New Jersey WasteWise Business Network

Transcription

1 New Jersey WasteWise Business Network Fall Meeting November 13 th,

2 Mission The mission of CARE is to facilitate market based solutions for the reuse and recycle of post consumer carpet and encourage design for recyclability. Created January 8, 2002 as a 501c3 organization 2

3 Biggest Challenges / Solutions PET growth in recycle stream Commercial glued down carpet Nylon carcass Procurement pull Progress being made but must accelerate 3

4 2014 Product Portfolio Post--Consumer Carpet Content Products Post May 2014

5 50 responders 37 primary collector/sorters 5

6 Historical Landfill Diversion ) ds (millions) Pound Introduced new calculation method in

7 Material Balance Approach Based on documented pounds shipped 7

8 Greenhouse Gas Reduction* Annual GHG savings: 193.9K metric tons of CO 2 equivalents and equivalent to: Annual GHG emissions from CO 2 emissions from * Based on the U.S. EPA WARM Model 8

9 Destination of Processed PCC 9

10 Outlets for PCC 10

11 End Product Markets (+25%) ( 20%) (+87%) 11

12 Face Fiber Collected* (+42%) * This chart excludes 2013 pounds of PCC collected from 3 sources that do NOT collected PET or PP. Thus, this chart more accurately reflects the actual flow of PET PCC in the marketplace. 12

13 Recycled PCC Face Fiber Historical i Trends* * This chart excludes 2013 pounds of PCC collected from 3 sources that do NOT collected PET or PP. Thus, this chart more accurately reflects the actual flow of PET PCC in the marketplace. 13

14 Where Collections Originate Arrows indicate change vs

15 Jobs in PCC Recycling Total 1,318 15

16 Summary 534 million pounds diverted 50% goes into engineered resins 28% (+87%) goes back into carpet face fiber Nylon decreasing: PET increasing (42%) 1,120 ( 15%) people employed directly 52% of gross collections were recycled 452 CARE members 3.25 billion pounds cumulative diversion 16

17 CARE 2013 CARE passed first ever audit clean result Passed AB 2398 first audit no material findings 2013 was a challenging year PET rises as biggest challenge Progress being made but must accelerate AB 2398: lost 2 CA based recyclers dealt with many issues & learned many lessons hired CA Program Manager: Brennen Jensen Thanks to Members and Board 17

18 CA AB 2398 CARE Carpet Stewardship Organization AB 2398 is an experiment working We arefacing many issues learning New Plan Version 3.2 approved by CalRecycle January

19 AB 2398 Performance Trends (pounds) *As of Q1-2014, Gross Collections (GC) include refined data historically collected, but not previously reported. These data adjust GC amounts beginning Q through the current period. **Beginning in Q1-2014, Recycled Output (RO) includes domestic data previously reported + estimated international RO based on a conservative 25% yield of reported pounds exported. RO is also adjusted to include only Type 1 + Type 2 pounds. Pounds diverted from landfill through CAAF and Kiln are no longer included in RO figures above. 19

20 AB 2398 Performance Trends (percentage) *As of Q1-2014, Gross Collections (GC) include refined data historically i collected but, not previously reported. These data adjust GC amounts beginning Q through the current period. **Beginning in Q1-2014, Recycled Output (RO) includes Domestic data previously reported + estimated international RO 20 based on a conservative 25% yield of reported pounds exported. RO is also adjusted to include only Type 1 + Type 2 pounds. Pounds diverted from landfill through CAAF and Kiln are no longer included in RO figures above.

21 Performance Trends 21 Net Diversion = Gross Collection Sent to landfill* * Sent to landfill is both PCC collected plus processing waste.

22 National vs. CA Comparison 2013 Data (million pounds) U.S. CA Total Discards 3, Gross Collections % Gross Collection 14% 24% Recycle Output* % Recycled 8% 12% GC lb/capita** % of US 16% of US * Recycle Output for US = reuse, recycle, CAAF/kiln, WtE, int l yield * Recycle Output t for CA = Type 1 & Type 2 only (excludes CAAF/kiln, WtE, int l yield) ** 2013 Population: US 317,297,938, CA 38,332,521 (12%) 22

23 CarpetCycle, LLC. Founded in Dover, NJ 2001, Moved to Elizabeth, ~18,000 SF facility for 11+ years Moved to 50,000+SF Newark facility March 1 st 2012 Provide PCC and ACT recycling services collection/sortation/baling Provide interior demolition service which earns LEED credits for your project We employ 45 full time employees Have diverted over 200MM lbs since inception Over 15 million pounds PCC reclaimed in 2013 Target goal is 30 MM pounds PCC reclaim in 2014

24 WE NEED MORE RESIDENTIAL CARPET: Current Municipal Procedure for old carpet collections: Trash trucks pick-up at curbside Carpets and underlayment comingled with other wastes Carpets susceptible to foul weather Wet carpets are difficult to handle and hard to recycle Currently collection rates <20% in NJ... Even less recovery in New England states

25 Where carpet types do we encounter in the US? 1) Residential Broadloom: ~60% Nylon Face Fiber Content ~15% Polypropylene ~20%+ PET ~5% Other types; Acrylics, PTT, Wool 2) Commercial Broadloom ~95%+ Nylon Face Fiber Content ~5% PP and other 3) Carpet Tiles (Backing type important) ~75% PVC Backed, close loop recycled ~25% Other, Urethane Cushion, bitumen etc disposition Typically some donation but mostly WTE

26 Our target is always changing.. Nylon % Declining

27 Our target is always changing.. PET % CONSISTENTLY INCREASING

28 Where does the carpet go??? Donation for Re-Use Carpet Tile to Carpet Tile Carpet Yarn to Recycled Content Yarn Engineered Resins Injected Molded Parts Auto-Industry Plastic Lumber: Mostly PP residue Energy from Waste EFW Displaces coal to fuel cement production

29 NEWARK NJ FACILTY

30 SORTING POLYMER TYPE WITH BRUKER

31 CAT TELEHANDLER MOVING CARPET

32 PREPARING NYLON FLATS

33 FEEDING SHEAR LINE 1

34 FIBER OUTFEED, QUALITY CONTROL

35 FIBER BALE IN PRESS

36 NYLON FIBER IN CLOSE

37 CAT LOADING SHREDDER

38 SHREDDER ROTOR, BED KNIFE

39 Cost to Recycle Recycling Service is Cost Neutral with respect to traditional demolition and landfill Labor and trucking equal Added handling cost offset by landfill savings Synergy with carpet and ceiling removal VCT and gyp board recycling in development

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43 CA Recovery vs NJ No EPR Something must change 3Q Q Q 2012 California 2Q Q 2012 NJ Estimate

44 Comparative Recycle Rates Percent Source: U.S. EPA

45 NJ Situation Currently estimate diversion is 20M lb/year Estimated landfill flow is 105M lb/year Collecting ~19% of all PCC 3.4lb/capita/year* = 30M lb w no EPR Could process 2 3x but not available Need something new to increase flow Can we use a different model for NJ to get to 35% like CA * Using CA estimate actual recovery 45