Shredder Residue Composition and Separation

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Waste Energy Research Group -
Led by Dr. Mari Harder
WERG
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Funded through the Landfill Tax Credit Scheme
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Polymer Processing ASR

• ELV information
• SR Composition
• SR Separation
• SR Polymers for Manufacturing
• Project Deliverables

WERG
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End-of-Life Vehicles (1.8Mt)
Recycling rates (iron/steel) 68-74 by weight
EU Directive proposals 85 by weight by
2006 95 by weight by 2015
1.8 million each year in the UK
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ELV Shredding Operation
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Ambrose 2000
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SHREDDER FRACTIONS
OVERSIZE(gt130mm) (10)
MIDDLE (15130mm (50)
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Shredder Residue (100)
Fines lt15mm
Fraction 15-130mm
Oversized gt130mm
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OVERSIZE Stream (gt130mm)
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Composition of OVERSIZE Stream
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Volume Percentage of OVERSIZE Stream
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Shredder Residue (100)
Fines (405)
Middle Fraction (505)
Oversized (105)
Oversized (105)
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MIDDLE Stream 15130mm
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Shredder Residue (100)
Shredder Residue (100)
Oversized (105)
Fines (405)
Polyolefins 1.3
Other Plastic 0.7
Miscellaneous 0.7
Miscellaneous 9.0
Foam 1.0
Foam 7.0
Metal 2.0
Metal 2.3
Textiles 0.7
Textiles 1.4
Tyre 3.0
Tyre 0.5
Wire 0.6
Wood 3.5
Rubber 6.0
Wire 2.7
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Polymers in Oversize Stream
Floats (1.3 of SR)
Sinks (0.7 of SR)
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Polymers in Middle Stream
Floats (2.5 of SR)
Sinks (13.5 of SR)
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Recovery of Other Materials

• Momentum separation concentrated some materials
• Air Knife concentrate foam away
• Cyclone pull off foam and fines
• Moving tables slotted trommels success will
  depend on size/shape

WERG
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Size Distribution
WERG
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Simple Approach
Isolate a plastics rich fraction
Separate plastics by density
Reprocess the plastic and analyse the properties
Manufacture products using 100 ASR material
WERG
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How do we get there?
Hand-picked SR plastic sample
WERG
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WERG
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What work needs to be done?
Product development
Reproducibility, quantity
Additives and fillers
New standards and specifications?
WERG
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First SR plastic product (!)
WERG
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Project Deliverables
Characterisation of SR in each stream
Targeting of groups of materials for crude
separation
Investigation of basic separating techniques with
SR
WERG
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Project Deliverables
Testing and analysis of most promising materials
from SR
Chemical and physical properties of these
recovered plastics extrusion and processing
trials to determine performance characteristics
WERG
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Pyrolysis of ASR
Funded through the Landfill Tax Credit Scheme
WERG
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Shredder Residue (100)
Shredder Residue (100)
Oversized (105)
Fines (405)
Polyolefins 1.3
Other Plastic 0.7
?
Miscellaneous 0.7
Miscellaneous 9.0
Foam 1.0
Foam 7.0
Metal 2.0
Metal 2.3
Textiles 0.7
Textiles 1.4
Tyre 3.0
Tyre 0.5
Wire 0.6
Wood 3.5
Rubber 6.0
Wire 2.7
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Pyrolysis Unit (schematic)
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Process 2 An alternative process
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Shredder Residue (100)
Shredder Residue (100) (divide by 4 for ELV)
Oversized (105)
Fines (405)
Polyolefins 1.3
Other Plastic 0.7
Miscellaneous 0.7
Miscellaneous 9.0
Foam 1.0
Foam 7.0
Metal 2.0
Metal 2.3
Textiles 0.7
Textiles 1.4
Tyre 3.0
Tyre 0.5
Wire 0.6
Wood 3.5
Rubber 6.0
Wire 2.7
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Recoverable Materials from Pyrolysis of
SR (divide by 8 for ELV )
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Project Deliverables
Pyrolysis of SR fines (and preliminary for
middles)
Development of separation processes for the
residues
Preliminary investigation of markets
WERG
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WERG
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40 bottles
WERG
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Material Composition of a Typical Car
ACCORD 2000
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Recycled Plastic into Automotive Products
Testing of sample specimens injection and
blow moulding
Automotive products possible high-end
products, but first... Recycled HDPE into fluid
containers
STEPPING STONES TO A HIGHER VALUE PRODUCT
WERG
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The Proof!
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Reprise Brighton Plastic
WERG
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Project Deliverables
Development of a trial product using HDPE
recovered from a MRF
Arranging for the processing of HDPE material,
making of moulds, and interacting with plastic
manufacturer to ensure products are produced to
specifications
WERG