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A Review of Developments in Pyrolysis of Automotive Shredder Residue

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17th International Symposium on Analytical & Applied Pyrolysis May 21-26 ... trommel. the (Big) Problem ... trommel ~25% waste SR: Shredder. Residue (or fluff' ... – PowerPoint PPT presentation

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Title: A Review of Developments in Pyrolysis of Automotive Shredder Residue


1
A Review of Developments in Pyrolysis of
Automotive Shredder Residue

M K Harder O T Forton Waste Energy Research
Group University of Brighton, UK
2
Introducing automotive shredder residue, ASR!
3
Outline of Talk
  • The (Big) Problem
  • The Solutions
  • The Problems of the Solutions
  • What we know
  • What we dont know
  • Possible Futures

4
  • the (Big) Problem

End of Life Vehicles (ELV) a growing problem!
  • 25 of the car is left as waste Automotive
    Shredder Residue
  • ASR has been categorized as hazardous in some
    countries
  • ASR has been banned from landfill in some
    countries
  • More cars worldwide gt More ASR worldwide
  • A big enough problem to earn its own EU
    Directive
  • The ELV Directive (End of Life Vehicle).
  • - More of the ELV must be recycled
  • - Manufacturers must take responsibility

5
  • the (Big) Problem

Initial Recycling rates 68-74 by weight iron
steel towards new cars ELV Directive
proposals 85 by 2006 lt5 for energy recovery
95 by 2015 lt10 for energy recovery
Where is the extra 21 coming from?? (and metal
content is decreasing with time..)
6
  • the (Big) Problem

Material Composition of a Typical Car
ACCORD 2000
7
  • the (Big) Problem

5 non-ferrous ferrous products
25 waste SR Shredder Residue (or fluff)
LANDFILLED!
15 -130 mm
metals separator
trommel
lt15 mm
air classifier
magnetic separator
shredder
62 ferrous product
Feedstock in
8
  • the (Big) Problem

OVERSIZE (gt130mm) (10)
FINES (lt15mm) (40)
MIDDLE (15130mm) (50)
9
  • the (Big) Problem

gt130 mm oversize
5 non-ferrous ferrous products
15 -130 mm middles
metals separator
trommel
25 waste SR Shredder Residue (or fluff)
to landfill light ASR
lt15 mm fines
air classifier
dense media plant 5 non-ferrous product
waste heavy ASR
magnetic separator
shredder
62 ferrous product
Feedstock in
10
  • the (Big) Problem

Light SR Composition Harder et al 2004
Fines (505)
Middle Fraction (505)
Too small sized to separate easily
11
  • the Solutions?

What are the solutions? Processes
developed As of 2001, several pyrolysis
processes appeared to offer near-solutions
Malkow 2002 Of these, only a few are still
contenders.
12
  • the Solutions?

Contherm Process by RWE
Steam
Pulver. Coal Fired boiler
Shredded MSW /- ASR
gases
500 C Rotary kiln
solids
Coal Mills (fuel)
Screen / sort
Fe non-Fe metals
Current status not actively pursued
13
  • the Solutions?

PKA Process
fuel gas
Shredded MSW, ASR, Tyres, Plastics soils
1000 C cracking
gases
500 C Rotary kiln 1 hour
solids
Fuel, Sorbent, or Raw material For bricks
Screen / sort
Grind lt2mm
Fe non-Fe metals
OR vitrify char at 1400 C, granulate lt1mm and
use for cement
Current status fully commercial (but not with
ASR)
14
  • the Solutions?

Pyrolmelt Process (Lurgi Entsorgung)
Steam
Shredded lt15cm MSW, ASR, Plastics 8-18 MJ/kg
Steam
gases
liquids
1200 C Pyrolysis
air For Combust.
Oxygen 1350 C
solids
Screen / sort
Fe non-Fe metals
Vitrified ash
Current status semi-commercial
15
  • the Solutions?

TWR Process (Takuma) (Siemens Schwel-Brenn ?
TWR / Mitsui Processes)
Air
Steam
1300 C
?
gases
450 C 1 hour
solids
Grind lt1mm
Screen gt5mm / sort
Granulated slag
Fe non-Fe metals
Current status semi - commercial
16
  • the Solutions?

Schwarze Pumpe ? SVZ ? Global Energy
pelletized ASR, Tyres, Biomass, RDF
Steam
oxygen
methanol
Gasn 800-1300 C 363psi
steam
slag
Current status demonstrator (not specifically
ASR)
17
  • the Solutions?

Other (gasification) processes WGT Process
(demonstrator) Precon (Krupp Uhde) Penflo
Process (fully commercial) Ebara/ Alstrom/
Twinrec TIFG Process (fully commercial) ______
__________ Of these, only Ebara Twinrec is fully
commercial and clearly treats ASR. Of these, only
Takuma TWR is semi-commercial and clearly treats
ASR.
18
  • Ebara Twinrec Plant
  • Fully commercial
  • ASR Sewerage Sludge 70/30
  • 100,000 t/pa

Figure taken from Ando et al, 2002
19
  • the Problem with the Solutions
  • Issues with these solutions especially
    inhibiting smaller sized plant
  • They all have problems with
  • Chlorine levels in the ASR (from PVC) high AND
    variable
  • Heavy metals in the char / ash, esp. Pb, Zn, Cu
  • Sudden variations in the composition of the feed
  • Some have problems with
  • Pre-shredding and mixing energy and financial
    costs
  • Granulation of slags energy and financial costs
  • Handling costs ASR to facility, or facility to
    ASR??

20
  • the Problem with the Solutions
  • What types of facilities will the small operators
    want?
  • Short residence time
  • Very robust plant that will not break down
  • Large throughput minimum 20 tonnes / day
  • Safe no steam production or high pressures
  • No stack if possible!
  • Plant not too big especially combustion chamber
  • Make useful fuel e.g. diesel
  • No hassle with the regulatory environment
    agencies

21
  • What we know
  • What do we know already that can help design
    facilities?
  • Material composition of the raw ASR
  • Elemental composition of the chars / ash
  • Levels of heavy metal contamination
  • Levels of chlorine
  • Calorific values
  • Whether char production volumes are sensitive to
    process parameters

22
  • What we know

ASR composition (by material type)
And more info in
23
  • What we know

ASR Energy Values
24
  • What we know

Metal Contaminations in ASR char
And more info in
25
  • What we dont know
  • What dont we know?
  • How to mechanically sort off the useful large
    pieces
  • Where the high level of lead is coming from
  • How to reduce the levels of heavy metal
    contamination
  • How to reduce the levels of chlorine
  • How to OPTMIZE THE RECOVERED PRODUCTS OVERALL
    not just for metals, just for energy
  • Whether the commercially proven Japanese plant
    will work with feed from other countries

26
  • Possible futures

Possible futures adaptations of the large plant
like these
Taken from Schwager Whiting, 2003
27
  • Possible futures

Ebara ASR plant 100,000 t/pa
Taken from Schwager Whiting, 2003
28
  • Possible futures

Possible futures small-scale niche plant
  • Designed for specific feed from a specific
    site
  • Designed for mixed local feeds e.g. sewerage
    ASR
  • Need to reduce risk of being wiped out by
    alternative competing processes e.g. mechanical
    separation
  • Hybrid schemes
    send middles ASR for
    sorting fines ASR for prolysis
  • Produce diesel for companys trucks only
  • Minimize gas production unless taken off site
  • Send ASR to central processing sites or collect
    ELVs at central sites so that Auto companies
    can take control!

29
  • Possible futures

Taken from Schwager Whiting, 2003
30
  • Possible futures

Taken from Schwager Whiting, 2003
31
  • Possible futures

Taken from Schwager Whiting, 2003
32
Conclusions
  • The first commercial ASR recycling plant have
    arrived!
  • They will need to be proven in the EU before
    bankable.
  • Small-scale, specialized processes will still
    develop.
  • More RD remains to be done for this but work
    with specific partners or you could be developing
    an unsuitable process.

33
  • Oops!

Just one more thing.
  • Shredder Residue (SR)
  • IS NOT THE SAME AS
  • Automotive Shredder Residue (ASR)

34
  • the (Big) Problem

Feedstock is. normally not just cars!
20 Domestic Goods
(washing machines, ovens)
40 End of Life Vehicles
(Cars, usually without tyres)
40 Light Iron
(bicycles, fences)
Shredder Plant
Waste shredder residue SR
35
  • the (Big) Problem

100 End of Life Vehicles
(Cars, usually without tyres)
Shredder Plant
Waste Automotive Shredder Residue ASR
(the responsibility of the automotive industry)
36
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