WASTE DELIVERY INFORMATION

Basis of (1) sizing the processing system and structures; (2) financing requirements for construction; (3) economic projections for operating costs and recovered product revenues.

Need reliable projections of the quantity of total deliveries (daily, weekly, seasonal, annual, long term growth), recyclables or organics available in the received materials and unrecoverable materials that require pre-screening or presorting

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COMPARISON OF MATERIAL COMPOSITION FOR SOURCE SEPARATED RECYCLABLES AND MSW

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1. ACQUIRING ACCURATE QUANTITY, COMPOSITION AND WASTE DELIVERY INFORMATION

Need information on the nature of the deliveries: types of trucks; daily and weekly delivery patterns; bagged vs. loose; residential/commercial; moisture content

Conduct a waste characterization study following ASTM specifications. Determine if a single characterization program is adequate or if multiple, seasonal programs are necessary.

Project trends in, quantity and composition - consider

impacts of light weighting, decline of ONP, etc.

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Presorting stations for single stream and MSW MRFs.

Hartford, CT – Single Stream: 25 feet Montgomery, Alabama – MSW: 55 feet

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2. AUTOMATED VS. MANUAL SORTING

a. Automated sorters can recover greater quantities of materials per unit time than manual sorting

Comparison of Manual and Automated Sorting Rates for Old

Corrugated Containers

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ALACHUA COUNTY MIXED WASTE MRF ANALYSIS

Manual Sorting Option: 56 Tons Per Day OCC Incoming 6 Sorters Sorting 700 lb/hr Recover 16.8 Tons Per Day

Automated Sorting Option: One Disk Screen with 85% Guaranteed Efficiency Recovers 47.6 Tons Per Day. Two Screens Recover 53.2 Ton Per Day


b. Automated incurs significantly greater capital costs than manual, but reduces labor costs - trade off between capital and operating costs

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*MSW Processing Options – 600 Tons Per Day

TRADE OFF BETWEEN CAPITAL AND OPERATING COSTS FOR MANUAL AND AUTOMATED SORTING


c. Automated changes the nature of staff duties from positive sorting to quality control sorting; and requires frequent attention from maintenance staff

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d. Manual pre-screening of bulky, hazardous and non-processable items is necessary for any system, no matter the level of automated and manual sorting.

e. Automated sorting equipment includes bag openers, ferrous magets, eddy current separators for nonferrous, vacuum systems for plastic film, ballistic sorters for light vs heavy materials, ballistics sorters for 2D vs 3D (fiber vs containers); and optical systems for nearly everything

Bag Opener 12


f. Many automated systems actually combine two or more approaches in order to achieve the desired result

Disc screens often utilize blowers to assist in the separation of fiber; optical sorters use air jets to sort targeted containers.

g. In recognition that no automated system is 100% efficient, multiple sorting devices targeting the same materials are often employed.

The greater the value of the targeted material, or greater the need for purity, the greater number of sorting passes can be employed in order to maximize recovery of that material.

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Material Infeed

Commingled System

Pre-Sort

Commingled Sort Stations

First Stage: 2D/3D/Fines

Screening

Tipping Floor

Fiber System

Baler

Bale Storage

Second Stage: 2D/3D/Fines Ballistic

Separation

SOURCE: MACHINEX 14 Multiple Screening Stages in a Single Stream MRF


h. Equipment manufacturers are constantly innovating to improve recovery rates and overcome shortcomings of existing sorting equipment

▫ Disc screens (star screens, banana screens, etc) have evolved from (1) sorting glass from containers to (2) sorting OCC from ONP; and (3) fiber (2D) from containers (3D) and fines.

▫ However, materials such as film plastics, and stringy items wrap around the rotating shafts of the disc screens. As a result, some manufacturers have improved disc screen designs and developed ballistic separators for the 2D and 3D sorting, which do not utilize shafts. [disc screen vs. ballistic separator]

Stars on Shafts From Sparta Recycling

Van Dyk “Anti-Wrapping” Disk Screen

SOURCE: MACHINEX

Ballistic Screen

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i. Equipment manufacturers are constantly innovating to improve recovery rates and overcome shortcomings of existing sorting equipment

Sorting recyclables and organics from MSW requires screening of rocks, dirt and other fines. This has led to the development of light/heavy separators that combine ballistic and air classification principles to achieve the desired sorting.

Density Separator SOURCE: BHS

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SOURCE: BHS

3. TRADE-OFFS BETWEEN SYSTEM CAPITAL AND

OPERATING COSTS AND RECOVERY/DIVERSION GOALS.

a. Costs and recovery rates are influenced by: (1) quantity and quality of materials processed; (2) number of items targeted for recovery; (3) number of sorting "passes" for individual materials;

600 TPD MSW - No Source Separation:

$14.4 M (2013 $)

600 TPD MSW - Post Source Separation:

$10.3M (2014 $)

▫ Quantity of materials processed - As tonnages increase, larger structures and more equipment and labor are required. MSW processing systems must be sized to receive and handle a significant amount of material that is not recoverable in order to recover the recyclables that are in the mix.

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COMPARISON OF PROCESSING EQUIPMENT COSTS FOR 600 TON PER DAY MSW MRFS: NO SOURCE SEPARATION AND POST SOURCE SEPARATION

Large Presort Bunkers for 600 TPD MSW MRF

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b. Number of items targeted for recovery: Construction and operations costs increase as the types of materials targeted for recovery increases - Particularly for MSW MRFs. As the list of materials recovered expands from the most plentiful and high value materials to less plentiful and lower

value, cost increases are not balanced by revenue increases.

* no black or microwavable 20



c. Number of sorting "passes" for individual materials - the recovery of a particular material can be increased and the quantity lost to residuals can be decreased by installing multiple sorting processes targeting that material. These multiple passes are often not sequential, but occur on downstream "tributary" processing lines.

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FERROUS

RECOVERY

FROM “OVERS”

FERROUS RECOVERY FROM

FINES: NAILS; STAPLES;

BATTERIES

FERROUS

RECOVERY FROM

“UNDERS”

SOURCE: MACHINEX

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4. PRODUCTIVE UTILIZATION OF RESIDUALS.

Organic residuals from MSW processing can be productively utilized through composting or Anaerobic Digestion. Although contaminants must be removed at a cost.

High fuel value residuals, such as unrecoverable plastics and paper can be converted to an engineered fuel or “solid recovered fuels” for combustion, gasification or pyrolysis; depending upon the nature of the residual.

QRS facility in Baltimore to sort residual plastics sourced from MRFs within a 400 mile radius to recover 1-7 plastics

Engineered Fuel Pellets Plastics Residuals Prior to Processing by Agilyx

SOURCE: AGILYX

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4. PRODUCTIVE UTILIZATION OF RESIDUALS.

EF/SRF can have energy values equivalent to coal (>10,000 BTU/LB)

Co-combustion in coal-fired plants can reduce the plant’s carbon footprint

The European Recovered Fuel Organization has established specifications for SRF

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5. ACCURATE SIZING OF RECEIVING, STOCKPILING, INFEED, PRODUCT STORAGE, BALING CAPABILITY, BALE STORAGE AND TRAILER LOADING.

Tipping floors and bale storage often undersized; said the same thing 10 years ago

Unloading approach can save space; back in requires less space than drive thru. However drive thru is better at limiting the escape of odors

Drive – Through Tipping Floor Back – In Tipping Floor

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6. REALISTIC EXPECTATIONS FOR PRODUCT QUALITY AND RECOVERY RATES BASED UPON INCOMING MATERIALS AND PROCESSING SYSTEM DESIGN.

Recovery of recyclables from MSW, particularly fiber, should be estimated conservatively in order to avoid over estimation of diversion rates and revenues and underestimation of additional processing or disposal costs.

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27 Recovery Projections for a 600 TPD Post Source Separation MSW MRF

7. ODOR CONTROL

Source separated recyclables and MSW pose different levels of odor potential – can be managed by: Limiting the number of building openings (see tipping floor

examples above)

Air flow management, odor treatment, deodorization Avoiding flow – through caused by to doors on opposite sides of

the building; aligned with prevailing wind

28 SOURCE: GRIMSHAW ARCHITECTS

8. USE OF PROCUREMENT PROCEDURES AND CONTRACTUAL FEATURES TO ENFORCE THE INTENT OF THE DESIGN.

Private sector expertise is essential to the success of advanced systems

The public sector should decide what it wants: Dual Stream MRF Single Stream MRF MSW MRF – Post Source Separation MSW MRF – No Source Separation Organics Recovery Least Most Automation

System suppliers innovations in equipment and processing sequences

An effective operation requires outstanding system design, facility management, operations and marketing and manual labor.

Several different options for attaining facility objectives and long-term successful operations

A public sector project sponsor can use a competitive procurement process to attain its goals: 100% Public 100% Private P3 (Public – Private – Partnership)

BUT THAT IS THE TOPIC OF ANOTHER PRESENTATION!

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THANK YOU!

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