Mass,energy and material balances of SRF production process. Part 1: SRF produced from commercial and industrial waste

This paper presents the mass, energy and material balances of a solid recovered fuel (SRF) production process. The SRF is produced from commercial and industrial waste (C&IW) through mechanical treatment (MT). In this work various streams of material produced in SRF production process are analyzed for their proximate and ultimate analysis. Based on this analysis and composition of process streams their mass, energy and material balances are established for SRF production process. Here mass balance describes the overall mass flow of input waste material in the various output streams, whereas material balance describes the mass flow of components of input waste stream (such as paper and cardboard, wood, plastic (soft), plastic (hard), textile and rubber) in the various output streams of SRF production process. A commercial scale experimental campaign was conducted on an MT waste sorting plant to produce SRF from C&IW. All the process streams (input and output) produced in this MT plant were sampled and treated according to the CEN standard methods for SRF: EN 15442, EN 15443. The results from the mass balance of SRF production process showed that of the total input C&IW material to MT waste sorting plant, 62% was recovered in the form of SRF, 4% as ferrous metal, 1% as non-ferrous metal and 21% was sorted out as reject material, 11.6% as fine fraction, and 0.4% as heavy fraction. The energy flow balance in various process streams of this SRF production process showed that of the total input energy content of C&IW to MT plant, 75% energy was recovered in the form of SRF, 20% belonged to the reject material stream and rest 5% belonged with the streams of fine fraction and heavy fraction. In the material balances, mass fractions of plastic (soft), plastic (hard), paper and cardboard and wood recovered in the SRF stream were 88%, 70%, 72% and 60% respectively of their input masses to MT plant. A high mass fraction of plastic (PVC), rubber material and non-combustibles (such as stone/rock and glass particles), was found in the reject material stream.     

Investigations on mechanical biological treatment of waste in South America: towards more sustainable MSW management strategies

This work presents an analysis on the suitability of mechanical biological treatment of municipal solid waste in South America, based on two previous experimental investigations carried out in two different countries. The first experiment was performed for determining the mass and volume reduction of MSW in the province of Concepción (Chile). The implemented bench-scale process consisted of a manual classification and separation stage, followed by an in-vessel biological degradation process. The second experiment consisted of a full-scale experiment performed in the city of Estrela (Brazil), where the existing municipal waste management facility was adapted to enhance the materials sorting and separation. Expressed in wet weight composition, 85.5% of the material input in the first experiment was separated for biological degradation. After 27 days of processing, 60% of the initial mass was reduced through degradation and water evaporation. The final fraction destined for landfilling equals 59% of the total input mass, corresponding to about 50% of the initial volume. In the second experiment, the fraction destined to landfill reaches 46.6% of the total input waste mass, whilst also significantly reducing the total volume to be disposed. These results, and the possible recovery of material streams suitable for recycling or for preparing solid recovered fuels, are the main advantages of the studied process.     

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.     

Mineral wool waste in Europe: a review of mineral wool waste quantity,quality, and current recycling methods

The construction and demolition (C&D) industry has been identified as a major source of waste. European Union legislation states that, by 2020, 70 % of C&D waste must be prepared for reuse, recycled or recovered. European Union member states must increase their C&D waste recycling percentages in order to meet this binding target. Utilization of mineral wool waste, often considered unrecyclable, could improve the recycling percentage of C&D waste. In this article, mineral wool production and waste volumes are estimated based on information from the Eurostat database. A literature survey is conducted to collect information about mineral wool material properties, current recycling methods, and barriers to recycling of mineral wool, and suitable methods for separating mineral wool from C&D waste streams and the economic viability of mineral wool recycling are discussed. It is noted that accurate estimation of mineral wool waste volumes is problematic due to the fragmented nature of available data. Based on the literature review, current methods for recycling mineral wool waste include utilization of mineral wool waste as a raw material in various products. Barriers to recycling include economic questions and issues related to the purity and health effects of mineral wool waste. Material properties of mineral wool waste, such as fire resistance, could provide improved properties in products utilizing mineral wool waste as a raw material.     

Comparison of coal/solid recovered fuel (SRF) with coal/refuse derived fuel (RDF) in a fluidized bed reactor

An experimental study was undertaken to compare the differences between municipal solid waste (MSW) derived solid recovered fuel (SRF) (complying with CEN standards) and refuse derived fuel (RDF). Both fuels were co-combusted with coal in a 50 kW fluidised bed combustor and the metal emissions were compared. Synthetic SRF was prepared in the laboratory by grinding major constituents of MSW such as paper, plastic, textile and wood. RDF was obtained from a local mechanical treatment plant. Heavy metal emissions in flue gas and ash samples from the (coal + 10% SRF) fuel mixture were found to be within the acceptable range and were generally lower than that obtained for coal + 10% RDF fuel mixture. The relative distribution of heavy metals in ash components and the flue gas stream shows the presence of a large fraction (up to 98%) of most of the metals in the ash (except Hg and As). Thermo-gravimetric (TG) analysis of SRF constituents was performed to understand the behaviour of fuel mixtures in the absence and presence of air. The results obtained from the experimental study will enhance the confidence of fuel users towards using MSW-derived SRF as an alternative fuel.     

Closed cycle construction: an integrated process for the separation and reuse of C&D waste

In The Netherlands, construction and demolition (C&D) waste is already to a large extent being reused, especially the stony fraction, which is crushed and reused as a road base material. In order to increase the percentage of reuse of the total C&D waste flow to even higher levels, a new concept has been developed. In this concept, called 'Closed Cycle Construction', the processed materials are being reused at a higher quality level and the quantity of waste that has to be disposed of is minimised. For concrete and masonry, the new concept implies that the material cycle will be completely closed, and the original constituents (clay bricks, gravel, sand, cement stone) are recovered in thermal processes. The mixed C&D waste streams are separated and decontaminated. For this purpose several dry separation techniques are being developed. The quality of the stony fraction is improved so much, that this fraction can be reused as an aggregate in concrete. The new concept has several benefits from a sustainability point of view, namely less energy consumption, less carbon dioxide emission, less waste production and less land use (for excavation and disposal sites). One of the most remarkable benefits of the new concept is that the thermal process steps are fuelled with the combustible fraction of the C&D waste itself. Economically the new process is more or less comparable with the current way of processing C&D waste. On the basis of the positive results of a feasibility study, currently a pilot and demonstration project is being carried out. The aim is to optimise the different process steps of the Closed Cycle Construction process on a laboratory scale, and then to verify them on a large scale. The results of the project are promising, so far.     

Sample preparation and biomass determination of SRF model mixture using cryogenic milling and the adapted balance method

The biogenic fraction of a simple solid recovered fuel (SRF) mixture (80 wt% printer paper/20 wt% high density polyethylene) is analyzed with the in-house developed adapted balance method (aBM). This fairly new approach is a combination of combustion elemental analysis (CHNS) and a data reconciliation algorithm based on successive linearisation for evaluation of the analysis results. This method shows a great potential as an alternative way to determine the biomass content in SRF. However, the employed analytical technique (CHNS elemental analysis) restricts the probed sample mass to low amounts in the range of a few hundred milligrams. This requires sample comminution to small grain sizes (<200 μm) to generate representative SRF specimen. This is not easily accomplished for certain material mixtures (e.g. SRF with rubber content) by conventional means of sample size reduction.This paper presents a proof of principle investigation of the sample preparation and analysis of an SRF model mixture with the use of cryogenic impact milling (final sample comminution) and the adapted balance method (determination of biomass content). The so derived sample preparation methodology (cutting mills and cryogenic impact milling) shows a better performance in accuracy and precision for the determination of the biomass content than one solely based on cutting mills. The results for the determination of the biogenic fraction are within 1–5% of the data obtained by the reference methods, selective dissolution method (SDM) and ¹⁴C-method (¹⁴C-M).     

Estimating construction and demolition debris generation using a materials flow analysis approach

The magnitude and composition of a region’s construction and demolition (C&D) debris should be understood when developing rules, policies and strategies for managing this segment of the solid waste stream. In the US, several national estimates have been conducted using a weight-per-construction-area approximation; national estimates using alternative procedures such as those used for other segments of the solid waste stream have not been reported for C&D debris. This paper presents an evaluation of a materials flow analysis (MFA) approach for estimating C&D debris generation and composition for a large region (the US). The consumption of construction materials in the US and typical waste factors used for construction materials purchasing were used to estimate the mass of solid waste generated as a result of construction activities. Debris from demolition activities was predicted from various historical construction materials consumption data and estimates of average service lives of the materials. The MFA approach estimated that approximately 610–780 × 10⁶ Mg of C&D debris was generated in 2002. This predicted mass exceeds previous estimates using other C&D debris predictive methodologies and reflects the large waste stream that exists.     

Pyrolysis of municipal plastic wastes II: Influence of raw material composition under catalytic conditions

In this work, the results obtained in catalytic pyrolysis of three plastic waste streams which are the rejects of an industrial packing wastes sorting plant are presented. The samples have been pyrolysed in a 3.5 dm(3) reactor under semi-batch conditions at 440 °C for 30 min in nitrogen atmosphere. Commercial ZSM-5 zeolite has been used as catalyst in liquid phase contact. In every case, high HHV gases and liquids which can be useful as fuels or source of chemicals are obtained. A solid fraction composed of the inorganic material contained in the raw materials and some char formed in the pyrolysis process is also obtained. The zeolite has shown to be very effective to produce liquids with great aromatics content and C3-C4 fraction rich gases, even though the raw material was mainly composed of polyolefins. The characteristics of the pyrolysis products as well as the effect of the catalyst vary depending on the composition of the raw material. When paper rich samples are pyrolysed, ZSM-5 zeolite increases water production and reduces CO and CO(2) generation. If stepwise pyrolysis is applied to such sample, the aqueous liquid phase can be separated from the organic liquid fraction in a first low temperature step.     

Chemical composition of material fractions in Danish household waste

The chemical composition of Danish household waste was determined by two approaches: a direct method where the chemical composition (61 substances) of 48 material fractions was determined after hand sorting of about 20 tonnes of waste collected from 2200 households; and an indirect method where batches of 80–1200 tonnes of unsorted household waste was incinerated and the content of the waste determined from the content of the outputs from the incinerator. The indirect method is believed to better represent the small but highly contaminated material fractions (e.g., batteries) than the direct method, because of the larger quantities included and the more homogenous material to sample from. Differences between the direct and the direct methods led to corrections in the of heavy metal concentration of a few fractions.The majority of the energy content of the waste originates from organic waste like paper, cardboard and organic fractions. The single fraction contributing most to the total energy content is the non-recyclable plastic fraction, contributing 21% of the energy content and 60% of the chlorine content, although this fraction comprises less than 7% by weight. Heavy metals originate mainly from inert fractions, primarily batteries.     

Effects of pre-treatment technologies on quantity and quality of source-sorted municipal organic waste for biogas recovery

Source-sorted municipal organic waste collected from different dwelling types in five Danish cities and pre-treated at three different plants was sampled and characterized several times during one year to investigate the origin of any differences in composition of the pre-treated waste introduced by city, pre-treatment technology, dwelling type or annual season. The investigated pre-treatment technologies were screw press, disc screen and shredder+magnet. The average quantity of pre-treated organic waste (biomass) produced from the incoming waste varied between the investigated pre-treatment technologies: 59%, 66% and 98% wet weight, respectively (41%, 34% and 2% reject, respectively). The pre-treatment technologies showed differences with respect to distribution of the chemical components in the waste between the biomass and the rejected material (reject), especially for dry matter, ash, collection bag material (plastic or paper) and easily degradable organic matter. Furthermore, the particle size of the biomass was related to the pre-treatment technology. The content of plastic in the biomass depended both on the actual collection bag material used in the system and the pre-treatment technology. The sampled reject consisted mostly of organic matter. For cities using plastic bags for the source-separated organic waste, the expected content of plastic in the reject was up to 10% wet weight (in some cases up to 20%). Batch tests for methane potential of the biomass samples showed only minor variations caused by the factors city, pre-treatment technology, dwelling type and season when based on the VS content of the waste (overall average 459STPm(3)/tVS). The amount of methane generated from 1t of collected waste was therefore mainly determined by the efficiency of the chosen pre-treatment technology described by the mass distribution of the incoming waste between biomass and reject.     

Production patterns of packaging waste categories generated at typical Mediterranean residential building worksites

The construction sector is responsible for around 28% of the total waste volume generated in Europe, which exceeds the amount of household waste. This has led to an increase of different research studies focusing on construction waste quantification. However, within the research studies made, packaging waste has been analyzed to a limited extent. This article focuses on the packaging waste stream generated in the construction sector. To this purpose current on-site waste packaging management has been assessed by monitoring ten Mediterranean residential building works. The findings of the experimental data collection revealed that the incentive measures implemented by the construction company to improve on-site waste sorting failed to achieve the intended purpose, showing low segregation ratios. Subsequently, through an analytical study the generation patterns for packaging waste are established, leading to the identification of the prevailing kinds of packaging and the products responsible for their generation. Results indicate that plastic waste generation maintains a constant trend throughout the whole construction process, while cardboard becomes predominant towards the end of the construction works with switches and sockets from the electricity stage. Understanding the production patterns of packaging waste will be beneficial for adapting waste management strategies to the identified patterns for the specific nature of packaging waste within the context of construction worksites.     

Characterization of household waste in Greenland

The composition of household waste in Greenland was investigated for the first time. About 2 tonnes of household waste was sampled as every 7th bag collected during 1 week along the scheduled collection routes in Sisimiut, the second largest town in Greenland with about 5400 inhabitants. The collection bags were sorted manually into 10 material fractions. The household waste composition consisted primarily of biowaste (43%) and the combustible fraction (30%), including anything combustible that did not belong to other clean fractions as paper, cardboard and plastic. Paper (8%) (dominated by magazine type paper) and glass (7%) were other important material fractions of the household waste. The remaining approximately 10% constituted of steel (1.5%), aluminum (0.5%), plastic (2.4%), wood (1.0%), non-combustible waste (1.8%) and household hazardous waste (1.2%). The high content of biowaste and the low content of paper make Greenlandic waste much different from Danish household waste. The moisture content, calorific value and chemical composition (55 elements, of which 22 were below detection limits) were determined for each material fraction. These characteristics were similar to what has been found for material fractions in Danish household waste. The chemical composition and the calorific value of the plastic fraction revealed that this fraction was not clean but contained a lot of biowaste. The established waste composition is useful in assessing alternative waste management schemes for household waste in Greenland.     

A holistic life cycle analysis of waste management scenarios at increasing source segregation intensity: The case of an Italian urban area

Life cycle analysis of several waste management scenarios for an Italian urban area was performed on the basis of different source segregation collection (SS) intensities from 0% up to 52%. Source segregated waste was recycled and or/recovered by composting. Residual waste management options were by landfilling, incineration with energy recovery or solid recovered fuel (SRF) production to substitute for coal. The increase in fuel and materials consumption due to increase in SS had negligible influence on the environmental impact of the system. Recycling operations such as incineration and SRF were always advantageous for impact reduction. There was lower impact for an SS of 52% even though the difference with the SS intensity of 35% was quite limited, about 15%. In all the configurations analyzed, the best environmental performance was achieved for the management system producing SRF by the biodrying process.     

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.     

Preliminary study for the management of construction and demolition waste

This paper refers to the management of the construction and demolition (C&D) waste since, according to the EU Waste Strategy, C&D waste is considered to be one of the priority waste streams and appropriate actions need to be taken with respect to its effective management. Initially, the paper presents the state-of-the-art of the problem of C&D waste, including the amount and composition of C&D waste in EU countries, differences in the characteristics of this waste stream depending on its origin, as well as collection and management practices that are applied. A methodology is described for the estimation of the quantities of the waste stream under examination, since in most cases quantitative primary data is not available. Next, the fundamentals for the development of an integrated scheme for the management of C&D waste are presented and discussed, such as appropriate demolition procedures and location of waste management (off-site waste management, on-site waste management, direct on-site recovery, centralized on-site recovery). Finally, taking into consideration all relevant parameters, alternative systems that could be applied for the management of the C&D waste are suggested.     

An empirical investigation of construction and demolition waste generation rates in Shenzhen city, South China

The construction and demolition waste generation rates (C&D WGRs) is an important factor in decision-making and management of material waste in any construction site. The present study investigated WGRs by conducting on-site waste sorting and weighing in four ongoing construction projects in Shenzhen city of South China. The results revealed that WGRs ranged from 3.275 to 8.791 kg/m² and miscellaneous waste, timber for formwork and falsework, and concrete were the three largest components amongst the generated waste. Based on the WGRs derived from the research, the paper also discussed the main causes of waste in the construction industry and attempted to connect waste generation with specific construction practices. It was recommended that measures mainly including performing waste sorting at source, employing skilful workers, uploading and storing materials properly, promoting waste management capacity, replacing current timber formwork with metal formwork and launching an incentive reward program to encourage waste reduction could be potential solutions to reducing current WGRs in Shenzhen. Although these results were derived from a relatively small sample and so cannot justifiably be generalized, they do however add to the body of knowledge that is currently available for understanding the status of the art of C&D waste management in China.     

Evaluation of methods for sorting CCA-treated wood

Construction and demolition (C&D) wood frequently contains treated wood including wood treated with chromated copper arsenate (CCA). Many recycling options for such wood require that the product be essentially free of preservative chemicals. The objectives of this study were to document the characteristics of the wood waste stream and to evaluate the effectiveness of sorting methods for identifying treated wood. Sorting methods evaluated included visual sorting and visual sorting augmented with the use of PAN indicator stain and/or hand-held X-ray fluorescence (XRF) units. Experiments were conducted on two types of construction and demolition (C&D) wood: source separated loads containing only C&D wood and wood hand-picked from commingled loads of general C&D waste. Results showed that 77% of the treated wood was CCA-treated. For uncontaminated piles (<1% treated wood) of source separated C&D wood, visual sorting was found to effectively remove the small amounts of treated wood present. For piles of source separated wood that were contaminated (approximately 50% treated wood), visual sorts were not accurate and benefited from augmented sorting using PAN indicator stain. The handheld XRF devices were found to be effective for sorting commingled C&D wood, as PAN indicator stain was not as effective due to the excessive amount of surface dirt associated with commingled wood waste. Visual sorting of source separated wood was estimated to cost between US$21 to US$96 per metric ton. These costs depended upon the amount of treated wood and whether or not augmentation with PAN indicator was necessary. Visual sorting augmented with hand-held XRF units was estimated at US$113 per metric ton. The bulk of these costs were associated with labor. Future efforts should focus on reducing labor costs by mounting automated XRF units on conveyor systems.     

Performance of a low cost MBT prior to landfilling: study of the biological treatment of size reduced MSW without mechanical sorting

In France, the interest in Mechanical Biological Treatment (MBT) prior to landfilling is actually growing. In the absence of acceptance criteria for the waste to be landfilled, an alternative to the intensive, high-technology MBT can only find its place in the French context if it shows substantial benefits from an environmental, economic or operational point of view. This paper presents an experiment of low-cost MBT of size reduced MSW without material splitting. The performance of an experimental, pilot-scale mechanical and biological treatment process has been studied on 37.5 Mg of raw municipal solid waste. The mechanical process has been kept simple with only coarse shredding and no material recovery. The biological treatment, which was a low-cost forced aeration process, was monitored for 25 weeks. The biogas production potential of the waste was reduced by 90% to 19 NL kgDM(-1). The initial AT4 index of 82.9 mg O2 gDM(-1) decreased to 16.0 mg O2 gDM(-1). After 25 weeks of aerobic treatment, the dry mass loss reached 37%, while the mass of waste going to landfill was reduced by 28%. The average performances of the process were explained by the biological process itself, which was not optimal, and also by the characteristics of the input waste. The high particle size of the treated waste and the high content of slowly biodegradable matter (such as paper and cardboard) may both be significant drawbacks for the biological stabilisation of waste.     

Pyrolysis of plastic packaging waste: A comparison of plastic residuals from material recovery facilities with simulated plastic waste

Pyrolysis may be an alternative for the reclamation of rejected streams of waste from sorting plants where packing and packaging plastic waste is separated and classified. These rejected streams consist of many different materials (e.g., polyethylene (PE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), aluminum, tetra-brik, and film) for which an attempt at complete separation is not technically possible or economically viable, and they are typically sent to landfills or incinerators. For this study, a simulated plastic mixture and a real waste sample from a sorting plant were pyrolyzed using a non-stirred semi-batch reactor. Red mud, a byproduct of the aluminum industry, was used as a catalyst. Despite the fact that the samples had a similar volume of material, there were noteworthy differences in the pyrolysis yields. The real waste sample resulted, after pyrolysis, in higher gas and solid yields and consequently produced less liquid. There were also significant differences noted in the compositions of the compared pyrolysis products.