ITP 411 Final
Life cycle and production of recycled Steel
20-30% recycled content generally used BOF - 28% recycled steel EAF - 100% recycled steel Environmental Impacts: -Mining -Energy use for manufacturing -Emissions associated with manufacturing Easy to sort due to inherent magnetism Virtually all steel packaging contains 20-30% recycled content Recycled steel has the same properties (performance and aesthetics) as virgin material Every ton of steel recycled avoids the use of 2,500 lbs of iron ore, 1,400 lbs of limestone Steel containers have a recycling rate of ~ 73%, but the volume is relatively low compared to other applications (automotive, appliance, construction, demolition) 20-30% recycled content optimizes costs associated with the manufacturing process Managing heat waste is key to managing costs (waste energy used to decarbonate virgin iron = energy required to melt scrap
Percentage of energy saved by recycling Corrugated board (unbleached)
22%
What is optimal % moisture? Problem of too high and too low % moisture.
55% is optimal moisture percentage Too high impedes airflow Too low impedes composting process
Percentage of energy saved by recycling Glass
57%
Life cycle and production of recycled Aluminum
60% of recycled contents are used Recycling reduces energy consumption by 95% Same mechanical properties as virgin aluminum Environmental Impacts: -Mining -Energy use for manufacturing -Emissions associated with manufacturing Recycled aluminum cans do not present any processing challenges Remelts at 600-700 degrees C, eliminates most impurities picked up in recycling stream Different components of cans are made of different alloys, diluted with virgin aluminum in order to achieve ideal chemical composition Recycling process: -Washed, shredded, and melted -Aluminum beverage can recycling is primarily a closed loop process -Aerosol containers typically do not contain post consumer recycled content due to different alloy, but post industrial recycled content is often present -Cans are widely accepted by municipal collection systems due to high commodity value with robust market demand -Aluminum cans are typically a mixture of virgin and recycled material Long distance transportation of recycled aluminum can erode the economic and environmental advantage LCA is an effective tool when used to measure long distance transport of recycled aluminum vs. virgin aluminum
Percentage of energy saved by recycling PET
76%
Percentage of energy saved by recycling HDPE
79%
Percentage of energy saved by recycling Steel
79%
Percentage of energy saved by recycling PVC
80%
Percentage of energy saved by recycling Aluminum
93%
Energy saved by aluminum recycling
95% energy savings
what is volatile solid? Minimum level of volatile solid to encourage microbial activity
A volatile solid is organic material that can be consumed by microbes Compost needs to be composed of at least 40% volatile solids to encourage microbial activity
Recyclability of Glass containers
Accepted by recycle
Recyclability of Glassware
Accepted by recycle
Recyclability of Paper towel and toilet paper rolls
Accepted by recycle
Recyclability of Shoe boxes
Accepted by recycle
Recyclability of Corrugated pizza box
Accepted only if they are clean with no food residue
Adv. & disadv. of incineration
Advantages: Reduce waste volume (80-95%) and demand for landfill space Produce heat and electricity Provide a low cost construction material Metals can be extracted from the ash Disadvantages: High capital cost and maintenance cost Produce harmful pollutants (dioxin, acid gases, nitrous oxide, heavy metals, particulates) Recyclable material could end up in landfill Only applicable if certain requirements are met -Composition of waste -Well-functioning waste management system -Must be disposed of in controlled, well-operated landfills -Stable supply of combustible waste (50,000 tons per year) -Community can absorb the increased cost
Density Blower MRF
Air is blown up through the conveyor belt Heavier glass products remain on the belt where they are then prepped for cullet prep
Life cycle and production of recycled Glass
Almost exclusively limited to recycling of packaging glasses Glass is heavy and expensive to transport Opportunities for use of post consumer glass in making new glass are limited 34% of glass is usually recycled 50% cullet (crushed up post consumer/industrial recycled glass) reduces: -Energy by 10-15% -Particulate by 40% -Nitrogen oxide by 20% -Sulfur oxides by 10% Cullet content of packaging glass is typically 30-70% Technically possible to make glass containers using up to 95% cullet Sensitive to contamination by other ceramic materials such as china, safety glass, and metals Non-packaging glass (such as windows and pyrex) generally cant be used to manufacture packaging glass Contaminated glass can be used for other applications (construction aggregate, filtration medium) therefore reducing impact on landfills Amber and green cullet are widely available due to wine and beer -They represent a large portion of glass collected for recycling Most recycled glass originates from a mix of flint (clear), amber, and green glass called a three-mix Then processed into furnace ready cullet Recycled glass is typically used within a few hundred miles of where it is collected (due to high transport costs)
Eddy Current Separator MRF
Aluminum is the target for this process, and is the predominant nonferrous metal in waste streams Repelled by magnetic force due to generation of a charge of opposite polarity Can be used to pull aluminum out of a stream of commingled recyclables
The causes of odor during compost process.
Ammonia is released when pH is too high (over 8.5) Volatile organic acids produced when pH is too low or compost is too wet Feedstock odors that persist during the compost process indicates a poor initial mix
Success story for Paperboard
Apple replaced a layer of solid bleached sulfate with recycled paperboard in their earbud and charger packaging within the iPhone box
Recyclability of Coke plant bottle #1
Available for CRV
Average content of recycled fiber in corrugate
Average content of recycled fiber in corrugate is 48%
Max amount of steel allowed for each steel making furnace (BOF vs. EAF)
BOF - Max 28% recycled steel EAF - Max 100% recycled steel
What is BPI and which ASTM standards are involved?
BPI: Biodegradable Products Institute ASTM 6400 and ASTM 6868 -Biodegrades 60-90% within 180 days -Disintegrate 90% into pieces no greater than 2mm -Leave behind no heavy metals beyond that of control
remember EPA waste management hierarchy
Best to Worst options: -Source reduction and reuse -Recycling/composting -Energy recovery -Treatment and disposal
Understand current problem associated with plastic pollution in the ocean
Biodegradable plastics behave differently in the ocean due to temperature and moisture differences Oxo-degradable polymers which promote fragmentation by UV irradiation and oxygen will add to the quantity of microplastics in the ocean
Manual Processing MRF
Bulky items and specific contaminants are removed Equipment involved in manual separation typically consists of a sorting belt or table, which contains a mixture of materials Hoppers or other receptacles for receiving sorted items are placed close to line
Recyclability of Dole salad bag
Can not recycle, garbage bin only
Recyclability of LDPE plastic bag for general curbside recycle bin
Can not recycle, garbage bin only
Recyclability of Lean cuisine frozen food boxes
Can not recycle, garbage bin only
Recyclability of Motor oil corrugated box
Can not recycle, garbage bin only
Recyclability of Motor oil plastic bottle type #1 or #2
Can not recycle, garbage bin only
Recyclability of Shredded paper
Can not recycle, garbage bin only
Recyclability of Hardcover books
Can not recycle, only softcover books
Recyclability of Tide detergent #2 plastic
Can only be recycled if cleaned and dried thoroughly
Reason to mix coarse and fines
Course materials facilitate aeration Fine materials accelerate breakdown
Success story for Glass
Diageo's Glass Good recycling program encourages bars, restaurants, and other consumers to sign up and let them have their used glass. They are then sent to grinding sites who grind it into cullet and ship it to glass manufacturers Absolut Vodka produces 600,000 bottles of vodka a day, but their bottle contains 40% recycled glass
How to improve the recyclability of Bags
Do: Light weighting Use paper from responsibly managed forests Use recycled fibers when possible Use functional barriers that do not harm recycling Use glue efficiently Use food safe inks Design the secondary package effectively and efficiently Don't: Use underperforming packaging - results in lost product Use elements other than cellulose fibers Use foils - they effect recycling Use staples, hot-melts, adhesive tape, plastic windows, or laminate, waxed, tarred, or siliconized paper
How to improve the recyclability of Boxes
Do: Light weighting Use paper from responsibly managed forests Use recycled fibers when possible Use functional barriers that do not harm recycling Use glue efficiently Use food safe inks Design the secondary package effectively and efficiently Don't: Use underperforming packaging - results in lost product Use elements other than cellulose fibers Use foils - they effect recycling Use staples, hot-melts, adhesive tape, plastic windows, or laminate, waxed, tarred, or siliconized paper
How to improve the recyclability of Glass Bottles
Do: Use light weighting Follow commission decision 2001/171/EC on glass packaging Try to use as much recycled content as possible Use water or alkali soluble in 60-80 °C wash off self-adhesive Use metal or plastic closures which can come loose if the glass is broken Use paper labels Use inks that are non-toxic and follow EUPIA guidelines Transparent colors and green Design the secondary package effectively and efficiently Don't: Use underperforming packaging - results in lost product Use heat resistant glass, lead crystal, opal glass, and enamels on glass Use hot-melts, self-adhesives labels (on-wash off) Use labels that are strongly glued onto glass Use direct printing (unless is does not affect recyclability) Use dark colors, opaque glass, or metallic bottles
How to improve the recyclability of Metal Cans
Do: Use light weighting Minimize non-steel elements that are not detachable from the metal packaging Use paper labels Design the secondary package effectively and efficiently Don't: Use underperforming packaging - results in lost product
How to improve the recyclability of PP Containers (Bowls, Cups, and Tubs)
Do: Use light weighting Use EVOH or PA for a barrier, but only if there is no other option Use PE, PP, or OPP for the lid Consider no label, and use a carton cover instead. Otherwise, use a small and easily releasable label Use non-toxic inks or laser marked direct printing Design the secondary package effectively and efficiently Don't: Use underperforming packaging - results in lost product Use PVDC or any other material that increases the density of PP Use aluminum, PVC, or silicon for the lid Use any other direct printing that was not previously mentioned
How to improve the recyclability of Thermoform PET trays
Do: Use light weighting Use absorption tissue integrated in the tray design Use PET for barrier properties, check if other barriers are needed Use lidding film with polyester coating Use transparent or clear PET Use water or alkali soluble in 60-80 °C wash off self-adhesive labels Design the secondary package effectively and efficiently Don't: Use underperforming packaging - results in lost product Use PE laminate for the lid Use black PET Use nylon and EVOH in barrier layers
How to improve the recyclability of HDPE Bottles
Do: Use light weighting Use mono PE Use water or alkali soluble in 60-80 °C Use all types of PE (HDPE, MDPE, LDPE, LLDPE), PE with EVA, PP in caps Use a label that is as small as possible Use non-toxic ink Design the secondary package effectively and efficiently Don't: Use underperforming packaging - results in lost product Use no color or light colored PE Use hot-melts or self-adhesives Use PVDC or any additives that increase the density of HDPE Use metal, aluminum, PS, or PVC caps Use PVC/PS/aluminum/or metallized labels Use direct printing (unless is does not affect recyclability)
How to improve the recyclability of Injection Stretch Blow Molded PET Bottles
Do: Use light weighting Use mono PET, this can contain recycled content (eg. post-consumer recycled content in a middle layer) Use water or alkali soluble in 60-80 °C wash off self-adhesive Use SIOx plasma coating for barrier Use a material with a density less than 1 (PE or PP) for cap to aid in recycling. Using PET is not possible due to difficulties uncapping Use as small a label as possible Use non-toxic inks Use transparent clear or transparent light blue Design the secondary package effectively and efficiently Don't: Use underperforming packaging - results in lost product Use PLA, PVC, PS, or PET-G for the bottle material Use hot-melts or self-adhesives Use EVOH or PA multilayer for the barrier Use direct printing (unless is does not affect recyclability) Use other colors, opaque, or metallic bottles
How to improve the recyclability of Pallets
Do: Use light weighting Use wood from responsibly managed forests Use paper labels Limit materials other than wood to what is strictly necessary Don't: Use underperforming packaging - results in lost product Use labels that are strongly glued to the pallet
How to improve the recyclability of Pouches
Do: Use light weighting and simplified packaging Use mono material, preferably PE or a combination of PE and PP Use a thin film barrier Make sure there are no small, loose parts Use as small of a label as possible Use non toxic inks Design the secondary package effectively and efficiently Don't: Use underperforming packaging - results in lost product Use PET or PVC as an external barrier Use glue that releases easily for the label
The reason to measure salinity and optimal level of salinity
High salinity can rob roots in soil of moisture Prefer less than 4 millimhos (measure of soil electrical conductivity) in soil
all good practices for composting.
Know your feedstocks C:N ratio, % moisture, bulk density, % carbon, % nitrogen, and texture No cross contamination of raw feedstocks and active compost/finished compost Pathogen Reduction Phase (PRP) -131 °F for 15 consecutive days, with a minimum of 5 turns -This will eliminate weed seeds, salmonella, and eColi Patience - composting takes time Understand the qualities of finished compost (stable) -Ammonia levels -Carbon Dioxide levels Testing: -Solvita test by woods end lab - tests ammonia and carbon dioxide -USCC STA program - certified lab for a finished compost analysis Understand the hazards of using an immature product -Ammonia damage to plants -Phytotoxicity of Volatile Organic Acids (VOA) -Nitrogen tie-up -Odors upon rewetting -Reheating of bagged compost
Plastic recycling compatibility for each other
LDPE, LLDPE, and HDPE are all mutually compatible PC is compatible with PET PP has fair compatibility with LLDPE and HDPE No other compatibilities for plastics
Life cycle and production of recycled HDPE (High density polystyrene)
Negligible performance and aesthetic deficiencies for recycled material Hard to achieve a bright white color, however, there are design choices that can be made to mitigate this Potential greenhouse gas reduction of 65-70% can be achieved by recycling HDPE Most recycled HDPE comes from milk jugs, water bottles, juice containers, cosmetics, hair products, household cleaners, and detergent Two main categories of recycled HDPE -Natural: partially transparent, made predominantly from milk jugs -Mixed color: predominantly from opaque, colored HDPE bottles Steady and stable supply of recycled HDPE due to widespread acceptance at recycling centers Natural recycled HDPE is more expensive than virgin HDPE Mixed color recycled HDPE may be cheaper or at the same price as virgin material Greatest demand is for natural HDPE, even for applications that will be made colored or opaque, since recycled HDPE is more conducive to adding color Challenges regarding recycled HDPE: -Injection molding can be difficult due to lack of total uniformity -Recycled HDPE tends to get stress cracking, particularly for larger bottle sizes (over 50 oz) -Requires producers to be careful about the design of the bottom of bottles -High oxygen barrier coating (EVOH or Nylon) can damage extruder -Main aesthetic challenge is color consistency, but can be spun to be a telltale sign that the plastic does indeed contain recycled material
Success story for PE Film
Novolex's "Gray is the New Green" marketing campaign seeks to reframe the sustainability value of grey, buff (tannish), or blue plastic bags because those darker colors signify higher recycled content to consumers Nike's Bag to Better program creates a closed loop system for their retail bags
Study the impact on aeration and optimal range of bulk density
Optimal range of bulk density is 800-1000 lbs/cubic yard Too high impedes aeration Too low cools off composting temperature
what is optimal C:N ratio?
Optional C:N Ration (carbon to nitrogen ratio) is 30:1
Typical glass cullet content of packaging glass
Packaging glass contains 30-70% cullet
Biodegradable plastic
Plastic that will degrade from the action of naturally occurring microorganisms over a period of time -Note there is no designation for how long it takes to degrade or toxins present after biodegradation
Bioplastic
Plastics derived from renewable biomass sources, such as vegetable fats and oils, corn starch, straw, wood chips, food waste, etc.
(Writing type) Briefly explain the recycling process of post consumed glass
Post-consumer packaging glass is broken down into cullet and placed into a three-mix (flint, green, and amber) and then processed into furnace ready cullet. Recycled glass is typically processed within a few hundred miles of collection due to high transportation costs.
open-loop recycling
Product is recycled and turned into a different product (steel cans into steel beam)
closed-loop recycling
Product is recycled and turned into the same product (aluminum cans into aluminum can)
Life cycle and production of recycled PE Film (Polyethylene)
Recycled PE film is used as a feedstock Incorporating recycled content into PE film presents its own challenges; processing, performance, and aesthetic can all be improved Using 30% recycled PE can reduce energy consumption by 25% and greenhouse emissions by 33% PE films (such as bags, wraps, and films) can be dropped off at stores participating in a store drop off program Only 7% of grocery bags and 3% of PE film packages are returned Very different from recycling rigid plastics Imperfections (holes, bubbles, gels) can form in film and ruin the final product Due to bumps, recycled PE has lower printability than virgin material
Life cycle and production of recycled PET (Polyethylene terephthalate)
Recycled PET very common Widely accepted in recycling systems, also has higher collection rate than many other plastics Heavy competition for highest quality food-grade recycled PET, resulting in higher prices, lower quality PET is more readily available No significant performance challenges when using recycled PET (unlike other plastics) Intrinsic viscosity of recycled PET can be upgraded to near-virgin levels Tends to be aesthetic changes (clarity, color, consistency) Some PET bottles are subject to container deposit legislation in 10 states, leads to greater recycling rates Recycling PET thermoforms is less widespread than PET bottles 30% of PET bottles are recycled, 24% of other PET packages Majority of recycled PET goes towards clear applications Heavy competition for supply of high quality, clear, food grade PET Degradation occurs during mechanical recycling of PET when it is shredded and exposed to high temperatures Contamination (PE, PVC, adhesives) can exacerbate degradation and loss of average molecular weight and intrinsic viscosity Discoloration is the principle aesthetics concern (yellowing/hazy appearance), but up to 25% recycled content can be used before noticeable difference Cost of recycled PET is highly variable Chemical recycling -Produces very high quality PET virtually indistinguishable from virgin material -Loop Industries: PET macromolecule is broken down through chemical depolymerization process into its monomers (DMP and MEG) -DEMETO: microwave-based process intensification process that can depolymerize PET on an industrial scale
What is RPTA?
Recycled Paperboard Technical Association
Life cycle and production of recycled Corrugate
Represents the largest single domestic end market for recycled fiber (36% of recycled paper) Amount of recycled fiber can vary from 0-100%, but on average, corrugated boxes contain 48% recycled fiber Use of recycled material does not significantly impact performance or aesthetics Principle feedstock stream for new corrugated boxes is OCC (Old Corrugated Containers) Recycling costs are relatively low, but fiber market is notoriously volatile Recycled corrugate is weaker than virgin material, but it can still meet the same performance standards as corrugated medium Untreated recycled corrugate exhibits a slightly uneven surface and inconsistent appearance compared to virgin material Uneven brown color may impact quality, but can be ignored since it is being used for a corrugated sheet 100% recycled paperboard packaging is common in the marketplace and generally in high demand -Demand is believed to have exceeded supply Recycled paperboard mills are operating at full capacity Cost is not considered a significant barrier to use recycled paperboard Cons of recycled paperboard -Potential for reduced strength and aesthetics such as whiteness, brightness, and printability -Large boxes can present a challenge -Lower surface strength that can result in delamination from glues -Cold glues must be used instead of hot glues Food packaging for recycled paperboard -Contamination migration into product packaged in recycled material is a big issue -Organic contaminants/microbial contaminants - removed during processing -Heavy metals/minerals - potential concern -Direct contact between recycled paper and food products is generally not allowed for liquids or oily foods -Food grade recycled paperboard is widely used and available -Recycled paperboard technical association (RPTA) provides standard through which mills can give assurance that all substances of concern are removed
Study about feasibility assessment and the typical cost of an incineration plant
Revenues from energy production only cover part of the costs Incineration costs = $100-$200 per ton of MSW (Municipal Solid Waste)
Success story for Aluminum
Reynolds wrap offers a foil made from 100% recycled aluminum. It comes from a mix of post-industrial recycled aluminum post-consumer recycled aluminum and is 100% food safe
Rotary Screen Separators MRF
Rotating disks with an interval between them allows for one component to fall through while others get passed along the top Works well for separating paper from other containers or OCC from other paper The small material may be compostable in a mixed waste MRF
Success story for HDPE
Seventh Generation created a new 100 oz laundry detergent bottle made from 80% recycled HDPE, 17% bio-based HDPE, and 3% colorant
Life cycle and production of recycled PP (Polypropylene)
Significant demand for recycled PP Supply availability, color deficiencies, and brittleness are current issues -Additives can correct some of the mechanical issues Greenhouse gas emission can be reduced by 65-70%by using recycled PP Low recycling rate (8%) PP caps and closures are an important constituent of the PP recycling stream Bulk of recycled PP comes from dairy product tubs (yogurt, butter, sour cream), caps and closures, and industrial sources such as cafeteria trays and retail hangers Volatile price due to limited availability Issues with recycled PP -Lower viscosity causes slower filling of molds -Increased melt index - makes it more suitable for injection molding than thermoforming -High brittleness means recycled packaging requires more curved edges and non hinged caps to prevent stress cracking -Recycled PP can be colored or recolored
Optical Sorting MRF
Sorts different plastics based on their resin identification and color Color is identified using vision technology (CCD linear cameras, CCPD) or spectroscopy Typical optical sorting sensor can operate at 500 feet per minute
Success story for PS
The EcoLid 25 is a hot beverage lid made with 25% post-consumer recycled PS by Ecoproducts. Ecoproducts' BlueStripe cutlery is made from 100% post-consumer recycled PS
Study the overall incineration process including flue gas and residue treatment.
The furnace must maintain 1560 °F to burn waste (ensures proper breakdown of toxic organic substances) Gas treatment is a very important part of the incineration process (need careful filters and gas washing system) The slags (22% of the initial waste) will be landfilled (after recuperating some metals like iron and aluminum) In modern incineration plants, heavy metals can be recovered and recycled
Success story for PP
TricorBraun was able to create a closure made from 100% post-consumer recycled PP with a hinge performance close to that of virgin PP. It has a round and smooth design and is primarily sourced from recycled PP clothes hangers.
True/False) Due to cost dynamics, using higher percentages of recycled aluminum may sometimes increase costs.
True
Success story for PET
UPM Rafatac has developed a PET pressure sensitive label face and liner composed of 90% post-consumer recycled PET. It is produced from bottle flake
Magnetic Separation MRF
Use a large magnet to separate ferrous metals from nonferrous metals and other materials Depending on how contaminated the waste stream is, multiple magnets may be used
Life cycle and production of recycled PS (Polystyrene)
Use of recycled PS in packaging is limited Post-industrial recycled PS is commonly used in levels up to 20%, often self-generated by the converter Biggest difficulty is lack of supply and lack of food grade PS Some technical performance and aesthetic issues (yellowing) but no when recycled content is kept under 25% PS recycling results in a 15-20% reduction of greenhouse emissions Low recycling rate (5.4% of post-consumer PS is recovered) Much harder for recycling for following reasons: -Small minority of consumers have access to recycling program -Often contains flame retardants -Tends to fragment and contaminate other material streams -Extremely low density restricts the weight of material that can be transported within a unit shipping volume Successful PS recycling programs involve densification Extremely limited quantities of food grade PS Recycled PS is cheaper than virgin material, but manufacturing processes are more expensive Recycled PS is blended with virgin PS during production to allow for more homogeneity Chemical recycling is possible, but not yet implemented due to scaling issues
Objective of incineration
Waste quantities reduction Use of the value of material and energy Environmental impact reduction
Multiple) Successful EPS recycling programs involve ___________. a.Densification b. purification c. blowing d.refining
a. Densification
Compostable plastic
undergoing biological decomposition in a compost site as part of an available program, such that the plastic is not visually distinguishable and breaks down to carbon dioxide, water, inorganic compounds, and biomass, at a rate consistent with known compostable materials and leaves no toxic residue
