Laboratory scale studies on gaseous emissions generated by the incineration of an artificial automotive shredder residue presenting a critical composition

Car manufacturers must eliminate automotive shredder residues (ASR). Two ways of incineration are of interest: at 850°C in municipal waste incinerators or at higher temperatures, above 1100°C in cement plants. These processes reduce the mass and the volume of waste to be disposed of in landfills and energy recovery might be possible. Regulations govern the emission of gaseous effluents to control environmental risk. To determine gaseous effluents from a pilot sacle or an industrial incineration plant, an artificial ASR was made by mixing three representative organic polymers present in the real ASR, namely polyvinylchloride, polyurethane and rubber. This mixture was incinerated at 850 and 1100°C in laboratory experiments and the analyses of the principal gaseous effluents such as carbon oxides, nitrogen oxides, volatile organic compounds, hydrochloric and hydrocyanic acids and sulphur compounds are presented and discussed. Lastly, in order to simulate artificial ASR behaviour, the composition of the combustion gases at equilibrium was calculated using a Gibbs energy minimisation code.     

Brominated flame retardants and heavy metals in automobile shredder residue (ASR) and their behavior in the melting process

The End-of-life Vehicles Recycling Act went into effect on January 1, 2005, in Japan and requires the proper treatment of airbags, chlorofluorocarbons (CFCs), and automobile shredder residue (ASR). The need for optimal treatment and recycling of ASR, in particular, has been increasing year after year because ASR is regarded as being difficult to treat. Dioxin-related compounds, brominated flame retardants (BFRs), heavy metals, chlorine and organotin compounds are all present in high concentrations in ASR. The authors conducted ASR melting treatment tests using a 10-tons/day-scale direct melting system (DMS), which employs shaft-type gasification and melting technology. The results obtained showed that dioxin-related compounds and BFRs were decomposed by this melting treatment. The high-temperature reducing atmosphere in the melting furnace moved volatile heavy metals such as lead and zinc into the fly ash where they were distributed at a rate of more than 90% of the input amount. This treatment was also found to be effective in the decomposition of organotin, with a rate of decomposition higher than 99.996% of the input amount. Via the recovery of heavy metals concentrated in the fly ash, all the products discharged from this treatment system were utilized effectively for the complete realization of an ASR recycling system that requires no final disposal sites.     

Full scale treatment of ASR wastes in a modified rotary kiln

A plant, designed for the thermo-valorisation of tyres, was specifically modified in order to treat Automobile Shredder Residue (ASR). Results from two full-scale combustion experiments, carried out on large ASR feeding lots (thousands of tons) indicate the proposed technology as a potential route to help the fulfilling of impending 95% reuse and recovery target set by the End of life Vehicle (ELV) Directive (January 2015). The paper describes the main operational troubleshot occurred during the first experiment (emissions at the stack out of regulatory limits and problems of clogging on the conveyer belt) and the consequent upgrading solutions (pre-treatment, introduction of waste double low-flow screw feeder and a cyclone prior to the main fan, modification of rotatory kiln inlet) adopted to allow, during the second long-term experiment, a continuous basis operation of the plant in full compliance with the discharge limit to the atmosphere. Characterization of both ASR and combustion residues allowed to quantify a 18% of combustion residues as not dangerous waste while only the 2% as hazardous one. A pre-treatment for the reduction of fines in the ASR was recommended in order to achieve the required energy recovery efficiency.     

On the ASR and ASR thermal residues characterization of full scale treatment plant

In order to obtain 85% recycling, several procedures on Automotive Shredder Residue (ASR) could be implemented, such as advanced metal and polymer recovery, mechanical recycling, pyrolysis, the direct use of ASR in the cement industry, and/or the direct use of ASR as a secondary raw material. However, many of these recovery options appear to be limited, due to the possible low acceptability of ASR based products on the market. The recovery of bottom ash and slag after an ASR thermal treatment is an option that is not usually considered in most countries (e.g. Italy) due to the excessive amount of contaminants, especially metals. The purpose of this paper is to provide information on the characteristics of ASR and its full-scale incineration residues. Experiments have been carried out, in two different experimental campaigns, in a full-scale tyre incineration plant specifically modified to treat ASR waste.Detailed analysis of ASR samples and combustion residues were carried out and compared with literature data. On the basis of the analytical results, the slag and bottom ash from the combustion process have been classified as non-hazardous wastes, according to the EU waste acceptance criteria (WAC), and therefore after further tests could be used in future in the construction industry. It has also been concluded that ASR bottom ash (EWC – European Waste Catalogue – code 19 01 12) could be landfilled in SNRHW (stabilized non-reactive hazardous waste) cells or used as raw material for road construction, with or without further treatment for the removal of heavy metals. In the case of fly ash from boiler or Air Pollution Control (APC) residues, it has been found that the Cd, Pb and Zn concentrations exceeded regulatory leaching test limits therefore their removal, or a stabilization process, would be essential prior to landfilling the use of these residues as construction material.     

Automotive shredder residue (ASR) characterization for a valuable management

Car fluff is the waste produced after end-of-life-vehicles (ELVs) shredding and metal recovery. It is made of plastics, rubber, glass, textiles and residual metals and it accounts for almost one-third of a vehicle mass. Due to the approaching of Directive 2000/53/EC recycling targets, 85% recycling rate and 95% recovery rate in 2015, the implementation of automotive shredder residue (ASR) sorting and recycling technologies appears strategic. The present work deals with the characterization of the shredder residue coming from an industrial plant, representative of the Italian situation, as for annual fluxes and technologies involved. The aim of this study is to characterize ASR in order to study and develop a cost effective and environmentally sustainable recycling system. Results show that almost half of the residue is made of fines and the remaining part is mainly composed of polymers. Fine fraction is the most contaminated by mineral oils and heavy metals. This fraction produces also up to 40% ashes and its LHV is lower than the plastic-rich one. Foam rubber represents around half of the polymers share in car fluff. Moreover, some chemical–physical parameters exceed the limits of some parameters fixed by law to be considered refuse derived fuel (RDF). As a consequence, ASR needs to be pre-treated in order to follow the energy recovery route.     

Life-cycle-assessment of the historical development of air pollution control and energy recovery in waste incineration

Incineration of municipal solid waste is a debated waste management technology. In some countries it is the main waste management option whereas in other countries it has been disregarded. The main discussion point on waste incineration is the release of air emissions from the combustion of the waste, but also the energy recovery efficiency has a large importance.The historical development of air pollution control in waste incineration was studied through life-cycle-assessment modelling of eight different air pollution control technologies. The results showed a drastic reduction in the release of air emissions and consequently a significant reduction in the potential environmental impacts of waste incineration. Improvements of a factor 0.85–174 were obtained in the different impact potentials as technology developed from no emission control at all, to the best available emission control technologies of today (2010).The importance of efficient energy recovery was studied through seven different combinations of heat and electricity recovery, which were modelled to substitute energy produced from either coal or natural gas. The best air pollution control technology was used at the incinerator. It was found that when substituting coal based energy production total net savings were obtained in both the standard and toxic impact categories. However, if the substituted energy production was based on natural gas, only the most efficient recovery options yielded net savings with respect to the standard impacts. With regards to the toxic impact categories, emissions from the waste incineration process were always larger than those from the avoided energy production based on natural gas. The results shows that the potential environmental impacts from air emissions have decreased drastically during the last 35 years and that these impacts can be partly or fully offset by recovering energy which otherwise should have been produced from fossil fuels like coal or natural gas.     

Processing plastics from ASR/ESR waste: separation of poly vinyl chloride (PVC) by froth flotation after microwave-assisted surface modification

The feasibility of the selective surface hydrophilization of poly vinyl chloride (PVC) using microwave treatment to facilitate the separation of PVC via froth flotation from automobile shredder residue (ASR) and electronic waste shredder residue (ESR) was evaluated. In the presence of powder-activated carbon (PAC), 60-s microwave treatment selectively enhanced the hydrophilicity of the PVC surface (i.e., the PVC contact angle decreased from 86.8° to 69.9°). The scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS) results are consistent with increased hydrophilic functional groups (i.e., ether, hydroxyl, and carboxyl), amounting to significant changes in the morphology and roughness of the PVC surface after treatment. After only 60 s of microwave treatment, 20 % of the PVC was separated in virgin and ASR/ESR plastics with 33 and 29 % purity, respectively, as settled fractions by froth flotation at a 150 rpm mixing speed. The microwave treatment with the addition of PAC had a synergetic effect with the froth flotation, which brought about 100 and 90 % selective separation of PVC from the other virgin and ASR/ESR plastics, with 91 and 82 % purity. The use of the combined froth flotation and microwave treatments is an effective technology for separating PVC from hazardous waste plastics.     

End-of-life vehicle recycling and automobile shredder residue management in Japan

The Japanese Government introduced the Law on Recycling of End-of-Life Vehicles (ELV Recycling Law) in 2002. This law requires manufacturers to retrieve chlorofluorocarbons (CFCs), airbags, and automobile shredder residue (ASR) from ELVs and to properly recycle the remaining materials. This framework is compared with European ELV directives. Pilot-scale incineration plant testing has revealed a greater formation of by-product persistent organic pollutants (POPs) during the primary combustion of ASR compared to normal municipal solid waste. This may be attributed to the abundance of chlorine, Cu, and Fe in ASR, as Cu and Fe have been found to catalyze the formation of POPs under certain conditions. However, most by-product POPs were destroyed by the secondary combustion, and almost all were removed after flue gas treatment. The direct melting system is a shaft-type gasification and melting technology that has proved effective in many municipal solid waste applications. This system can be applied to ASR recycling for effective decomposition of brominated flame retardants and polybrominated dioxins.     

Recycling plastics from automotive shredder residues: a review

Automotive shredder residue (ASR) is an inevitable by-product of car recycling, i.e. removal of all liquids and hazardous or valuable components from the car and shredding of the hulk, followed by the recovery of steel, iron, and non-ferrous scrap. The European Union (EU) ELV Directive requires attaining higher recovery and recycling rates, resulting in a reduction of the amount of ASR going to landfill. The most plausible methods to achieve a considerable reduction of ASR are as follows: either recycling of separated materials and dismantled bulky parts, such as bumpers, dashboards, cushions, and front and rear windows, or else systematic sorting of the commingled and size-reduced materials, resulting from shredding. After a brief comparison of the actual situation in the EU, the USA, and Japan, the characteristics of actual ASR are reviewed, as well as some of the most prominent efforts made to separate and recycle specific fractions, such as polyolefins, ABS, or polyurethane. Attention is paid to some major players in the EU and to some of the pitfalls that besiege these ventures.     

Energy recovery from sewage sludge by means of fluidised bed gasification

Because of its potential harmful impact on the environment, disposal of sewage sludge is becoming a major problem all over the world. Today the available disposal measures are at the crossroads. One alternative would be to continue its usage as fertiliser or to abandon it. Due to the discussions about soil contamination caused by sewage sludge, some countries have already prohibited its application in agriculture. In these countries, thermal treatment is now presenting the most common alternative. This report describes two suitable methods to directly convert sewage sludge into useful energy on-site at the wastewater treatment plant. Both processes consist mainly of four devices: dewatering and drying of the sewage sludge, gasification by means of fluidised bed technology (followed by a gas cleaning step) and production of useful energy via CHP units as the final step. The process described first (ETVS-Process) is using a high pressure technique for the initial dewatering and a fluidised bed technology utilising waste heat from the overall process for drying. In the second process (NTVS-Process) in addition to the waste heat, solar radiation is utilised. The subsequent measures--gasification, gas cleaning and electric and thermal power generation--are identical in both processes. The ETVS-Process and the NTVS-Process are self-sustaining in terms of energy use; actually a surplus of heat and electricity is generated in both processes.     

Analysis of energy recovery potential using innovative technologies of waste gasification

In this paper, two alternative thermo-chemical processes for waste treatment were analysed: high temperature gasification and gasification associated to plasma process. The two processes were analysed from the thermodynamic point of view, trying to reconstruct two simplified models, using appropriate simulation tools and some support data from existing/planned plants, able to predict the energy recovery performances by process application. In order to carry out a comparative analysis, the same waste stream input was considered as input to the two models and the generated results were compared. The performances were compared with those that can be obtained from conventional combustion with energy recovery process by means of steam turbine cycle. Results are reported in terms of energy recovery performance indicators as overall energy efficiency, specific energy production per unit of mass of entering waste, primary energy source savings, specific carbon dioxide production.     

Energy from gasification of solid wastes

Gasification technology is by no means new: in the 1850s, most of the city of London was illuminated by "town gas" produced from the gasification of coal. Nowadays, gasification is the main technology for biomass conversion to energy and an attractive alternative for the thermal treatment of solid waste. The number of different uses of gas shows the flexibility of gasification and therefore allows it to be integrated with several industrial processes, as well as power generation systems. The use of a waste-biomass energy production system in a rural community is very interesting too. This paper describes the current state of gasification technology, energy recovery systems, pre-treatments and prospective in syngas use with particular attention to the different process cycles and environmental impacts of solid wastes gasification.     

Environmental burdens in the management of end-of-life cathode ray tubes

We compared the environmental burdens in the management of end-of life cathode ray tubes (CRTs) within two frameworks according to the different technologies of the production of televisions/monitors. In the first case, CRT recycling is addressed to the recovery of the panel and funnel glass for the manufacturing of new CRT screens. In the second case, where flat screen technology has replaced that of CRT, the recycling is addressed to the recovery of the glass cullet and lead for other applications. The impacts were evaluated according to the problem-oriented methodology of the Institute of Environmental Sciences, Leiden University, Leiden, The Netherlands. Our data confirm that in both cases, the recycling treatment allows benefits to be gained for the environment through the recovery of the secondary raw materials. These benefits are higher for the “CRT technology” framework (1 kg CO₂ saved per CRT) than for the “flat screen technology” (0.9 kg CO₂ saved, per CRT, as the highest possible), mainly due to the high energy consumption for lead separation from the funnel glass. Furthermore, the recovery of yttrium from the fluorescent powders that are a residue of the recycling treatment would further improve the CO₂ credit for both the frameworks considered, which would provide a further saving of about 0.75 kg CO₂ per CRT, net of the energy and raw materials needed for the recovery.Overall, this study confirms that, even with a change in the destination of the recovered materials, the recycling processes provide a benefit for the environment: indeed the higher loads for the environment are balanced by avoiding the primary production of the recovered materials.     

Automobile Shredder Residues in Italy: characterization and valorization opportunities

At the moment Automobile Shredder Residue (ASR) is usually landfilled worldwide, but European draft Directive 2000/53/CE forces the development of alternative solutions, stating the 95%-wt recovery of an End of Life Vehicle (ELV) weight to be fulfilled by 2015. This work describes two industrial tests, each involving 250-300 t of ELVs, in which different pre-shredding operations were performed. The produced ASR materials underwent an extended characterization and some post-shredding processes, consisting of dimensional, magnetic, electrostatic and densimetric separation phases, were tested on laboratory scale, having as main purpose the enhancement of ASR recovery/recycling and the minimization of the landfilled fraction. The gathered results show that accurate depollution and dismantling operations are mandatory to obtain a high quality ASR material which may be recycled/recovered and partially landfilled according to the actual European Union regulations, with particular concern for Lower Heating Value (LHV), heavy metals content and Dissolved Organic Carbon (DOC) as critical parameters. Moreover post-shredding technical solutions foreseeing minimum economic and engineering efforts, therefore realizable in common European ELVs shredding plants, may lead to multi-purposed (material recovery and thermal valorization) opportunities for ASR reuse/recovery.     

Optimal utilization of waste-to-energy in an LCA perspective

Energy production from two types of municipal solid waste was evaluated using life cycle assessment (LCA): (1) mixed high calorific waste suitable for production of solid recovered fuels (SRF) and (2) source separated organic waste. For SRF, co-combustion was compared with mass burn incineration. For organic waste, anaerobic digestion (AD) was compared with mass burn incineration. In the case of mass burn incineration, incineration with and without energy recovery was modelled. Biogas produced from anaerobic digestion was evaluated for use both as transportation fuel and for heat and power production. All relevant consequences for energy and resource consumptions, emissions to air, water and soil, upstream processes and downstream processes were included in the LCA. Energy substitutions were considered with respect to two different energy systems: a present-day Danish system based on fossil fuels and a potential future system based on 100% renewable energy. It was found that mass burn incineration of SRF with energy recovery provided savings in all impact categories, but co-combustion was better with respect to Global Warming (GW). If all heat from incineration could be utilized, however, the two alternatives were comparable for SRF. For organic waste, mass burn incineration with energy recovery was preferable over anaerobic digestion in most impact categories. Waste composition and flue gas cleaning at co-combustion plants were critical for the environmental performance of SRF treatment, while the impacts related to utilization of the digestate were significant for the outcome of organic waste treatment. The conclusions were robust in a present-day as well as in a future energy system. This indicated that mass burn incineration with efficient energy recovery is a very environmentally competitive solution overall.     

Cogeneration from thermal treatment of selected municipal solid wastes. A stoichiometric model building for the case study on Palermo

This paper aims to calculate the energetic and environmental effects of an integrated solid waste management system in Palermo, Italy. In particular, the thermal treatment of Municipal Solid Waste (MSW) with energy recovery is assessed. The current characterization at the local scale is taken into account. Two different options of collection are taken into account: (1) unselected wastes; and (2) sorted collection, according to the current Italian regulation. Combustion process is analyzed and the following features are calculated: (1) stoichiometric content of air and air excess; and (2) temperature and enthalpy of flue gases. Energy recovery is performed in the hypothesis of Hirn cycle both with steam condensation to produce only power, and with bleeding cycle for the combined production of power and thermal energy. Total electric efficiency is assumed as representative index of the technological level of the assessed plant. Results show that the thermal treatment of selected MSW, associated with a cogenerative recovery of energy, represents a relevant sustainable strategy of waste valorization as an alternative to fossil fuels.     

Driving forces for import of waste for energy recovery in Sweden.

Between 1996 and 2002, the Swedish import of so-called yellow waste for energy recovery increased. The import mainly consisted of separated wood waste and mixes of used wood and paper and/or plastics that was combusted in district heat production plants (DHPPs). Some mixed waste was imported to waste incineration plants for energy recovery (10% of the import of yellow waste for energy recovery in 2002). The import came primarily from Germany, the Netherlands, Norway, Denmark and Finland. We identified six underlying driving forces for this recent increase of imported waste which are outlined and their interactive issues discussed. --The energy system infrastructure, which enables high energy recovery in Sweden. --The energy taxation, where high Swedish taxes on fossil fuels make relatively expensive solid biofuels the main alternative for base load production of district heat. --The quality of the waste-derived fuels, which has been higher in the exporting countries than in Sweden. --The bans on landfilling within Europe and the shortage of waste treatment capacity. --Taxes on waste management in Europe. --Gate fee differences between exporting countries and Sweden. In the future, the overall strength of these driving forces will probably be weakened. A Swedish tax on waste incineration is being investigated. In other European countries, the ambition to reach the Kyoto targets and increase the renewable electricity production could improve the competitiveness of waste-derived fuels in comparison with fossil fuels. Swedish DHPPs using waste-derived fuels will experience higher costs after the Waste Incineration Directive is fully implemented. The uncertainty about European waste generation and treatment capacity, however, might have a large influence on the future gate fees and thus also on the yellow waste import into Sweden.     

Proposal of an environmental performance index to assess solid waste treatment technologies

Although the concern with sustainable development and environment protection has considerably grown in the last years it is noted that the majority of decision making models and tools are still either excessively tied to economic aspects or geared to the production process. Moreover, existing models focus on the priority steps of solid waste management, beyond waste energy recovery and disposal. So, in order to help the lack of models and tools aiming at the waste treatment and final disposal, a new concept is proposed: the Cleaner Treatment, which is based on the Cleaner Production principles. This paper focuses on the development and validation of the Cleaner Treatment Index (CTI), to assess environmental performance of waste treatment technologies based on the Cleaner Treatment concept. The index is formed by aggregation (summation or product) of several indicators that consists in operational parameters. The weights of the indicator were established by Delphi Method and Brazilian Environmental Laws. In addition, sensitivity analyses were carried out comparing both aggregation methods. Finally, index validation was carried out by applying the CTI to 10 waste-to-energy plants data. From sensitivity analysis and validation results it is possible to infer that summation model is the most suitable aggregation method. For summation method, CTI results were superior to 0.5 (in a scale from 0 to 1) for most facilities evaluated. So, this study demonstrates that CTI is a simple and robust tool to assess and compare the environmental performance of different treatment plants being an excellent quantitative tool to support Cleaner Treatment implementation.     

LCA of local strategies for energy recovery from waste in England, applied to a large municipal flow

An intense waste management (WM) planning activity is currently undergoing in England to build the infrastructure necessary to treat residual wastes, increase recycling levels and the recovery of energy from waste. From the analyses of local WM strategic and planning documents we have identified the emerging of three different energy recovery strategies: established combustion of residual waste; pre-treatment of residual waste and energy recovery from Solid Recovered Fuel in a dedicated plant, usually assumed to be a gasifier; pre-treatment of residual waste and reliance on the market to accept the ‘fuel from waste’ so produced. Each energy recovery strategy will result in a different solution in terms of the technology selected; moreover, on the basis of the favoured solution, the total number, scale and location of thermal treatment plants built in England will dramatically change. To support the evaluation and comparison of these three WM strategy in terms of global environmental impacts, energy recovery possibilities and performance with respect to changing ‘fuel from waste’ market conditions, the LCA comparison of eight alternative WM scenarios for a real case study dealing with a large flow of municipal wastes was performed with the modelling tool WRATE. The large flow of waste modelled allowed to formulate and assess realistic alternative WM scenarios and to design infrastructural systems which are likely to correspond to those submitted for approval to the local authorities. The results show that all alternative scenarios contribute to saving abiotic resources and reducing global warming potential. Particularly relevant to the current English debate, the performance of a scenario was shown to depend not from the thermal treatment technology but from a combination of parameters, among which most relevant are the efficiency of energy recovery processes (both electricity and heat) and the calorific value of residual waste and pre-treated material. The contribution and relative importance of recycling and treatment/recovery processes change with the impact category. The lack of reprocessing plants in the area of the case study has shown the relevance of transport distances for recyclate material in reducing the efficiency of a WM system. Highly relevant to the current English WM infrastructural debate, these results for the first time highlight the risk of a significant reduction in the energy that could be recovered by local WM strategies relying only on the market to dispose of the ‘fuel from waste’ in a non dedicated plant in the case that the SRF had to be sent to landfill for lack of treatment capacity.     

Energy implications of mechanical and mechanical–biological treatment compared to direct waste-to-energy

Primary energy savings potential is used to compare five residual municipal solid waste treatment systems, including configurations with mechanical (MT) and mechanical–biological (MBT) pre-treatment, which produce waste-derived fuels (RDF and SRF), biogas and/or recover additional materials for recycling, alongside a system based on conventional mass burn waste-to-energy and ash treatment. To examine the magnitude of potential savings we consider two energy efficiency levels (state-of-the-art and best available technology), the inclusion/exclusion of heat recovery (CHP vs. PP) and three different background end-use energy production systems (coal condensing electricity and natural gas heat, Nordic electricity mix and natural gas heat, and coal CHP energy quality allocation).The systems achieved net primary energy savings in a range between 34 and 140 MJ_primary/100 MJ_{input waste}, in the different scenario settings. The energy footprint of transportation needs, pre-treatment and reprocessing of recyclable materials was 3–9.5%, 1–18% and 1–8% respectively, relative to total energy savings. Mass combustion WtE achieved the highest savings in scenarios with CHP production, nonetheless, MBT-based systems had similarly high performance if SRF streams were co-combusted with coal. When RDF and SRF was only used in dedicated WtE plants, MBT-based systems totalled lower savings due to inherent system losses and additional energy costs. In scenarios without heat recovery, the biodrying MBS-based system achieved the highest savings, on the condition of SRF co-combustion. As a sensitivity scenario, alternative utilisation of SRF in cement kilns was modelled. It supported similar or higher net savings for all pre-treatment systems compared to mass combustion WtE, except when WtE CHP was possible in the first two background energy scenarios. Recovery of plastics for recycling before energy recovery increased net energy savings in most scenario variations, over those of full stream combustion. Sensitivity to assumptions regarding virgin plastic substitution was tested and was found to mostly favour plastic recovery.