1. The optimization of the resource cycle impact of the combination of technology, legislation and economy
Prof.ir. W.L. Dalmijn
November 23, 2018

2. Complex multi-component products
Oil
ZnO
CO2
November 23, 2018

3. The resource cycle Resource Waste Recycling technology Recycling
Remanufacture
Repair
Resource
Waste
Production
Manufacturing
Consumption
November 23, 2018

4. The resource cycle Recycling technology Recycling Remanufacture Repair
Waste
Production
Manufacturing
Consumption
Design for sustainability
November 23, 2018

5. The resource cycle Waste Recycling technology Recycling Remanufacture
Repair
Resource
Waste
Production
Manufacturing
Consumption
Design for sustainability
November 23, 2018

6. Legislation 0%
RECOVERY
100%
November 23, 2018

7. Market 0%
100%
GRADE
November 23, 2018

8. Technology and Process
November 23, 2018

9. Innovation 100% 0% 100% TECHNOLOGY GRADE LIBERATION RECOVERY
November 23, 2018

10. Economics Economics of recycling route are determined by:
Recycling costs
Revenues - metal prices
Market demand
November 23, 2018

11. Recycling targets EU End of life vehicles
November 23, 2018

12. Electrical and electronic equipment 2006-
Category
Target I
80% by weight, max. 5% thermal processing II
60% by weight, max. 10% thermal processing
III
75% by weight, max. 10% thermal processing IV
80% by weight, no thermal processing V
75% by weight, max. 5% thermal processing
The different categories are: I.
Heavy household appliances as refrigerators and washing machines
II.
IT equipment as mainframes computers and notebooks
III.
Radio and television equipment
IV.
Toys V.
Electrical and electronic tools
November 23, 2018

13. Bulk Processing of Recyclables
Cars
End-of-life cars
Electric/electronic appliances
Municipal/Industrial solid waste
Production waste
In our modern industrial world the secondary resources of materials are large. Above are shown waste glass packing (glass cullet), which are collected separately in many European countries, and refuse cars. In the Netherlands alone they add up to yearly amounts of approximately tonnes and tonnes respectively. Currently approximately 90% of this material is recycled into high grade material, thanks to advanced recycling technology. From waste to glass and from obsolete cars to new metals.
Glass bottles
To New Raw Materials!
November 23, 2018

14. Recycling end-of-life products
Selective
dismantling
Shredding /
separation
Processing/
smelting
Recycling
technology
Process
specifications
Design
November 23, 2018

15. Classification of materials (a) (b) Recycling process
Pre-concentration through
selective collection
Mono
component
Dismantling / mechanical
size reduction
Liberated
Multi
component
Sizing
Non-liberated
Liberation
Concentration
(a)
Products
(b)
November 23, 2018

16. Particle for particle sortation Bulk sortation Liberation
PRODUCTS
FEED
November 23, 2018

17. Automatic identification and sorting
For:
quality control
process control
sorting A B
November 23, 2018

18. Glass recycling,1980 Product Feed Iron Paper, plastics, etc.
Air-sifter
Hand sorting
55 mm
Crusher
Contaminants, off-colour glass
Iron
Hand sorting
10 mm
Contaminants, off-colour glass
Quality control
Magnetic separator
Eddy current separator
CSP
CSP separator
M+CSP
Metal and CSP separator
Product
November 23, 2018
Colour
Colour separator X
X-ray sorter

19. Glass recycling, 2005 Product Feed Iron Paper, plastics, etc.
Air-sifter
Hand sorting
55 mm
Crusher
Contaminants, off-colour glass
Iron
Visionware
Green & brown or
white cullet
CSP
M+CSP
Colour X
25 mm
Quality control
Green & brown or
white cullet
CSP
M+CSP
Colour X
10 mm
Magnetic separator
Eddy current separator
CSP
M+CSP
CSP
CSP separator
M+CSP
Metal and CSP separator
Product
November 23, 2018
NF metals
Colour
Colour separator
Reject (to reprocessing) X
X-ray sorter

20. The quality control system
November 23, 2018

21. Share of secondary material in glass production
Major stages of technological progress in the recycling of discarded glass packaging
Color sorting
100
Share of secondary material in glass production
[%]
Stone sorting 70
Metal sorting 50
Crushing 30
Manual sorting 10
Washing, crushing
1970
1980
1990
1995
Year
November 23, 2018

22. Increase of investment and processing costs in the recycling of discarded glass packaging in The Netherlands; refer to Figure 8 for a description of development stages
* For the sake of convenience, an exchange rate of 1 USD = 1 EURO was used
** Automated process control, sampling and quality control
November 23, 2018

23. Major process steps in the mechanical processing of car scrap
November 23, 2018

24. Processing of the 16-100 mm or 16-65 mm fractions
November 23, 2018

25. The car recycling cycle
ELVs
Spare
parts
Dismantling
company 19
ARN
materials
Dismantled
Shredder
waste
Metals
Mechanical processing
Materials
ASR
November 23, 2018

26. Not all roads lead to Rome: how to optimise ELV processing
Thermal
processing
Dismantled
ELVs
Shredder
waste
ELVs
Dismantling
company
Shredder
Mechanical processing ?
ARN
materials
Spare
parts
Metals
Materials
Metals
Inerts
Electricity or
synthesis gas
November 23, 2018

27. X-ray transmission X X - - ray ray Product 1 Product 2 Feed Feed
November 23, 2018

28. DE-XRT Metal alloy sorting TU Delft, L3 Communications
Magnesium
Heavy NF
Aluminium
Easy distinction between wrought and cast aluminium alloys
Thickness independent classification
Inclusions are visible (Cu, Fe inclusions in Al)
No sensitivity for dirt and coatings (paint)
Internal structure is visible
Heavy alloying elements (Cu, Zn) in Al and Mg are visible
November 23, 2018

29. Shredder residue preparation
Feed forward of waste incineration, and secondary fuel improvement:
remove particles that cause high emission of toxic materials in advance
???
PVC
Metal
PVC (can you see it ?)
November 23, 2018

30. Process control process characterizing sensor quality control sensor
sensors and
reject mechanisms
characterizing
sensor
quality control
sensor
feed
process control

31. Integrated quality control
Management
recycling plant
Management
end-user
Engineering
Integration of sensor technology
Quality control
system
Quality control
system
END-USER
(s)melting, regranulation,
Incineration, ....
Feed
PROCESSING
recycling plant
Product
shredding, separation, (automatic) sorting
November 23, 2018
Material
Waste
Data

32. Economics of recycling (end-of-life vehicles)
November 23, 2018
Recovery [%] with zero profitability

33. Recycling costs vs. complexity
Product complexity
Battery
Limit of viability
Value of materials
Land filling costs
Chips
Aluminium cans
Building material
Miniaturisation
Recycling costs
per tonne ($)
Household appliances
November 23, 2018

34. Development of recycling costs (end-of-life vehicles)
Revenues or costs 1950,
costs of landfilling € 5 per tonne
Revenues or costs 2000,
costs of landfilling € 70 per tonne
Revenues or costs 2010,
costs of landfilling ?
100 75 50
Costs 25 €
Revenues 50 70 80 90
100 25
Recovery
November 23, 2018

35. X rec % time Grade Quality EU legislation 0 % Rec. 100 % 1 technologyst
technology 3 rd 2 nd
100
100 %
0 %
Rec.
Grade X
EU legislation
Quality
November 23, 2018

36. The closure of material cycles can be optimised by feedforward control of the various processes within the interconnected resource cycle system.
Major improvements in the recycling of end of live products can be expected from design for recycling selective dismantling improved separation technology and the legislation for product responsibility.
The combination of cheap bulk sorting technology with multi-sensor technology will increase grade and recovery of materials in the resource cycle.
The X-ray transmission sensor can be applied in many-material cycles for feedforward control, quality control, process control and multi-sensor separation systems.
November 23, 2018