Designing Recycling Solutions

Transcription

1 Designing Recycling Solutions An EU project on environmentally sound recycling of bitumen sheets for roof waste and the story of how a good idea, financially supported by the EU environmental program, has created a new Danish recycling company. The project has been implemented by companies owned by the Enviso Group A/S and NNC Roads A/S and Waste Plus I/S. The project period for "From Roof to Road" was 1 January 2009 to 31 December 2011 with financial support from the EU LIFE+ as project LIFE07 ENV/DK/ December 2011

2 The project aim Production of building materials, the building process, building renovation and demolition of buildings generates large amounts of waste. Part of this waste is bitumen sheets for roof waterproofing that under normal circumstances is deposited in landfills or incinerated. The aim of this project was to develop a new method to recycle bitumen sheets for roof waterproofing from construction. To reduce consumption of resources it is necessary to modify the laws of Denmark and EU to demand more recycling. We also need to identify new methods to recycle waste, so that raw materials can be recycled and converted into new materials. Potentially the materials can be either directly recycled or used as a substitute for other materials. The purpose of the project was to show that the oil product bitumen, which is a big part of roofing felt, can be reused as bitumen in asphalt. To be able show this, the project developed a new machine that could crush the old roofing felt. In addition a method to separate and collect bitumen sheets for roof needed to be established. Previously, bitumen sheets for roof were mixed with other types of construction waste. Finally, the project needed to produce a large enough quantity of the new product called bitumen mix so that a road surface company could show that the bitumen, originating from the bitumen sheets for roof could replace some of the new bitumen, which is used to make asphalt roads. In order for the new company to be sustainable, the solution should economically benefit both waste producers, (that at present pay to either landfill or incinerators for disposal), and to the companies that until present only used new bitumen. The solution should also provide the possibility for the new recycling company to make money all in all a win/win situation for all involved. The recycling idea for bitumen sheets for roof originated in Denmark and Denmark was used as test country. But the project should also demonstrate that recycling of bitumen is possible in other EU countries. An important part of the project was to show that it was not more expensive for companies to sort and recycle compared to expose of the waste material as previously. The project should also demonstrate that new jobs are created by recycling waste. Project implementation and results The starting point for product flow from the waste feedstock is the need to dispose of the residue produced at the beginning of the value chain - Figure 1 Waste Producer Collection of roofing waste Handling / sorting Production / recycling process Delivery of "raw material" Asphalt Producer Figure 1: Value Chain, the recycling process A project supported by EU LIFE+ Page 2 of 8

3 The "blue" arrows are the new activities envisaged by the project, while the red arrows represent the existing companies. Many of the blue activities are already being carried out, but previously they were not targeted to recycling of roofing felt. A particular problem was the lack of a machine that could re-form the bitumen sheets for roof into "bitumen mix". Another challenge was that the road manufactures did not know whether they could use the new bitumen mix directly in their production processes and if so, in what quantities could the bitumen mix be added. Enviso Group, which initiated the project, has for many years worked with sorting and handling construction waste. To increase the percent of construction waste for reuse the owner of Enviso Group has invented equipment and machines that can increase recycling. As example a machine for the recycling of gypsum waste can be mentioned, where waste is converted into a new raw material gypsum powder. The gypsum powder can be used in the production of the new gypsum boards. However, it was clear that it would hardly be possible to recycle waste from bitumen sheets for roof directly in new roofing felt. The requirements for bitumen, which is the most important material in the roofing felt, could not be achieved by the old roofing felt, because bitumen to some extent degrade when exposed to weather and wind. Bitumen is used in very large quantities in asphalt production. The bitumen mix is mixed in small amounts with many other raw materials to produce different kinds of road surfacing. Also recycled road surfacing is used as a component. Enviso Group entered collaboration with a road manufacture NNC Roads A / S, and based on the material produced in smaller volumes, it became apparent that a new recycling machine could transform bitumen sheets for roof into a new bitumen rich product. This new product could most likely be used as a substitute for part of the new bitumen. This was documented by the results achieved in the initial laboratory tests. EU LIFE + program granted co-financing for the collection and production of a large quantity of bitumen mix. The large scale made it possible to test in large scale and to test whether it technically and economically is feasible to collect and process bitumen sheets for roof to replace new bitumen in roads. It has taken 3 years to complete this development work. The result is as planned, a new company that in the future will supply bitumen mix for the production of new asphalt roads. Waste producers want to increase the recycling of their waste for both environmental and ideological reasons, but it must not be too expensive if recycling must be done voluntarily. A project supported by EU LIFE+ Page 3 of 8

4 Waste producers can promote their own "green image" by recycling the waste, thereby contributing to increased community value. Waste producers must separate their waste fractions already at the source. But a separate bitumen separation has until now not been the practice. Roofing waste is generated in many ways: Residual waste from roofing felt/bitumen production Demolition and sorting of old roofing from buildings and facilities Roofing cuts from contractors who are doing new construction and/or restorations From damage/movement of new roofing We do not know exactly how much bitumen sheets for roof are produced annually in Denmark. But we expect that the amount is approximately 40,000 tons. In the EU, the volume is up to 2 million tons. The new processes in the waste chain have related to gathering, processing and manufacturing. In order to accomplish this task - A new company Tarpaper Recycling was established. Establishment of equipment needed to collect the waste from the producer if required Logistics, collection of roofing waste at the waste producer location Receiving facilities and quality control at the collection location and if possible sorting of waste Transportation of homogeneous recyclable roofing waste to production facilities Production of bitumen roofing waste converting it into a commodity Storing and quality control of raw material Delivery, just-in-time, the feedstock/ raw material for asphalt production A project supported by EU LIFE+ Page 4 of 8

5 The project's biggest challenge was the development of the brand new process plant and a total processing line, which could handle and process many different types of bitumen sheet roofing waste, to produce a uniform product "bitumen mix" in the process. The principles for the process equipment is patent pending, but the practical operation, where the operator must take many factors into account and the results documented such as, the distribution of different types of waste, seasonal variations in temperature, etc. had to be established and the results documented. Production is taking place indoors and it is also possible to store material indoors to a large extent. This is carried out in the Danish town of Herning, where the decommissioning of a power plant, has left a suitable production site. The move to an indoor facility has contributed to a more consistent production and a better delivery ratio. The initial proto type production equipment that was built during the project has since undergone many improvements, and the equipment will shortly be replaced by a large-scale installation. The prototype equipment will subsequently be used to commission the recycling of bitumen sheets for roof in other countries. The right production equipment requires that you have built a comprehensive delivery system. During the project, a supply chain was built up in Denmark consisting of 150 manufacturers of roofing waste and it is estimated that there is approx. 400 roofing waste producers in Denmark. Everyone can help to recycle waste. One of the project partners Affald Plus, a large municipal waste management company in South Zealand, has made it mandatory to hand in bitumen sheets for roof separately. They have set up special containers at the Affald Plus collection points, where anyone can hand in old bitumen sheets for roof. All other municipal recycling centres are able to use the idea, the practice and system of Affald Plus. Fifty municipal recycling centres have joined the scheme. From waste to saleable material The final but crucial step in the project, was to demonstrate that waste based materials can be used not only for a single purpose by a client, but in generally by replacing the companies new/previously used materials, and make the replacement acceptable to all relevant customers. The companies concerned in this project, are the asphalt producers that uses this material to produce roads. The asphalt producer uses the new recycled raw material, bitumen mix in custom specified "recipes" for asphalt. The typical processes include: Receipt of raw Quality control and stacking of commodity Mixing Process pursuant to prescription of A project supported by EU LIFE+ Page 5 of 8

6 commodities Production of asphalt Analysis of asphalt in laboratory Marketing of asphalt for road layout The bitumen mix that is produced in the project has gone through this entire control. After many attempts, we have managed to produce a bitumen mix which NNC Roads can vouch for. The analyzes carried out, the actual production of asphalt and the results of major and minor paving trial means that the NNC's customers in the future will receive roads with a certain amount of recycled bitumen. Before the project was finished, more than 1000 tons of waste based road material were handled. Because each asphalt producer has their own production processes and recipes, all of our new end customers need to commission the use of this new material. But as all road producers must provide road surfaces that meet the same requirements and standards, NNC Roads' approval is very important. NCC Roads is a major international company with a green image. Asphalt Producers are interested in recycling the commodity, because it replaces the new/virgin materials, and substitution is socially useful. The producer also achieves an economic and image-related gain from recycling roofing waste as feedstock rather than using virgin materials. Waste producers will just like Asphalt producer be able to market themselves using the "green image" by increasing consumption of recyclable commodities. The project's environmental and other societal results The environmental aspects and results The project shows how targeted efforts can reduce society's waste production, as illustrated by the Environmental Protection Agency's waste hierarchy in the figure below. A project supported by EU LIFE+ Page 6 of 8

7 The goal is to minimize waste disposed of by landfill and incineration, and to re-use the maximum amount possible or by direct recycling. There is a societal benefit by recycling roofing waste as a valuable raw material. In Denmark, the distribution of roofing felt waste at present is approx. 60% to incineration and 40% to landfill. When the results of this project is fully phased in, which is expected within approx. 2 years, it is anticipated that at least 70% of total roofing waste will be recycled as a substitute for new bitumen. The bitumen sheets for roof contains approximately 60% bitumen, therefore, the asphalt companies can save the purchase of more than 20,000 tons of new bitumen. All the roofing waste can be included in the bitumen mix, and the waste will not be sent to landfill or incineration. The additional components are just not as valuable to asphalt producers. The University of Appled Sciences (Hochschule Augsburg - University College), has conducted a preliminary analysis showing that there is a positive social impact on the environment by recycling through Tarpaper Recyclings processes. The C0 2 savings compared to incineration amounted per kilo roofing waste to 1,677 kilo CO 2 under conditions that are directly related to the project data. A more detailed LCA analysis is planned in collaboration with the Danish Environmental Protection Agency. Internationalization Tarpaper Recycling has its source in Denmark, but during the project activities were extended to the south of Sweden to demonstrate that the concept can be used in other countries. It is in particular the surrounding countries in Scandinavia with close proximity and Germany, and other countries in the euro zone, that are faced with the challenge to increase their level of recycling. The development of use of the recycling concept in these countries will take place successively and in a controlled extent. It is estimated, that the total annual amount of waste from bitumen sheets for roofing in the EU, is approximately 2 million tonnes. This amount represents a potential to replace more than 1 million tons of new bitumen with the recycled material. The potential industrial economic potential A project supported by EU LIFE+ Page 7 of 8

8 Tarpaper Recycling ApS is a new company that during the coming years expects a significant growth in both turnover and in the number of employees. At the close markets the activity is expected to be conducted through subsidiaries of Tarpaper Recycling Denmark. The business model for the overall development has not been finally decided. There is a potential for the employment of 20 employees in Tarpaper Recycling Denmark and again the same number of people could be employed by supplying equipment and improving the sorting of material. In the EU the concept provides a potential of up to 500 employees. Information More information can be obtained at Tarpaper Recycling ApS. info@tarpaper.dk Webpage: A project supported by EU LIFE+ Page 8 of 8