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

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

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

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

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

Legislation 0% RECOVERY 100% November 23, 2018

Market 0% 100% GRADE November 23, 2018

Technology and Process November 23, 2018

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

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

Recycling targets EU End of life vehicles November 23, 2018

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

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 400.000 tonnes and 200.000 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

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

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

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

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

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

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

The quality control system November 23, 2018

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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