Euro 12,– IN THE DOCK...mining is an alternative route to Circular Economy. No one can say for...

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MAY-JUNE 2017P.b.b. 02Z030115 M, Industriemagazin Verlag GmbH, Lindengasse 56, 1070 Wien, Retouren an Postfach 100, 1350 Wien

Euro 12,–

Special EditionRECYCLING

Ship owners called to account over recycling on beaches

IN THE DOCK

Tackling TyresCarbon black goes circular

6

Leachate Lessons Reverse osmosis and more

Page 32

Metso Denmark A/S, DK-8700 Horsens, Denmark, Tel.+45 7626 6400 www.metso.com/recycling

Non-shreddables? We don’t think so.

The M&J PreShredders have long been recog-nized for their out-standing strength. It might have something to do with the reliable open cutting table, the robust and wear-resist-ant construction or the extremely aggressive knife design. Most-ly, though, people tend to focus on how easy they shred tons upon tons of mixed waste – even the most non-shreddable.

148894 Nyt layout af annoncer 2016.indd 21 01/09/16 15.52

FROM THE EDITOR

FOOD: THE FIRST FRONTIER OF THE

CIRCULAR ECONOMY

I t seems strange that in a world which put a man on the moon nearly half a century ago, today hundreds of millions of people go without the most basic of provisions - food and clean water. It seems stranger yet

that around one third of all the food produced globally ends up as waste.A recent report by MEP Biljana Borzan found that in developed countries food is mostly wasted at the end of the chain, at distribution and consumption. “Everyone has a responsibility to tackle this problem,” she said. And she’s right. But where do we start?One starting point may be the vast quantity of edible food which can be found in the bins of the average supermarket. But in most developed countries legisla-tion hinders food donations and the retailer’s hands are tied. Consumers themselves also shoulder considerable blame. I doubt anyone reading this has not discarded food they probably shouldn't have bought, or could still have eaten. In a bid to reduce household food waste, Borzan’s report called for a coordinated policy response to labelling, liability and education. Consumers, she argued, do not understand the meaning of “best before” and “use by” labels.It’s an argument backed by the UK’s Waste & Resource Action Programme, which recently found that in the UK alone some 2 million tonnes of food is thrown away by households due to not being used in time, with the date label cited as a factor in around a third of cases.MEPs advocate efforts to halve food waste in the EU by 2030. To achieve this, they propose lifting existing restrictions on food donations and eliminating confusion around labels.Less advanced countries, however, face different challenges. Consumers in the developing world are far less wasteful, but with less sophisticated harvesting, packaging and storage for fruit, crops and vegetables, huge quantities of food are lost further up the supply chain. The Food and Agriculture Organization of the United Nations estimates that the food currently lost in Africa could feed 300 million people.There is no single solution, rather a plethora of small actions and projects that can chip away at the problem. On page 30 we take a look at a project in Ghana which, while not reducing wasted food, is certainly making good use of it. Using simple, cheap technology, not only food waste, but also human waste col-lected by the local municipality is being composted and made safe for use as an effective fertiliser to boost food production. Resource management doesn’t get much more circular.In stark contrast to this low-tech solution, on page 26 we have two examples of ultra high-tech systems using artificial intelligence and state-of-the-art robotics to identify and pick specific items from the waste stream. If that’s not ambitious enough, then turn the page and ponder Antonis’s thoughts on asteroid mining.Enjoy the issue.

Ben Messenger, Chief Editor

“I DOUBT ANYONE READING

THIS HAS NOT DISCARDED FOOD

THEY PROBABLY SHOULDN'T

HAVE BOUGHT, OR COULD STILL

HAVE EATEN.”

Ben Messenger Chief Editor

Eliminating food waste is probably impossible. Using it better is not.

3MAY-JUNE 2017 WASTE MANAGEMENT WORLD

Carbon Black, Black Gold?Dutch company Black Bear Carbon has proven its process for recycling high-quality carbon black from tyres. Page 16

Meet Clarke – The Robotic SorterAMP Robotics' sorting robot Clarke is exceeding the picking capability of a human, averaging one beverage carton pick per second. Page 24

Leachate LessonsFrank Natau, member of the ISWA Working Group on Land-fills, talks with WMW about the importance of proper leachate treatment. Page 32

4 WASTE MANAGEMENT WORLD MAY-JUNE 2017

NOW! BREAKING BOATSLast year, ship recycling on South Asian beaches caused the deaths of 52 workers and countless more injuries. NGO Shipbreaking Platform is trying to stop it.

Page 8

MAY–JUNE 2017

CONTENTSVOLUME 18, ISSUE 3

Now!

8 Time for Ship Owners to Shape Up Last year, alone 52 workers were killed

breaking ships on South Asian beaches. NGO Shipbreaking Platform is trying to find ways to stop the practice.

Letter

15 A Letter From: Israel A new RDF facility in Israel is the largest

environmental project undertaken in the country and is of national importance.

Recycling Special

16 Closing the Loop on Carbon Black Following the successful operation of its

first commercial-scale facility for recy-cling carbon black from tyres Dutch firm Black Bear Carbon is looking to roll out its technology.

20 WEEEthinking Reuse Legislation DIGITALEUROPE is calling on the EU

to recognise the ICT industry’s repair, refurbishment and remanufacturing infrastructure as it updates WEEE regula-tions.

25 Sachet Recycling Endeavour in Indonesia

Unilever is preparing to open a pilot plant in Indonesia to test a new technol-ogy to recycle plastic sachet packaging.

26 Recycling Robot Recovering Cartons in Colorado

AMP Robotics and Alpine Waste & Recy-cling are teaching robots to identify and then pick food and beverage cartons.

28 Cost Cutting HSM Baler for Recycling Firm

German firm Halter Rohstoff is cutting costs and increasing efficiency with a new baler from HSM.

GUEST AUTHORS

“Up till now we are the only one, or one of very few, that can extract car-bon black at such a high quality that it can be used in high- value applica-tions.”Page 17

Rik Leunissen, commercial and business manager at Black Bear Carbon

28 Taking MRF Automation to the MAX

Featuring deep learning technology, Max-AI is BHS’s first commercially available robotic sorting system.

Biowaste

30 Growing in Ghana Backed by the IWMI, a project in

Ghana is producing valuable com-post from a combination of human and organic wastes.

Landfill

32 Landfill Leachate Treatment 101 Industry expert Frank Natau speaks

with WMW about what a landfill operator should consider when selecting the most appropriate leach-ate treatment system.

Waste to Energy

36 50 MW Waste to Energy Plant Nears Completion in Ethiopia

WMW takes an in-depth look at a 50 MW waste to energy facility under construction in Addis Ababa following the $120 million deal between the Ethiopian Electric Power Corporation and UK-based Cam-bridge Industries.

REGULARS

3 Editor’s Letter 6 ISWA Comments12 News35 Imprint, Index To Companies40 ISWA Information 42 Country Spotlight: UK

“Nobody seems to know that the ICT sec-tor is already repairing, refurbishing and rema-nufacturing.”Page 20

Cecilia Bonefeld-Dahl, director general of DIGITALEUROPE

“The state-of-the-art technology for separation today is a stand-alone reverse osmosis system with pH adjustment of leachate.”Page 32

Frank Natau, ISWA Working Group on Landfills

C LLECTION HANDLINGC LLECTION LLECTION LLECTION HANDLING

New Compact Dennis RCV Less Unladen Weight.

Loads More Payload

FIRST IMPRESSIONS

WATER – FAUN VIATEC MAKES IT HOT

WASTE – JCB MAKES A SHOW OF IT

+++ PLUS

MAY–JUNE 2017

KEEN TO BE GREEN?New Electric Sennebogen ‘Green Line’ Machines Might Help.

Collection &HandlingSPECIALEDITON


ISWA COMMENT

SPACE: THE FINAL FRONTIER FOR THE LINEAR ECONOMY?

Antonis MavropoulosPresident, ISWA.

P resident Donald Trump re-

cently stimulated the efforts to utilise metals and rare earths from non-earth resources such as asteroids, the Moon, and Mars by pushing NASA towards this direction. President Obama was the one who signed the US Commercial Space Launch Competitiveness Act, the framework that allows US companies to extract and own any materials they find in non-earth resources. In 2014, the financial services site Motley Fool esti-mated the mineral wealth of the moon to be between $150 quadrillion and $500 quadrillion.The on-going efforts to utilise these resources are a strong argument for the Circular Economy. In a very symbolic way, they highlight that the Linear Business Model is going very close to (or maybe it has already surpassed) Earth’s planetary boundaries.While the EU tries to close the loops and optimise the use of limited resources to manage the upcoming resource scarcity and stimulate a circular economy, the US set the scene for exploiting resources beyond Earth’s limits as a means to pave the way for private companies to own any natural resources they manage to mine from asteroids. If you look at it from a certain perspective, it makes sense.

“CLEARLY, THE SHIFT TO ASTEROIDS AND MOON MINING IS AN ALTER-NATIVE ROUTE TO CIRCULAR ECONOMY. NO ONE CAN SAY FOR SURE IF THE REQUIRED TECHNOLOGICAL ADVANCES WILL TAKE 5, 10 OR 15 YEARS.”

Instead of the serious disruption of changing the business models and devel-oping closed- loop markets and services, mining the Moon and asteroids would allow and stretch the dominance of the Linear Model. It would also allow higher profitability under resource scarcity con-ditions, and provide a new attractive way to spend the hundreds of billions that are looking for investments with high returns in the current global financial crisis and instability.Clearly, the shift to asteroids and Moon mining is an alternative route to Circular Economy. No one can say for sure if the required technological advances will take 5, 10 or 15 years. In any case, it is a visible development that will radically reshape the raw ma-terials market landscape. I am afraid that it will also undermine our efforts to move away from the Linear Economy concept. If we could spend the same amount of money for shifting the in-dustrial business models to Circular Economy, I am sure that we would have better, long-lasting and more sustainable results. Unfortunately, utilising resources from space will be both a proof of the great human ingenuity and of the business ob-session with Linear Economy.

Harvesting valuable materials from extra-terrestrial bodies may sound like science fiction, but it could undermine the move to a circular economy.


SEPTEMBER 25–27, 2017 | BALTIMORE, MD

No Time to Waste... Register Now at ISWA2017.org

Circular EconomyClimate Change Marine Litter Smart Technologies &Innovations

The Roadmap for Closing Dumpsites Energy Recovery New ConnectionsResource Management

Antonis Mavropoulos, President, International Solid Waste Association

Steve Jones, CEO, Covanta

Jim Fish, CEO, Waste Management

Nate Morris, CEO, Rubicon Global

Jim McKay, General Manager, Solid Waste Management Services, City of Toronto

Gary Crawford, Vice President, International Affairs, Veolia

David Biderman, Executive Director & CEO, SWANA

Kathryn Garcia, Commissioner, New York City Department of Sanitation

TIME FORDISCUSSIONS

2017WASTECON_Keynotes_MWM_210mmx297mm.indd 1 5/11/17 9:39 AM

SHIP OWNERS:SHAPE UP,DON’T SHIP OUT

FACTS

862Vessels sent for dismantling in 2016.

668 Vessels were sold to South Asian beaching yards in 2016.

84% Of all European end-of-life vessels by weight ended up in either India, Pakistan or Bangladesh. 40% Of the tonnage broken on the beaches in South Asia came from the EU.

28Workers killed in a single explo-sion in a breaking yard in Gadani, Pakistan. A further 60 were injured.


COVER STORY

While ship recycling yards in Europe, Turkey, China and the US operate

under capacity, ship owners are still opting to scrap hundreds of ships on the beaches of South Asia. Last year alone

the practice caused the deaths of 52 workers and countless more injuries. NGO Shipbreaking Platform is trying to find ways to stop the practice.

By Ben Messenger

I n it’s annual report published 16 May, Shipbreaking Platform reports that last year was one of

the worst on record for injuries and fatal-ities to workers dismantling often con-taminated vessels on the tidal beaches of India, Pakistan and Bangladesh. The worst explosion in the history of ship-breaking struck an oil tanker beached in Gadani, Pakistan. It left 28 workers dead and injured a further 60.

Speaking at an event held at the of-fices of law firm Leigh Day the day be-fore the report was published, Ingvild Jenssen, founder and director of NGO Shipbreaking Platform said: “At least 300 workers have died in the ship breaking industry since the adoption of the new Hong Kong Convention. This is just due to accidents on the yards. Many more workers get sick after having inhaled toxic

fumes and having been exposed to asbes-tos without protective equipment. This is an industry with a human cost to it.”

“The challenges of this industry are not only the human costs, but also that it pollutes a lot,” she continues. “Ships are rammed up tidal beaches with a tidal range of 10 to 13 metres. There is no con-tainment of pollutants such as paint chips which contain heavy metals. They fall into the tidal zone and are washed out by the tide. There’s also no proper down steam waste treatment in these countries. For ex-ample they sell the asbestos in India.”

“This is an industry which often likes to boast about being extremely green be-cause they recycling 95% of the ship, but they also recycle the aesbestos. While ship recycling is something we should continue with, there’s no reason why this shoudn’t be done in a proper way,” adds Jenssen.

INTERNATIONAL REGULATIONSIn 1992, the UNEP Basal Convention came in to protect developing countries from the dumping of toxic waste. It’s Ban Amendment is supposed to prevent the export of hazardous materials from OECD countries to non-OCED coun-tries. However, the ownership structures of the shipping industry and the fact that a ship is a waste which can move on its own have allowed it to easily circumnavi-gate this regulation.

Vessel themselves are owned by the Beneficial Owner, a shipping company which takes the business decisions, costs and profits from the vessel. Then there is a Commercial Operator, in many cases the same company as the Beneficial Owner but not in all cases. Next there is the Registered. This is the company to whom the ship's legal title of ownership has been registered and under whose flag the vessel sails. These are often registered in a country whose tax on the profits of trading ships is low/absent or whose requirements concerning manning or maintenance might be more relaxed.

In 2009 the Hong Kong International Convention for the Safe and Environmentally Sound Recycling of Ships was adopted. It is an initiative of the International Maritime Organization,


COVER STORY

Ship breaking on tidal beaches causes significant pollution to the environment

with no containment of fuel, heavy metals, aspestos and other hazardous substances.

Ingvild JenssenFounder of NGO Shipbreaking Platform

“We do not believe it is possible to use a tidal beach and comply with EU standards.”

which was not happy about the prospect of ship owners being obliged to meet the regulations of their own country, rather the country of the flag under which it flies.

It will not come into force until 24 months after ratification by 15 States, representing 40% of world merchant shipping by gross tonnage. As yet is has only been ratified by seven countries. Even if it does ever come into force, it has been heavily criticised for permitting the beaching of end-of-life vessels.

TOO MANY LOOPHOLESAccording to Jenssen in many cases the Registered Owner will be a post box com-pany established only to deal with that ship. The maritime law applicable in the country flag state will be that under which the vessel is obligated. This pro-vides the loophole through which huge cargo vessels can slip, allowing owners to reflag ships at short notice and bypass the obligations their own environmental and maritime laws may hold them to.

“The absurd situation is that if the vessel is in international waters when the intent to discard is disclosed, there is no export-ing state. What happens in most cases how-ever is that a vessel sails on an 'operational voyage' all the way to Bangladesh, and the intent to disclose is only revealed once it is actually in Bangladesh. Technically there has been no transboundary movement of the vessel as a waste,” she says.

In her presentation Francesca Carlsson, corporate liaison and policy officer at Shipbreaking Platform explained that cash buyers are used as intermediaries for end-of-life sales to the beaching yards. These companies become the new owners of the

ship for a couple of weeks before selling it for the highest scrap price. The cash buyers usually re-flag and re-name the ship.

Typically these buyers use flags known for their poor implementation of interna-tional maritime law. Small island tax ha-vens offer their flag for a cheap ‘last voy-age’ registration fee, often not even with a requirement to incorporate with a post box company.

“Many of these flags provide a discount for registering ships at the end-of-life. They have very low standards for environ-mental protection and crewing,” Carlsson tells delegates. “It’s extremely cheap and it can take a maximum of 24 hours.”

THE EU SHIP RECYCLING REGULATIONIt’s not only the Basel Convention being given the slip. The EU Ship Recycling Regulation requires vessels sailing under a Member State’s flag must send vessels for recycling to an EU approved facility.

Speaking with WMW Jenssen ex-plains: “If you compare the Hong Kong Convention to the EU Ship Recycling Regulation you can understand why we’re much more in favour of the EU regula-tions. They are higher, they include down-stream waste management requirements, labour rights etc. The Commission will be considering a number of applications from around the world including China, Turkey, India and the US. We believe that the regulation will have a global impact.”

Currently all 18 of the approved fa-cilities, with a total capacity of 1.1 million Light Displacement Tonnage (LDT) are located within the EU, but the Commission is currently revising 18 addi-tional applications from facilities located outside the EU. However, even those yards approved are currently running under ca-pacity as owners continue to send ships, often via some murky dealings with cash buyers, to be beached.

In a bid to address that situation a group of five approved recycling yards re-cently signed an agreement to establish the European Ship Recyclers Group (ESR).

“Our first target is to create aware-ness of the recycling capacity in Europe which today is over 1 million tonnes,“ explains newly elected ESR chairman,

Shipbreaking Platform is calling upon the European Union to maintain high standards when publishing its list of approved ship recycling facilities and not to give in to shipping interests that want to continue earning dirty money by using the dangerous, polluting and low-cost method of beach-breaking. It is also calling upon the Member States to support the introduction of a financial scheme based on the polluter pays principle that would incentivise ship owners to opt for a ship recycling facility on the EU list.

CALL FOR ACTION


COVER STORY

In addition to the environmental harm these yards also pose a significant risk to workers’ health and safety. Last year alone 52 people were killed at such facili-ties. The ongoing health problems caused by exposure to hazardous materials and fumes is immeasurable.

Peter Wyntin. "We have to ensure that our member yards are on the top of the ship-owners’ list for dismantling their ships. Our message is a clear one. If we can handle them let’s keep the EU flagged ships in Europe.’’

According to Jenssen one of the prob-lems the European yards have is size, with most of them unable to handle the larg-est vessels. Investment in the infrastruc-ture upgrades to allow these ships to be recycled has not been forthcoming simply because they would not be able to com-pete with the prices offered to ship own-ers by the Asian yards operating on tidal beaches. However, she also notes that disused ship building capacity in Europe could provide a readymade solution.

CONCLUSIONShipbreaking Platform agues that the cri-sis cannot be be effectively regulated by

flag state jurisdiction, as the cash buyers, or the ship owners themselves, will always be able to find flag states that are known for not ratifying or properly implement-ing international conventions and laws, including those regulating ship recycling.

However, the organisation does pro-pose a financial incentive be introduced in Europe which would encourage ship owners to recycle responsibly. One pos-sible way of implementing this would be to make ship owners pay a fee each time they use a port in the EU. At the end of the ship’s life this could be re-turned if the vessel is dismantled in an approved yard.

With the tidal yards of South Asia looking to expand, lets just hope that at least some progress can be made to stop vessels containing large quantities of haz-ardous materials simply shipping out at end-of-life.

Ritwick Duttaenvironmental lawyer based in India

“Unlike in Bangladesh, and to some extent Pakistan, the issue of shipbreaking is not part of the environmental discourse in India.”

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ENTWURF LEA_WMW_EN_1_2 Seite quer.indd 1 22.05.2017 13:54:08

COVER STORY

NEWS

EVENTSDIARY OF

33RD ANNUAL INTERNATIONAL FUEL ETHANOL WORKSHOP AND EXPOMinneapolis19-21 June 2017www.2017.fuelethanolworkshop.com

2ND WORLD BIOENERGY CONGRESS AND EXPO Madrid, Spain29-30 June 2017www.bioenergy.conferenceseries.com

4TH WORLD CONGRESS AND EXPO ON RECYCLING Barcelona 3-5 July 2017 www.recycling.omicsgroup.com

AD & BIOGAS 2017 Birmingham, UK 5-6 July 2017 www.adbioresources.org/uk-ad-biogas-2017

24TH ANNUAL NORTH AMERICAN WASTE-TO-ENERGY CONFERENCE (NAWTEC) West Palm Beach, Florida23-14 July 2017www.swana.org/Events/NAWTEC

IFAT INDIAMumbai26-28 September 2017www.ifat-india.com

IFAT AFRICA Johannesburg 12-14 September 2017 www.ifat-africa.com

RWM Birmingham, UK 12-14 September 2017 www.rwmexhibition.com


Austrian equipment manufacturer, Komptech, is celebrating its 25th anniversary with the launch of the new Topturn X4500 compost turner - a direct descendant of the machine that started the company’s story.A quarter of a century ago, separate collec-tion in the Frohnleiten area of Austria was a new development. It offered an opportunity for Komptech with its Topturn compost turner, which entered what was at the time a new equipment category.What began in a small workshop in Graz grew to become a global player in waste treatment. By 1997 the company had out-grown its contract manufacturing model in nearby Slovenia and set up a new produc-tion facility in Frohnleiten that would also become its headquarters. In 2006, ballistic separators were added to round out its portfolio. "There is no antidote to constant innovation,” said the company’s founder Josef Heissenberger.For its 25th anniversary, the company is also offering a free warranty for 25 months or 2500 operating hours on new machines through to 31 August 2017.

KOMPTECH MARKS 25 YEAR ANNIVERSARY WITH NEW COMPOST TURNER

With the new Topturn X4500 Komptech is continuing a tradition - the first Komptech machine was also a compost turner called the Topturn.

WELSH FIRM FLINTEC LAUNCHES ON-BOARD VEHICLE WEIGHT INDICATORForce and weight measurement specialist Flintec has released a touch-screen vehicle weight indicator, alongside a range of purpose built load sensors and accessories. According to the manufacturer, the FT-30M offers a complete on-board weighing solution capable of displaying weights in either kg or lbs and recording and printing container receipts. Weights can also be linked to customer accounts and transferred easily to back-office software systems for administrative purposes. Data can be downloaded, viewed or printed via the multiple connections available, including USB and RS232.

The FT-30M is VCA approved, CE compliant and has undergone vibration testing.

WEEEUSE TARGETS FOR WALLONIAFollowing a pioneering move by Spain in 2015, the southern Belgian province of Wallonia is next to introduce a target for the reuse of waste electrical items. The target covers six categories of waste appliances, making it wider in scope than the Spanish measures. This Belgian initiative comes as the European Commission publishes its fea-sibility study on setting a separate "prepar-ing for re-use" target for WEEE for the whole EU. In the report, countries with national targets are acknowledged to be more likely to increase preparing for re-use and promote access to WEEE for re-use centres as required by the current WEEE directive.

“If Europe wants to develop the sector and seize the environmental, social and economic benefits of reuse a high ambition must be encouraged EU-wide, with a common ‘preparing for re-use’ target that is separate from recycling.”

Michal Lendirector of RREUSE

NEWS


The humble bag opener may sit at the less glamorous end of the spectrum when it comes to MRF equipment, but it serves a vital role. German manufacturer BRT HARTNER, a part of the Eggersmann Group, has recently installed and commissioned its 500th bag opener at an AGR-DAR recycling plant in Herten, Germany. The plant sorts lightweight packaging material for recycling. The procedure starts with the BO Bag Opener. Its integrated feed hopper is filled by a wheel loader with bags stored in the reception hall. A moving floor conveyor with a modified drive pushes the material to the two-part drum. The two halves of the drum are driven separately and create a relative movement which leads to reliable and efficient opening of the plastic bags. The content of the bags is loosened up but not shredded during this process. The manufacturer explained that the drum and its ripping fingers are extremely rigid and feature a new special coating which quadruples their lifespan. Currently, BRT HARTNER’s largest machine achieves a throughput of up to 220 m³ of light weight packaging per hour with an opening effi-ciency of 95%. The material processed at the Herten facility is sent for further treatment on a down-stream inclination conveyor belt supplied by Eggersmann Anlagenbau.

BRT HARTNER INSTALLS 500TH BAG OPENER AT GERMAN RECYCLING PLANT

BRT HARTNER Bag Opener combined with Eggersmann Anlagenbau's downstream conveyor belt.

Austrian waste processing equipment manufacturer ANDRITZ has received an order from Chinese paper maker, Nine Dragons Paper, to supply a total of five cir-culating fluidised bed boilers (Powerfluid) for utilisation of in-house waste materials.The boilers will be installed at the Nine Dragons’ locations in Taicang, Quanzhou, Yongxin, Chongqing, and Dongguan. Start-up is scheduled for the second half of 2018. Andritz said that the boilers will only process waste from the recycling of waste

paper such as rejects and sludges. The materials will undergo thermal treatment, with the high-pressure steam produced being used to generate electricity and supply the Nine Dragons paper mills with process steam. The Austrian firm explained that rejects and sludge are a considerable challenge in boiler operations due to the corrosive substances and impurities they contain, and they require a special design in this regard. Nine Dragons Paper is the largest paper producer in Asia.

GLASS: STELLAR ENVIRONMENTAL CREDENTIALSAn independent pan-European survey, commissioned by Friends of Glass, has found that despite glass being one of the most sustainable and eco-friendly forms of packaging on the planet, there are still too many people who are not fully aware of its stellar environmental credentials. According to the study, despite being 100% and endlessly recyclable, over one third of respondents were still in the dark. As concerns about the environment and health continue, 9 out of 10 consumers expect companies to operate responsi-

bly to address social and environmental issues. Educating younger people is key to driving up recycling rates. They are not as aware as the older generations about the sustainable credentials of glass packaging.“By recycling glass, consumers are help-ing to reduce CO2 emissions and save energy. Recycled glass melts at lower temperatures than virgin raw materials so less fuel is needed to make new glass packaging,” says Dr Nick Kirk, technical director of British Glass.

“THE MESSAGE THAT ALL GLASS PACKAGING CAN BE

RECYCLED IS STILL NOT BEING UNDERSTOOD BY

SOME, MOSTLY YOUNGER, CONSUMERS.”

Dr Nick Kirktechnical director of British Glass

The survey showed that 44% of the population realise that glass is the

safest packaging option for food and 64% think it is best for beverages.

The order from Nine Dragons marks ANDRITZ’s return to the

Chinese power boiler market after an absence of almost

20 years.

ANDRITZ WINS CHINESE PAPER CHASE

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NEWS

THE NEWS IN NUMBERS

568,696 TONNES OF PVC RECYCLED IN 2016 through the framework of VinylPlus, the European PVC industry sustainable development programme.

20 MAYEelco Leemans and Wouter Jan Strietman will be setting off for the island of Jan Mayen and Svalbard in order to INVESTI-GATE THE QUANTITY AND TYPE OF WASTE ON ARCTIC BEACHES.

2%The Walloon Government Decree requires 2% OF WEEE TO BE ‘PRE-PARED FOR RE-USE’ from January 2020.

$2 MILLIONPrize for inventors to devise products that are practical and easily recycled launched by PRINCE CHARLES IN LONDON.

8 JUNE

WORLD OCEANS DAY. As part of the UN'S OCEAN CONFERENCE, the Plastic Oceans Foundation will be screening the 22-minute educational version of A Plastic Ocean.

13 RECIPIENTS

of the Oregon Department of Energy’s $2 MILLION IN RENEWABLE ENERGY DEVELOPMENT grant funds, including anaerobic digestion and biomass projects.

LETTER FROM

15MAY–JUNE 2017 WASTE MANAGEMENT WORLD

A LETTER FROM…ISRAELIsrael’s largest refuse derived fuel project is underway with a sorting and recycling facility which will process half a million tonnes of waste per year. It is the largest environmental pro-ject undertaken in the country and is of national importance.

In December 1998 three goals were set: rehabilitation of a

mountain of waste at a former land-fill site in the Gush Dan region to the south of Tel Aviv, its transformation into a green park, and the building of a recycling facility to use the resources within the waste.In 2017 the Hiriya Recycling Park’s Refuse Derived Fuel (RDF) plant was in-augurated. The waste sorting and recy-cling plant will produce alternative fuel from wastes for cement manufacturing at Nesher Cement Works. The facility is one of the largest plants of its kind in the world and will receive feedstock from Israel’s largest environmental ser-vices firm, the Veridis Corporation.The plant, which costs around NIS 400 million ($110 million), will process half of the waste produced by the Tel Aviv Metropolitan Area - 500,000 tonnes per year. Its construction involved many challenges, planning and a lot of hard work.The Hiriya facility represents a revo-lution in the way waste treatment is perceived in Israel. For the first time, there is a solution that uses waste for cement manufacturing and reduces the amount of waste being sent to landfill substantially.Household waste is first sorted and shredded. The components suitable for combustion (plastic, nylon bags,

textile, green waste, cardboard and paper) are then sent as RDF to the Nesher cement plant. The use of sorted waste delivers several environmental advantages, including saving landfill space, re-duction in the volume shipped to the south of the country, and reduction in greenhouse gas emissions. The plant is expected to produce about 500 tonnes per day.The project is one of the largest and most advanced of its kind in the world - the spearhead in the Dan Municipal Sanitation Association’s determined effort to improve and advance waste management in Israel as a whole, and in the Tel Aviv Metropolitan Area in particular. It’s a flexible and modular facility. It’s also a good example of a successful three-way match between an industry in need of raw materials and energy, the urban sector in need of a solution for its waste problem, and a technol-ogy enterprise willing to risk tackling the challenge. This model exists else-where around the world and now it has arrived in Israel. The combination of resources, technologies, and public willingness to alter consumption and recycling habits, is key to an environmentally sustainable future and to protecting our environ-mental resources.

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RECYCLING

Carbon black is used as a reinforcing agent in rubber products, including the 2.5 billion tyres produced globally each year.

However, the closed loop recycling of the fossil based material has not taken off at commercial scale. Dutch firm Black Bear Carbon

could be about to change that.

By Ben Messenger

CLOSING THE LOOP ON CARBON BLACK

FACTS

1.5 BILLION Tyres, or 13.5 million tonnes waste, are removed from vehicles each year.

500,000Tyres which are either burned or buried in landfill each year.

2.5 LITRESOil required to make 1 kg of carbon black.

90 %Of global carbon black production which is used in rubber products.

>1 MILLIONTrees needed to absorb the carbon saving of Black Bear’s facility.

2.4 BILLION Tyres manufactured each year.


RECYCLING

C arbon Black’s history can be traced back as far as an-cient Egypt, where it was

used as a pigment in early inks. Today, two carbon black manufacturing pro-cesses are in widespread use (furnace black and thermal black) and produce nearly all of the global production of around 8.1 million tonnes of the material per year. Traditionally, as oil prices and, in turn, feedstock prices have fallen, so have the costs for carbon black producers.

However, in an interview with Asia Rubber, Bart Kalkstein, senior vice presi-dent and president of the Reinforcement Materials Segment at Cabot Corporation, one of the world’s largest carbon black suppliers, said that while oil process are currently low, the actual costs of carbon black feedstocks relative to fuel oil indi-ces have been rising.

“This widening difference between the indices and actual costs has per-sisted since early 2015, and is forecasted to continue into the future putting pres-sure on our business and causing us to raise our prices in many places simply to

keep up with feedstock costs,” he said.With around 2-2.5 kg of oil used to

make 1 kg of carbon black, some 20 mil-lion tonnes of petroleum products are being burned globally each year in its production. Rising feedstock costs could prove to be a significant factor in the move to a more circular use for end-of-life tyres and other rubber products.

For years there have been efforts to de-liver a commercially viable, closed-loop recy-cling process for tyres, but until recently the challenge has proved to be a bridge too far. For the most part, tyre waste has been either used for granulate in low value applications, sent for energy recovery, or simply buried.

Now, however, there are now a hand-ful of companies getting ready to roll out large-scale closed-loop recycling facilities for rubber materials. One of those, Dutch firm Black Bear Carbon, is already operat-ing its first commercial scale plant.

“Over the past decades, there have been tens or even hundreds of projects which have used pyrolysis to recover raw mate-rials from tyres, but they mostly recover oil. In terms of recovering carbon black, there have been several projects to recover carbon black so that it can be used again. But up till now we are the only one, or one of very few, that can extract carbon black at such a high quality that it can be used in high-value applications," says Rik Leunissen, commercial and business manager at Black Bear Carbon.

TECHNOLOGYThe company was founded at the end of 2010 by three partners including a waste management entrepreneur who had never found a good solution to disposing of tyres, a chemical engineer with significant knowledge of pyrolysis processes, and a rubber industry expert with decades of experience with carbon black.

The pyrolysis process they developed uses end-of-life tyres as a feedstock and is claimed to produce consistent, high-qual-ity carbon blacks consistent in perfor-mance and with unique properties com-pared to traditional grades.

Speaking with WMW, Leunissen ex-plains: “We have developed our technology to extract the carbon black from the

With 2.5 billion tyres being manufactured every year, and 1.5 billion entering the waste stream, recovering

carbon black from waste tyres has long been an enticing prospect - but it’s not easy.


RECYCLING

tyres at such a high quality that you can reuse it again in high-quality applications like new tyres. That allows us to close the loop on a significant portion of the car-bon black cycle. We do this through a pyrolysis-based process with some addi-tional elements.”

Prior to arriving at Black Bear’s facility the steel is removed from the tyres and sent for recycling. The remaining rubber then undergoes a carbonisation process. Here the rubber is heated in the absence of oxygen and broken down into gaseous molecules. The solid carbonaceous char left behind is valuable because it contains all of the high value 'furnace' carbon blacks that were used to make the tire, but the process of recovering them is far from complete.

“After the pyrolysis step, what you’re left with is char,” explains Leunissen. “It’s globs of carbon black stuck together. It looks like something you might find in your fireplace. It’s Actually, it is a useless product in this state. Depending on how you do the pyrol-ysis, even the carbon black particles that are in there might not be useful.”

Consequently, the next stage in pro-ducing high value carbon black is a de-ag-glomeration process. Here the char is bro-ken down into smaller particles, or aggre-gates. The process controls the ‘particle size distribution’ (PSD) of the final prod-uct. PSD is a key product performance property as it relates to carbon black’s reinforcing effect in rubber compounds.

“We’re really talking nanometre size,” says Leunissen. “It’s not entirely separate particles, but almost. The primary par-ticle size is around 30 NM. Depending on the application, we then pelletize it. This makes small granules out of it, like instant coffee. This eases handling and transportation, but they do break down very easily when necessary. This is what they typically use in the tyre industry, but we can also pack it as a powder.”

To achieve the correct consistency in the pelletizing process, the company uses small amounts of water and binding agents in a pelletiser mixer. Large volumes of air are removed from the carbon black powder and pellets. Once pelletization is complete, the water that was used is

evaporated under controlled conditions in a drying stage. A very small amount of binding agent remains behind and en-sures that the dried pellets hold together.

PURITYDifferent parts of a tyre require differ-ent physical characteristics. To achieve this, there are six to eight different types of carbon black used in a typical tyre. Currently, Black Bear’s facility is recov-ering a mix of those different types of carbon black, which has both advantages and disadvantages and offers a mix of mechanical reinforcement and dynamic performance.

“Because it’s a mix of different types of carbon black, it’s never a full one-to-one replacement,” says Leunissen. “The per-formance impact will always be slightly different to the pure form that the cus-tomer was using before. The carbon black has unique properties when compared to traditional blacks. It can very often give performance improvements, but it is something to be aware of and something that we educate and support our custom-ers with regarding understanding what the impact will be, and how to use the product best."

However, in the future Leunissen sees the potential to recover the various types of car-bon black more specifically than is currently possible by adding additional pre-treatment steps to sort the various parts of the tyres prior to the pyrolysis process.

“The more specific you can be in sepa-rating the different rubber compounds of a tyre before processing, the more specific the type of carbon black you can recover,” says Leunissen. “We need to separate the sidewall from the tread. At the moment we process the whole tyre with the steel

Rik Leunissencommercial and business manager at Black Bear Carbon

“THE MORE SPECIFIC YOU CAN BE IN SEPARATING THE DIFFERENT RUBBER COMPOUNDS OF A TYRE BEFORE PROCESSING, THE MORE SPECIFIC THE TYPE OF CARBON BLACK YOU CAN RECOVER.”

Black Bear Carbon’s first commercial scale facility can process 15,000 tonnes, or 1.5 to 2 million tyres per year, recovering around 5000 tonnes of carbon black.

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removed. We are working on automating separation of the tyre because the mar-gins are too low to have people doing it manually and it will be relatively easy to automate."

CARBON NEGATIVEWhile the recycling of carbon black is the company’s primary objective, the facility also produces other valuable products from the process.

“In the Netherlands we have our first industrial scale factory, which has a ca-pacity of 15,000 tonnes, or 1.5 to 2 mil-lion tyres per year,” explains Leunissen. “The output from that is 5000 tonnes of carbon black, 4000 tonnes of oil, and 3000 tonnes of gas. We use the gas for en-ergy generation on site.”

The plant generates around 95% of its energy needs using a combined heat and power gas engine. To do this, it first has to scrub the gas to remove the sulphur. The electricity generated is fed into the national grid rather than being used di-rectly on-site, as that setup provides a more stable supply.

An independent Life Cycle Assessment to validate its environmental impact found that the process is net ‘negative' - meaning it takes more CO₂ out of the at-mosphere than it consumes. A key driver of this is the production of energy in the process, which otherwise would have to be produced using fossil fuels. The pro-cess produces around 1.6 MWe and ap-proximately 1 tonne of oil per tonne car-bon black.

THE FUTURELeunissen sees a bright future for the tech-nology: “We’re now at a stage where we have proven the technology at industrial

scale. We’re now starting to actively en-gage with the bigger tyre collectors in the world to partner with them to provide a higher-value way of recycling those tyres. Because of the logistical costs of transport-ing waste tyres, it will likely be a technol-ogy which will provide a local solution.”

In terms of the business model, the firm pays for its rubber granulate feed-stock and does not need a gate fee to be commercially viable.

“Of course life becomes much easier if there’s a gate fee,” concludes Leunissen. “It also becomes easier if the oil price is twice as high because the carbon black price is linked to oil.”

Depending on the markets and the di-rection EPR regulations take, that could well happen. Even if there is little change in those regards, it’s good to see a com-mercially viable solution which retains the valuable valuable of fossil-based ma-terials and keeps them in circulation.

The carbon black recycled can be used as a reinforcing agent in rub-ber based products such as drive belts, as well as new tyres.

RECYCLING

bers are already contributing to through repair, refurbishment and remanufac-turing activities. In a recently published report the organisation notes that in order to provide cost efficient services its members have established central facilities inside and outside of the EU. This infrastructure, next to the waste collection and treatment facilities, is the circular economy backbone of the ICT industry in Europe. According to the re-port it contributes to reuse and increased lifetime of IT devices on the European

S peaking at the recent 5th International WEEE Forum C o n fe r e n c e i n M a l t a ,

Karmenu Vella, EU Commissioner for the Environment, Fisheries and Maritime Affairs, said: “We are also developing a number of measures under the Circular Economy package which will contribute to closing the cycle, promoting products de-signed for reuse and recycling, and business models that go with such transformation.”It’s a transition which IT industry trade body DIGITALEUROPE says its mem-

As the Circular Economy Package continues to stir debate, DIGITALEUROPE has published a report calling

on the EU to recognise the ICT industry’s existing and significant repair, refurbishment and remanufacturing

infrastructure as it updates WEEE regulations.

By Ben Messenger

TIME TO WEEETHINK

REUSE & REPAIR LEGISLATION?

FACTS

65 % By weight of EEE placed on the market to be recycled by Member States in 2019.

118,000 TONNESGlobal shipments for repair and remanufacturing per year.

$6.9 BILLIONTurnover of ICT remanufacturing business in Europe.

9 WEEE generated in the EU in 2005 - expected to grow to more than 12 million tonnes by 2020.

MILLION TONNES


RECYCLING

market. “As part of the Circular Economy and the Waste Framework Directive, we’ve been discussing reuse and reus-ability, and the design of equipment,” Cecilia Bonefeld-Dahl, Director General of DIGITALEUROPE. “Nobody seems to know that the ICT sector is already re-pairing, refurbishing and remanufactur-ing, so we produced a report to showcase what our industry is already doing.”

“For us, the most important part of the Circular Economy Package is the re-

Since 1991, Nokia has been remanufactur-ing telecommunications equipment as an “eco-sustainable” alternative to manufacturing new equipment. The Finnish firm has refined its business to provide a variety of used equip-ment offers. This includes a full and expanding line of Nokia remanufactured products across all business groups, multi-vendor reuse, buy-back / trade-in offers and a Client Asset Man-agement program for clients’ surplus inventory, in support of continued use of its mature and end-of-life products.

NOKIA GLOBAL ASSET RECOVERY & REMARKETING SERVICESCONNECTING USED EQUIPMENT

vision of the Waste Framework Directive. Some of the proposed amendments would require tools and software to be made publicly available, and that risks undermining the established repair and refurbishment industry across Europe,” she tells WMW.

CROSS BOARDER SHIPMENTSAccording to the report, in order to en-able DIGITALEUROPE member com-panies to expand this business and con-tribute further to the circular economy, reuse, repair, refurbishment and remanu-facturing should not be addressed under waste legislation.

While the shipping of WEEE under the guise of being products destined for repair and reuse has caused problems, most notably with illegal exports to devel-oping countries, Bonefeld-Dahl says that DIGITALEUROPE fully supports the goal of stopping the illegal shipment of e-waste. However, she adds that she does believe though that legitimate repair / re-furbishment and remanufacturing prac-tices of used EEE should be preserved.

“Working on the premise that the cir-cular economy is the political objective, the prolonging of product lifetimes of complex high value products becomes a condition sine qua non. This requires in turn the permission to ship used EEE across borders for testing, route cause

Cecilia Bonefeld-Dahl director general of DIGITALEUROPE

Remanufacturing is a process where a non-functional, discarded

or traded-in product is returned “to at least its original perfor-mance with a warranty that is

equivalent or better than of the newly manufactured product”.


“IF YOU MAKE IT A WASTE, THEN TRANSPORT IS MORE EXPENSIVE, ESPECIALLY IF IT’S CLASSIFIED HAZARDOUS WASTE. IT HAS AN IMPACT ON COST.”

RECYCLING

analysis and refurbishment/re-manufac-turing,” Bonefeld-Dahl explains/

A case in point is the administrative burden from waste shipment regulations for shipments of products destined for failure analysis, repair or remanufacturing.

“You need certain facilities to test them and you can only have these in a regionally centralised place,” she notes. “Therefore you need to allow shipment of used equip-ment across boarder. If you make it a waste then transport is more expensive, espe-cially if it’s classified hazardous waste. It has an impact on cost and it makes the re-used product less price competitive.”

“If you have a reused product and it’s being sent for repair, you would have it packaged and it would have paperwork with it. For example, there could be a service contract which says ‘these servers need to be upgraded,’ so there’s a paper trail with it,” continues Bonefeld-Dahl.

ECODESIGNWhile Vella says that the Directive has “driven better product design to facili-tate the reuse and recycling of products”, DIGITALEUROPE is urging the legislators not to “impede product innovation” or “af-fect product reliability and functionality”.

“Under the current Ecodesign Working Plan, we are focusing on requirements for durability, reparability, design for disassembly, and ease of reuse and recy-cling when addressing product design for important product groups,” says the Commissioner.

However, DIGITALEUROPE says that when manufacturers design for durabil-ity, the aim is to reduce the likelihood of a necessity for a repair event during the life of the product to the minimum. According to Bonefeld-Dahl, there are trade-offs be-tween durability and repairability that need to be considered on product level reg-ulation. For a highly durable product or part of a product that is unlikely to fail a more complex, professional service repair option might be preferable and in many cases the only way (think for example of waterproof electronic products).

For these reasons the organisation argues that in legislating for a circular economy it is important to ensure safety and quality of the repair experience of consumers by recognising the trusted status of authorised repair networks and refurbishment/ remanufacturing facili-ties. The report also calls for IP rights as-sociated with the innovative nature of the sector even in the aftersales, maintenance and repair market, in particular with re-gard to license agreements and access to proprietary information, to be protected.

“If a repair is undertaken by the man-ufacturer, or an authorised company, then if it turns out that the repair is not possible, we know that the device will en-ter the waste stream in the proper way,” says Bonefeld-Dahl. “If the repair was a DIY repair we do not. If someone replaces their phone battery at home, what hap-pens to the old one?”

The organisation is also calling on the EU not to revise laws to enable the con-sumer rather than the trader to choose the remedy in disputes over faulty de-

Deloitte Global estimated that in 2016 approximately 120 million used smartphones were sold or traded in by consumers, calling it the “$17 billion market you may never have heard of”.

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With the remanufacturing of used printer cartridges, RICOH is following the Comet Circle strategy created in 1994 and developed in Europe since 2008. In 2012, RICOH launched its GreenLine. Whereas manufacturing of new products takes place outside Europe, the remanufac-turing business was able to create new jobs in Europe: for example, the 3R activities at RICOH today employ about 400 people in the Green factory located in France. Remanufactured MultiFunction Printers are offered by RICOH and certified as new, with the same warranties as new products, but with a lower environ-mental impact.

RICOH’S COMET CIRCLE DELIVERING JOBS

vices. It argues that this would result in a significant increase of electronic devices being unnecessarily refunded or replaced rather than repaired – at a cost and with local job impact.

CHANGING BUSINESS MODEL – PERFECT STORM FOR RECYCLERS?The DIGITALEURPE paper notes that in some business models the business rationale inherent in leasing models or offering product functions rather than products is on the rise - e.g. selling copies rather than printers.

“It's almost the perfect storm for recy-clers; digital transformation, multi-func-tional devices, pay-per-use services replac-ing buying a product and ever greater re-use and refurbishment are already making dramatic changes to their world,” says John Higgins, director general, DIGITALEUROPE.

Walter Stahel, professor and founder of The Product-Life Institute, concludes: “Selling the functional services of EEEs in-stead of the goods themselves results in a much higher efficiency in the use of re-sources and high prevention of e-waste, but requires a shift from a Linear Industrial Economy to a Performance Economy, and similarly a shift to Space X selling space transport to NASA, instead of industry man-ufacturing space shuttles for NASA.”

In order to reuse, repair and remanufacture a substantial quantity of equipment signifi-

cant regional infrastructure is required, such as Ricoh’s Collection Centre in France.


RECYCLING

G lobally hundreds of bil-lions of single-use sachets are sold every year, but

without a viable recycling solution, sa-chet packaging ends up in landfill or as litter. As part of its Sustainable Living Plan, Unilever has committed to finding an alternative.

The resulting technology, dubbed the CreaSolv® Process, has been devel-oped with the Fraunhofer Institute for Process Engineering and Packaging IVV in Germany and is inspired by an innova-tion used to recycle TV sets.

The process has been adapted from a method used to separate brominated flame retardants from waste electrical and electronic equipment polymers. During the process, the plastic is recovered from the sachet, and then used to create new sachets for Unilever products - creating a

With the collecting, sorting, and processing of waste plastics becoming more important than ever, WMW takes a brief look at some of the most innovative projects of the year.

By Ben Messenger

IN SHORT: PLASTIC

PROGRESS #1: WORLD FIRST PLASTIC SACHET RECYCLING PLANT COMING TO INDONESIA

“I SAW HOW WELL THE MACHINE WORKS UNDER HIGH STRESS DURING EVERYDAY OPERATION.”

Hans-Peter Kremertechnical developer at Thommen AG PAGE 28

#3


RECYCLING

Plastic sachets are a particularly popular form of packaging in the

developing world as they allow low-income consumers to buy

small amounts of product.

fully circular economy approach. “Billions of sachets are used once

and just thrown away, all over the world, ending up in landfill or in our waterways and oceans,” explained David Blanchard, chief research and development officer at Unilever. “At the start of this year we made a com-mitment to help solve this problem, developing new recycling technolo-gies. We intend to make this tech open source and would hope to scale the technology with industry partners, so others – including our competitors – can use it.”

THE PROCESSAt the start oft he process sachets get shredded then mixed with a non-clas-sified solvent. “Studies have shown that even in mixed batches of flexibles,

Working with Germany’s Fraunhofer Institute, consumer products firm Unilever is preparing to open a pilot plant in Indonesia to test a new technology to recycle the materials.

around 60% of the polymer content is polyethylene – so we are focussing in extracting this. It is then made into a paste and the solvent is evaporated.,” Blanchard explains.

“This is then extruded into good quality polyethylene pellets which can be literally wheeled across back to the supplier and blown into film. The rest of the Film residue can be reused for other purposes (e.g. compression moulding plastic pallets), hence we close the loop and have circular econ-omy,” he tells WMW.

The vast majority of material recov-ered is polyethylene. What is left over is residual waste comprising of poly-ester, aluminium, polypropylene and sometimes nylon.

“We can take all flexible materials into the process – so they don’t have to be separated, however the compo-

sition mix does affect the efficiency of the system i.e. more polyethylene content, the better the yield,” adds Blanchard.

To test the long-term commercial viability of the technology, Unilever will open a pilot plant in Indonesia later this year. According to the com-pany, Indonesia is a critical country for projects tackling waste. It pro-duces some 64 million tonnes every year, with an estimated 1.3 million tonnes ending up in the ocean.

“There is a clear economic case for delivering this. We know that globally $80-120 billion is lost to the economy through failing to properly recycle plastics each year,” says Blanchard. “Finding a solution represents a huge opportunity. We believe that our commitment to making 100% of our packaging recyclable, reusable or com-

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postable will support the long-term growth of our business.”

COLLECTION SCHEMESUnilever is looking to create a sus-tainable system change by setting up waste collection schemes to channel the sachets to be recycled. Currently the company is testing this by work-ing with local waste banks, govern-ments and retailers. It will also look to empower waste pickers, integrate them into the mainstream economy and provide a potential long-term in-come, generating wider growth in the economy.

This initiative is part of Unilever’s pledge to ensure that all of its plastic packaging is fully reusable, recyclable or compostable by 2025. The com-pany had already committed to re-ducing the weight of its packaging by one-third by 2020 and to increasing the use of recycled plastic content in

its packaging to at least 25% by 2025.“By this innovative pilot-plant we

can realise for the first time the recy-cling of high-valuable polymers from dirty post-consumer multilayer sa-chets,” says Dr. Andreas Mäurer, de-partment head of Plastic Recycling at the Fraunhofer IVV. “Our aim is to proof both: economic profitabil-ity and environmental benefits of the CreaSolv® Process.”

Unilever concluded that while the new technology represents a ma-jor step forward, plastic waste is a multi-faceted challenge that will re-quire continued innovation in tech-nology, design, delivery models and materials to create a fully circular economy for plastics. The company will also continue its work with the Ellen MacArthur Foundation's New Plastics Economy initiative and con-tinue looking for additional solu-tions.

R obotics and artificial in-telligence offer tremen-dous opportunities to

automate tasks in many industries. In Colorado, a pilot program led by the Carton Council, AMP Robotics and Alpine Waste & Recycling is teaching robots to identify and then pick food and beverage cartons.

The Carton Council, a trade body composed of four major carton manu-facturers explained that AMP’s Cortex robot continually learns to recognise the various types of food and bever-age cartons, allowing for the system to meet accuracy levels of existing solu-tions. This learned information can be transferred to robots at other MRFs.

In this project the system has learned to identify the wide variety of food and beverage cartons in order to grab and separate them from the recy-cling stream.

Launched in 2015, AMP is based in Bolder, Colorado, and applies ma-chine learning and robotic technol-ogy to the recycling process. "AMP" stands for Autonomous Manipulation and Perception. According to the company, it is a scalable robotic sys-tem that reduces costs and enables

“IT IS CLEAR THAT IF WE WANT TO CONTINUE TO REAP THE BENEFITS OF THIS VERSATILE MATERIAL, WE NEED TO DO MUCH MORE AS AN INDUSTRY TO HELP ENSURE IT IS MANAGED RESPONSIBLY AND EFFICIENTLY POST CONSUMER USE.”

Paul PolmanUnilever CEO

‘Clarke’ has exceeded the picking capability of a human, averaging one pick per second.

FACTS

14 %Plastic packaging is recycled globally.

1/3Of plastic waste estimated to end up in fragile ecosystems globally.

100 % Unilever’s packaging to be recyclable, reusable or compostable by 2025.


RECYCLING

#2: RECYCLING ROBOT ‘CLARKE’ RECOVERING CARTONS FOR RECYCLING AT COLORADO MRF“smart” recycling facilities. The sys-tem is a combination of state of the art computer vision and machine learning with robots that can identify and pick recyclable materials from a conveyor belt. A typical AMP deploy-ment fits on existing recycling lines, with no retrofit costs, and is claimed to reduce sorting costs by over 50%.

At the Alpine Waste & Recycling facility, the system has specially de-signed grips to pick up and separate the cartons, which are sold and made into new paper products and green building materials. It has the ability to sort at super-human speeds, diverting material for re-processing that might otherwise be lost to a landfill.

Nicknamed “Clarke”, after the sci-fi author and futurist Sir Arthur Charles Clarke, the AMP Cortex has spider-like arms with specially designed grip-pers to pick up and separate cartons at a materials recovery facility (MRF). Clarke was installed in late 2016 and, through fine-tuning and adjustments, has achieved a pickup rate of 60 car-tons per minute – a human averages around 40 picks per minute.

“Everything Clarke has learned about identifying cartons can be

transferred to robots at other MRFs. We are excited to bring innovation to carton recycling and believe this technology has widespread implica-tions for the recycling industry, as it can be adapted to other materials,” commented Jason Pelz, vice president of recycling projects for the Carton Council of North America and vice president, environment, for Tetra Pak cluster Americas.

The project was possible through a grant from the Carton Council. Ultimately, the Carton Council and AMP Robotics hope to duplicate the success of Clarke at other MRFs as an innovative, cost-effective, long-term solution to sort cartons.

“Clarke provides a new and excit-ing approach to sorting recyclables. Currently there is nothing out there that does what this system does,” said Matanya Horowitz, founder of AMP Robotics in Denver. “Clarke can be a cost-effective way for facilities to intro-duce new packaging that does not al-ways have a large volume. Additionally, unique grippers can be developed to identify and pick contaminants, which is one of the biggest issues our indus-try currently faces.”


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Phone: +49 2661 62 [email protected] | www.vecoplan.com

SHREDDING – CONVEYING – SEPARATING

Reprocessing technologies for optimum output

results:

production waste

EFFICIENT.COMPACT.OUTSTANDING.

post consumer waste

residual waste

post consumer waste

residual waste

RECYCLING

#3: COST CUTTING HSM BALER FOR RECYCLING FIRM

fter 20 years of service, a large-format baling press at Halter Rohstoff

AG’s facility in Biel, Switzerland, was beginning to cause concern. The solu-tion is cutting costs and energy con-sumption.

With the aging baler at Halter Rohstoff AG becoming increasingly expensive to maintain, the company, a subsidiary of Thommen AG, decided an upgrade was in order.

According to Hans-Peter Kremer, technical developer at Thommen AG made several reference visits to HSM customers in south Germany. Among others, he visited a company which has been pressing the entire range of materials in constant alteration with a large-format channel baling press from HSM for seven years without complaint.

Having made its decision, Thommen AG went on to make some clear demands on the manufacturer. It was agreed that the machine would be returned and penalty payments would be due if promises (throughput, bale weight, electricity consumption, etc.) were not kept.

REDUCED RUNNING COSTSAt Halter Rohstoff AG, the bales were previously strapped vertically with five wires. Today they are only strapped with four wires using the same wire strength, thereby saving

#4: BHS TAKES MRF AUTOMATION TO THE MAXAs it continues to expand its product range, Eugene, Oregon-based Bulk Handling Systems (BHS) has unveiled Max-AI, an artificial intelligence that identifies recyclables and other items for recovery.

eaturing deep learning technology, Max-AI™ is BHS’s first commercially

available robotic sorting system de-signed to automate picking processes at material recycling facilities.

The system employs both multi-lay-ered neural networks and a vision sys-tem to see and identify objects similar to the way a person does. According to BHS, the technology will drive improve-ments in MRF design, operational effi-ciency, recovery, system optimisation, maintenance, and more.

The first available machine utilising Max-AI technology is an Autonomous Quality Control (QC) unit which sorts container streams following op-tical sorting. The robotic sorter uses its vision system to see the material, its artificial intelligence to think and identify each item, and a robot to pick targeted items.

“This technology was simply not possible until now,” states Thomas Brooks, BHS Director of Technology

2%. For certain materials, a fifth wire can be connected.

The Swiss operators also opted for a stepless frequency-controlled drive of the HSM VK 12018. In com-bination with the HSM pump con-cept, this leads to an energy saving of around 50,000 kWh/year in continu-ous operation.

With this combination, HSM said that its machine has already reached the energy efficiency class IE 4 – even though IE 3 will only become a legal requirement in 2017. “The HSM press is almost a full step ahead of the legis-lation,“ said Kremer.

At Thommen, it is expected that the electricity savings of one machine over 20 years will amount to one third of the purchase price of a new press.

Low maintenance was another sell-ing point. The stress-free, cardanic suspension of the press cylinder, for example, prevents stresses and tilting, so no expensive cylinder replacement is expected. Additional wear plates made of high-strength XAR500 steel make it possible to exchange only these plates, but Hans-Peter Kremer is not expecting this: “With our mate-rial, the sheets last 30 years“.

There is also an advantage in the logistics as the new bales are around 150 kg heavier than the old bales with the same bale volume, the trucks can be loaded faster.

Following a selection process, Halter Rohstoff and Thommen AG opted for the channel baling press HSM VK 12018 R FU from HSM.


RECYCLING

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Development. “Recent advances in computer processing capabili-ties have enabled us to develop this ground-breaking machine learning platform.

Max-AI is said to be able to make multiple sorting decisions autono-mously, for example separating var-ious materials such as thermoform trays, aluminium, and fibre while re-moving residue from a stream of PET bottles. All of this is done at rates ex-ceeding human capabilities.

“Labour is a significant challenge for MRF operators and it’s obvious that Max will be very beneficial in helping our customers manage that aspect of their business,” noted BHS chief executive officer Steve Miller. “However, the highest returns will come from complete integration of Max-AI technology throughout every

“THIS IS AN

EXCITING TIME

INDEED.”

Roy MillerBHS’s vice President of engineering

Max is an artificial intelligence that uses machine vision to analyse

and sort material streams. Its first deployment is at Athens Services’

MRF in Sun Valley, California.

advanced BHS system. Our custom-ers will not only have autonomous sorting, but also an intelligent central nervous system that observes what’s happening in the plant in real-time and adjusts process parameters to maximise profits.”

TAKING CONTROLBut Max-AI is not just a robotic sorter. Max-AI technology will soon become the active brain of BHS’s MRFs, con-trolling various robotic, optical, and other sorting equipment, providing real- time material composition analysis, and making autonomous decisions.

The first commercial Autonomous QC unit is already in operation at Athens Services’ Materials Recovery Facility (MRF) in Sun Valley, California. The plant won the prestigious SWANA Award for Excellence in 2016 and was

the ideal location for the first installa-tion of Max-AI robotic sorters. The sys-tem now complements the advanced screen, air, and optical separation technology already in use. Integrating with the company’s existing NRT op-tical sorters, BHS said that Max pro-vides a fully autonomous PET sorting solution. Max is central to BHS’s plan to bring autonomous optimisation to MRFs over the coming years, increas-ing performance and profitability.

“For me, this is the culmination of decades of technological devel-opment in recycling,” BHS’s vice President of engineering, Roy Miller, says. “Operating costs will go down while uptime, throughput, recovery and purity will all increase, leading to significant economic benefits for our customers and environmental gains for stakeholders everywhere.”


RECYCLING

ronmental health, and on the other, frag-ile food security, due in large part to low soil fertility,” says Josiane Nikiema, the IWMI scientist leading the project.

Jekora Ventures aims to produce and market around 500 tonnes of an organic fertiliser named Fortifer™ over the next 12 months. The product is made from processing both human and other or-ganic waste including food. It is a safe, nutrient-rich compost which the plant will sell in powder and pellet forms. To achieve this, the company says that it will invest US$90,000 of its own funds for plant operations and maintenance, as well as commercialising the product.

AIDING AGRICULTUREAccording to IWMI, the product has been extensively demonstrated in field trials and proven to improve the yields of com-mon grains, like maize and rice, as well as vegetable crops, including okra, to-matoes, pepper, cabbage and lettuce. To manufacture the product, the plant will treat 12,500 cubic metres of fecal sludge from the septic tanks of household and

In May this year, Ghana’s first pub-lic-private enterprise dedicated solely to producing affordable fer-

tiliser began operations. The JVL Fortifer Compost Plant in the community of Borteyman in Greater Accra uses simple technology based on research carried out by the International Water Management Institute (IWMI).

The plant, which will contribute to improving urban sanitation, while at the same time helping to boost farm produc-tivity, is the result of an alliance of public and private sector partners.

Founded in 2003 as a routine main-tenance contractor with the Accra Metropolitan Assembly (AMA) to pro-vide cleaning services at a truck park, Jekora Ventures will operate the facility which is located in the Borteyman area of Greater Accra.

“The establishment of this plant rep-resents a bold move to confront with one blow two challenges that Ghana and other African countries face. On the one hand, inadequate handling of domestic waste, which threatens human and envi-

“IN A RAPIDLY URBANISING

WORLD, THIS IS WHERE WE CAN

FIND NOVEL DEVELOPMENT

SOLUTIONS THAT LEAD

TO GREEN ECONOMIES.”

Jeremy BirdIWMI’s director general


BIOWASTE

In Ghana a new project backed by the IWMI and supported with funds from OECD countries, as well as

the Bill and Melinda Gates Foundation, is producing valuable compost from a combination of human and

organic wastes.

FROM WASTE TO

FIELDPERFECT PARTNERS AT

GHANAIAN COMPOST PLANT

The land on which the plant has been built was the provided by the Tema

Metropolitan Assembly, which will also ensure feedstock supplies.

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public toilets – the quantity generated by around 100,000 people. The plant will also recycle around 700 tonnes of organic food waste.

Before the dried sludge is mixed with organic food waste or sawdust and “co-composted” for 3 months, it is dried on beds of sand. The composting process involves regular heaping and turning of the material as it decomposes. Heat gen-erated in the process kills any pathogens in the waste, giving a product that meets the safety standards set by the World Health Organization (WHO) for reuse of human excreta.

According to Pay Drechsel, who leads IWMI’s Urban-Rural Linkages Program, the plant does not require sophisticated or expensive technology and expertise.

“Its success depends on a viable busi-ness model, which we and our partners have refined over the years at our re-

search-for-development hub in Ghana,” he says. “We are also now promoting it in Asia, as part of a wider effort to achieve more circular economies in the develop-ing world.”

The IWMI’s Nikiema adds: “Farmers participating in our research have con-sistently expressed a willingness to buy a locally produced organic fertiliser, so we believe there is strong potential for ex-panding this product’s market share in Ghana,” said Nikiema. Pilot trials suggest that the waste recovery process can gener-ate enough income to earn a profit. This should attract further public and private investments to help cover the costs of waste treatment, creating more benefits for society through reduced pollution.”

Pilot trials suggest that the process can generate enough income to earn a profit. If all goes to plan researchers ex-pect further investments.


BIOWASTE

FACTS

700 TONNES Pure organic food waste to be processed each year.

500 TONNES Fertiliser to be produced for sale to local farmers.

12,500 m3 Of Fecal sludge to be co-processed with food waste.

difficult and very expensive – often with unwanted side effects.

What should the landfill operator consider when looking for possible solutions?Frank: In order to create the most suita-ble leachate treatment solution, it is im-portant to consider the type of waste dis-posed, for instance municipal solid waste or hazardous waste, the overall climate conditions, the discharge parameters – as the more or less given boundaries for the engineering design.

Strategic considerations include: What lifespan the landfill is designed for? Will it be extended in future? Will it be partly capped - or even upgraded with a preced-ing MBT process? The answers to these questions have major impact on leachate production and leachate pollution – not to forget the usually long lifetime of 30 years or more plus the necessary aftercare period. In summary, the environmental and commercial importance is huge.

What needs to be considered in the fundamen-tal landfill design and what is the typical setup for a landfill in regard to emissions?Frank: The two main emissions of a land-fill are the landfill gas and the leachate. The gas, after collection, is often flared or

WMW: Frank, in the ISWA Working Group on Landfills you are one of the experts for lea-chate treatment. What makes leachate treat-ment so special and important?Frank: Improvement in environmental protection can be efficiently realised by taking care of the main pollution zones, such as landfills. Effective treatment of leachate is essential for public accept-ance of modern waste handling facilities. Being aware of this, many countries al-ready developed local regulations for the discharge of leachate. However, sustaina-ble solutions are often still missing – in most cases due to lack of knowledge.

What makes leachate treatment so difficult? Frank: Compared to sewage, leachate is highly polluted – up to a hundred times or even more. Most challenging is the complex matrix of multiple water pol-lutants all rolled into one. Besides the unknown number of organics, it also contains salts, heavy metals, halogens and – very critical with the increasing age of the landfill – nitrogen as toxic am-monia at very high levels. An upcoming issue is also the increase of pharmaceu-tical ingredients – such as hormones. Besides this, leachate has a very high buffer capacity, so that pH variation is

Selecting the most appropriate leachate treatment system is vital not only for environmental protection,

but for the landfill operator’s bottom line. Ben Messenger speaks with Frank Natau, member of the

ISWA Working Group on Landfills, to find out what operators need to know.

By Ben Messenger

LANDFILL LEACHATE 101

“THE MOST IMPORTANT

ADVICE I WOULD GIVE

TO OPERATORS OF LANDFILLS

OR MBT PLANTS THAT ARE

FACING THE NEED FOR AN

EFFLUENT TREATMENT:

GO AND VISIT EXISTING PLANTS.”

Frank NatauISWA Working Group on Landfills


LANDFILL

TWO-STAGE TREATMENT CTS

Table 1: typical process data for landfill leachate with a two-stage (MBR + NF) treatment process

oxidised – sometimes energised via CHPs. For the leachate a drainage system is re-quired, then a leachate buffer or lagoon, and a regular monitoring system to con-trol increase of pollution while landfill-ing. But lagooning by itself will not solve the leachate problem. To find the optimal treatment method and plant size, moni-toring results are helpful.

Unfortunately, there are only very few international consultants that recognise the economic as well as environmental im-portance of leachate treatment in the land-fill design. Often the operator is left alone to deal with it, receiving generalised, but partly misleading advice. One of the most frequent is that returning leachate to the landfill will increase the landfill gas gain. This may be correct for a short period of time – usually only a very few years. So, lea-chate recirculation might be a solution in the beginning or in case of emergencies – but it is not a long-term reliable solution.

We have been contacted several times by landfill operators worldwide who have been in trouble, not only from the point of fulfilling environmental obligations, but also due to economic reasons that re-quire a quick and reliable solution. This also includes leachate treatment systems which failed, for example due to long-term recirculation of leachate or leachate concentrates to the landfill body. This contaminated the landfill and therefore in some projects our first priority is to de-contaminate the landfill again!

What processes have been proven to be fit for this purpose?Frank: All known wastewater treatment methods have been tested on leachate: bi-ological systems (Conventional Activated Sludge – CAS, Sequence Batch Reactors – SBR), chemical/physical treatment meth-ods, Advanced Oxidation Processes (AOP), Adsorption and so on. In the last three decades, more or less two main treatment principles have shown reliable technical performance on an acceptable commercial level: “elimination” by biological processes and “separation” by membrane processes.

Membrane process technologies are comparatively new in water science - new in comparison to conventional treatment

technologies. Membranes have been used for wastewater treatment for about 40 years now, but have had a remarkable evolution over time, also due to required water supply systems in arid areas as de-salination units. In wastewater treatment, the adoption of membranes is leading to many advantages when it comes to the treatment of complex wastewaters. Even more so, since membrane technology also allows combination of both principles, “elimination” and “separation”.

Does this work on any leachate worldwide?Frank: It depends on the complexity of the leachate and the discharge limits. Beside the landfilling strategy, the re-quired levels of discharge quality are the most decisive factor for the choice of the process. In central Europe, many landfills are connected to the sewers. Therefore, an advanced biological elimination unit is sufficient to achieve the so-called indirect discharge limits.

For landfills not connected to the sew-ers, which are discharging into rivers or irrigation, a combination of an elimina-tion unit plus additional post-treatment units for “polishing” is the most reliable solution with lowest costs for lifetime of landfill. In humid countries it is allowed to discharge salts as well – then “salt pas-sage” processes can be included. In arid countries, where there is no receiving wa-ter body, salts often must be retained in the system and the leachate must be com-pletely treated to saltless irrigation quality, sometimes even Zero Liquide Discharge (ZLD) is required. To fulfil these require-

PARAMETER / UNIT RAW LEACHATE MBR EFFLUENT NF PERMEATE

COD concentration (mg/l) 5000 - 10000 800 - 1200 < 125

BOD5 concentration (mg/l) 150 - 300 < 3 < 3

Ammonia concentration (mg/l N) 800 - 3000 < 5 < 3

pH 7.5 – 9 6.8 – 7.4 7

Total phosphate (mg/l) 5 - 15 < 2 < 1

Total Suspended Solids – TSS (mg/l) 250 - 500 < 10 < 2

Chloride (mg/l) 1000 - 4000 800 - 3600 800 - 3000

Conductivity (µS/cm) 10000 - 35000 5000 - 20000 2000 - 6000

Dipl.-Ing. Frank Natau is a member of the ISWA Working Group on Land-fills and area manager for Eastern Europa and Poland at WEHRLE


LANDFILL

FACTS

LANDFILL

ments, it is conceivable that different pro-cess stages must be combined.

In general, it is recommended to create sustainable solutions with a central elimina-tion unit to avoid any kind of “unexpected surprise” later on the landfill with increasing problems of accumulation of pollution.

What do these solutions look like in reality? What are the benefits for the landfill operator?Frank: The state-of-the-art technology for separation today is a stand-alone Reverse Osmosis system with pH adjustment of lea-chate. Due to the evolution in desalination markets, modern systems are using stand-ard spiral-wounded membranes in contain-erised units that can be realised with several stages to achieve the desired discharge qual-ity. Yet, there is a single disadvantage that counts for a lot: separation means that all pollutants from the leachate will be kept in a concentrate while letting the filtered water leave the landfill. All pollutants such as ammonia, all organics, heavy metals etc. will be kept back – where to go with this? As mentioned already, recirculation of the concentrate to the landfill body can only be a short time solution. Especially ammonia will accumulate, well-known to be an inhib-itor for biological anaerobic processes.

The required reduction of pH in RO sys-tems will lead to the effect that originally inert metals from the landfill body can di-lute into the leachate. As a result, conduc-tivities will rise, leading to less performance of the RO system with decreasing yield and increasing consumption of energy, chemi-cals, membranes, man power. Nevertheless, RO systems can also be recommended as stand-alone solutions due to their mobil-ity – but only for short periods of operation without ignoring connected risks for the landfill operation.

The other principle, elimination of lea-chate pollution, works best with a Membrane BioReactor (MBR) system, well-known worldwide for achieving the highest bio-logical elimination rates. MBR technology combines all advantages of biological elim-ination processes with total retention of activated biomass and a barrier in form of an Ultrafiltration Membrane. Especially toxic ammonia can be eliminated by 100%. However, for the design of this process, a deep

understanding of the interface between biol-ogy and membrane functions is mandatory.

Without going into too much technical detail – just two examples: MBR evolution over the last three decades has shown that • MBR systems with submerged mem-

branes comprising outside-in filtra-tion by vacuum are beneficial and es-tablished for low-pollution waste wa-ter with high flow – such as sewage.

• MBR systems with external tubular membranes in a side-stream setup with inside–out filtration including the self-cleaning effect by the flow velocity have proven to be fit for treatment of high pollution liquids – especially such as leachate.Biological treatment of leachate also

requires high efficiency aeration systems typically without any wear by moving parts inside the aeration reactors to al-low long-term reliable operation without maintenance or downtime for replacing aerators. Well-known standard systems are blocked within one to two years by precipitation of leachate ingredients on the aerator surfaces.

But are these plants not rather expensive and complicated to operate? How difficult is it to op-erate such treatment plants?Frank: These questions are very impor-tant as the best technology will fail with-out qualified operational support how to do it! If we look at the investment costs, CAPEX, of such a plant, we should also consider the operation costs, OPEX, as these can be far higher within 5 to 10 years than the investment itself. Besides, please keep in mind that such an investment is for a plant operating 20 years or even more.

Summarising both, TOTEX, MBR solutions with external membranes for leachate treatment have turned out to be the most economical solution – proven! Yes, they cost more upfront - this is cor-rect - but this is quickly compensated by low operation costs for consumables, maintenance, control, labour costs, etc.

What happens if the landfill is full? How will this influence the leachate treatment?Frank: If you look at Germany, nearly all sanitary landfills have been closed since

Leachate treatment plant of Al Multaqa landfill, Muscat / Oman: BIOMEMBRAT® MBR + RO.

BIOMEMBRAT® MBR leachate treatment plant in La Pradera landfill, Medellin / Colombia.

100 xLeachate is 100 times more polluted than sewage.

GRAMMATIKO LANDFILL IN ATHENSLeachate treatment capacity for Grammatiko landfill in Athens which handles 100,000 tonnes of waste per year.

60 % Of total operating budget being taken up by leachate treatment at some closed landfill sites.


LANDFILL

2005. The obligation by law for controlled aftercare for all emissions is at least 30 years. Therefore, most leachate treatment plants are still in operation today – if they are operating economically. Receiving no more income by tipping fees, costs for leachate treatment becomes an even more dominating cost factor – from some opera-tors we know that this can increase to 60% of the total yearly budget. From this aspect, you can see how important customised plant design, including modular setup, is.

Globally landfilling is declining. ISWA is work-ing hard on getting landfills closed. Waste should is better utilised for energy and material recov-ery. How does this affect what you are doing?Frank: We welcome this development to reduce the amount of uncontrolled land-fills including all negative aspects to all of us. We also welcome the installation of ad-vanced treatment technologies for waste, based on overall good results in developed countries, as WEHRLE is also experienced

Chief EditorBen MessengerEmail: [email protected]: +44 7917 566259

International Advertising ManagerTerry AshEmail: [email protected]: +44 (0)20 3667 3715 Mobile: +44 (0)7956 491159

PublisherINDUSTRIEMAGAZIN Verlag GmbHHans F. Zangerl, General ManagerEmail: [email protected] 56, 1070 Vienna, Austriawww.industriemagazin-verlag.atArt Director: Nicole Fleck Graphic Design: Johanna Kellermayr

AdvertisingEditorial/News Contact: [email protected] Correspondence/Press Releases: Please send to Waste Management World at [email protected]

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Alpine Waste & Recycling 26AMP Robotics 26ANDRITZ 13Ashfords LLP 42Athens Services 29Babcock & Wilcox Vølund 44Bill and Melinda Gates Foundation 30Black Bear Carbon 16Bollegraaf Recycing Solutions 2 5British Glass 13BRT HARTNER 13Bulk Handling Systems 28Cabot Corporation 17Cambridge Industries Ltd 36China National Electric Engineering Co 36China’s Cambridge Industries Limited 36CSO Technik 23DIGITALEUROPE 20Donasonic Spare Parts 22DP Cleantech Ltd 36Eldan Recycling 19Ethiopian Electric Power 36Flintec 12Fraunhofer Institute 24Halter Rohstoff AG 28HAMMEL 43hina Everbright International 37

HSM 14, 28International Water Management Institute 30ISWA 7, 40, 41IVECO 37Jekora Ventures 30Keppel Seghers 39KOMPTECH 12Leigh Day 9Martin GmbH 37Menart 30Nine Dragons 13Nokia 21Presona 29Ramboll 36RICOH 23Shipbreaking Platform 8SWANA 7, 40, 41The Carton Council 26The Product-Life Institute 23Unilever 24UNTHA 38Vecoplan 27Veridis Corporation 15VinylPlus 14WASTECON 2017 40WEHRLE 11, 32

COMPANIES INDEXCOMPANY PAGE COMPANY PAGE

in MBT technology and incinerators. It should not be forgotten, however, that also waste handling stations, waste incin-erators and MBT plants are faced with effluents similar to leachate, especially in countries with very humid waste, like in Asia or South America. These effluents are even more polluted than normal leachate, since their waste is fresh and the effluent is less diluted.

The most important advice I would give to operators of landfills or MBT plants that are facing the need for an effluent treat-ment. Go and visit existing plants, talk to the technical or commercial supervisors and operators, and get a first-hand impression of how well plants are designed, how simple they are to operate and what the real costs for operation including man power are.

Taking some more time in the planning phase will secure your investment and get yourself a long-term reliable system that you can use through the whole lifetime of your landfill.


WASTE TO ENERGY

rific value and high moisture content in comparison with that typically found in Europe. However, the unique nature of African waste has enabled the creation of the CIL-CNEEC consortium, which aims to design, construct and in some cases own extremely cost-competitive and scal-able facilities customised for sub-Saharan Africa, the group says.

BUILDING A UNIQUE WTE PROJECTUnder construction since September 2014, the Reppie project is being devel-oped on a 53,120 m2 plot of reclaimed land adjacent to the 37 hectare Koshe dumping site. For the past 40 and more years this open site has seen some 900 tonnes of untreated mixed waste dumped daily and is home to a multitude of peo-ple who eke out a living hunting for met-als, plastics and other commodities in the city’s waste.

Upon completion though, the Reppie plant will process around 1400 tonnes of municipal waste per day, close to three quarters of the typical waste generated by the Addis Ababa Metro Area popula-tion of more than 4.6 million. With an annual waste-disposal capacity of around

O n the outskirts of the Ethiopian capital Addis Ababa, Africa’s first energy

from waste project is close to completion. The so-called Reppie project is set to trans-form waste disposal for the rapidly expand-ing city’s population, but is also expected to serve as a waste management blueprint for the whole of sub-Saharan Africa.

Being developed and constructed as a turnkey project by an Engineering, Procurement, Construction (EPC) con-tracting consortium, upon completion Reppie will be owned by the national power utility Ethiopian Electric Power (EEP). The facility will supply some 50 MW of electric-ity to the national grid, supporting about a quarter of the city’s power demand.

The EPC consortium conducting the development includes China’s Cambridge Industries Limited (CIL) together with China National Electric Engineering Co. Ltd (CNEEC). Cambridge Industries Ltd was formerly a subsidiary of biomass combustion specialists DP Cleantech Ltd. Denmark’s Ramboll is acting as the own-er’s engineer on behalf of EEP.

Africa’s mixed municipal waste stream is characterised by its relatively low calo-

A new waste to energy plant near

completion in Ethiopia is set

to showcase the opportunities for

cleaner energy and a cleaner environment across sub-Saharan

Africa’s rapidly expanding urban

centres.

By David Appleyard

ETHIOPIA – SPEARHEADING AFRICA’S WASTE

MANAGEMENT FUTURE


WASTE TO ENERGY

438,000 tonnes, Reppie is expected to supply some 185 GWh of electricity an-nually for export to the grid during its roughly 300 days or 7200 hours of oper-ations per year.

To meet the demands of EEP in terms of ensuring increased plant availability and reliability, the project will use two process lines and twin boilers, each with an air-cooled step grate of the SITY2000 model from Martin GmbH and made under license by Chongqing Sanfeng Covanta Environmental Industry Co., Ltd. Each grate line, which measures 9.7 m by 10.6 m, has a nominal daily com-bustion capacity of 640 tonnes of waste and is designed to accept a calorific value range of 5.5 – 9.5 MJ/kg of waste.

Unsorted Municipal Solid Waste (MSW) will be delivered via two 50 tonne weigh bridges to the waste reception hall by the Municipality’s 16 tonne compac-tor IVECO trucks operated by the Addis Ababa City Administration (AACA). EEP is said to be working in collaboration with Addis Ababa’s City administration to ensure waste collection is streamlined to secure feedstocks. There are six tipping platforms in the 75.6 metre-long and 24 metre-wide tipping hall and a maximum bunker capacity of 22,000 m3. The facility uses magnets to recover steel and other ferrous metals for recycling before two semi-automatic grab cranes mix the waste ahead of combustion.

The two single drum natural circulation boilers feature four vertical gas ducts plus one horizontal gas duct and each produces more than 54 tonnes per hour of super-heated steam at 420°C and some 60 bar.

Throughput per line can range from 471 tonnes per day to a maximum of 678 tonnes per day while each boiler has an output of between 36.3 MWth and 55 MWth to make a total maximum thermal capacity of 110 MWth.

Designed and manufactured by China’s Hangzhou Boiler Group (HBG), each boiler has a claimed efficiency of above 80%. The high pressure steam in turn drives two 25 MWe condensing steam turbines.

The Reppie Facility has also adopted modern back-end flue gas treatment

technology using selective non-catalytic reduction (SNCR) as well as semi-wet and dry scrubbing together with pow-der activated carbon (PAC) injection and baghouse filtration. The plant is designed to meet the European emission standards under the EU 2000/76/EC Directive. This ensures that almost all of the nitrogen ox-ides (NOx), sulphur dioxide (SO2), heavy metals and dioxins produced by the plant are eliminated. Both on-site and online flue gas emission monitoring is featured.

Any residues leftover from the flue gas treatment is recycled or safely disposed of whilst the scrubbed and cleaned flue gas is released into the atmosphere through the plant’s twin stacks. More than 80% of the daily volume of 220 m3 of mixed solid waste is expected to be combusted and what remains is converted into ash.

An anaerobic leachate treatment system with a membrane bio-reactor (MBR) will be supplied by Hong Kong-based waste to energy project developer China Everbright International for the Reppie project.

The lead design firm is the CNEEC af-filiate China Urban Construction Design and Research Institute Co., Ltd. China’s national design institute has been re-sponsible for designing dozens of such facilities across China, a country with a waste stream composition very similar to that found in Africa.

Scheduled for completion in 2017, ac-cording to Ethiopia’s Ministry of Water, Irrigation and Electricity, at present more than 87% of the construction work on the project has been completed, including the installation of the two turbine generators and power control units.

Major civil and electro-mechanical works are close to completion together with much of the balance of the plant. Civil works of the leachate treatment site and access roads within the site area are being finalised. Roofing of the waste bun-kers has been completed, installation of turbine hall crane and the steel structure of the boiler is being completed. Materials and equipment for the power house are also currently being transported from the port to the project site. In addition, exca-vation of three groundwater wells with a depth of about 180 metres each and

Samuel Alemayehumanaging director of Cambridge Industries

“WHY CAN’T WE HAVE THIS

IN THE MIDDLE OF KAMPALA,

IN THE MIDDLE OF NAIROBI, IN

THE MIDDLE OF LAGOS… WE COULD

TURN AFRICA’S WASTE INTO A

TREASURE.”

With construction of the waste to energy plant over 80%

complete, pre0construction preparations for the erection

and installation of a 132 kV sub-station and a 3 km power export

transmission line to link with the Mekanissa – Sabetta grid

network are also underway.


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installation of two 48 metre-high flue stacks, a 132 kV transformer, two 10.5 kV generators, two steam condensers, two oil tanks, steam turbines, and the erection of the lower case have also been carried out.

“The project will be finalised within the schedule unless we face unforeseen challenges going beyond our capability,” Bizuneh Tolcha, director at Ethiopia’s Ministry of Water, Irrigation and Energy is reported to have said.

Some 189 Ethiopians and 87 expatri-ates are currently employed on the project.

WASTE TO ENERGY SHOWCASEAccording to its developers, Reppie will be the first major waste to energy facility in Africa. By diverting waste from landfill and by adhering to the strict European environmental standards for this kind of project, the facility will be a showcase for other cities and countries across Africa.Indeed, Cambridge Industries suggests

the development is part of a programme for seven city waste to energy plants across Africa and thus represents the first phase of a wider rollout of multiple waste to energy plants across sub-Saharan Africa’s major cities. This chimes with a preliminary government report which in-dicates the project could be the first of 35 such facilities, according to local media outlet Capital Ethiopia.

Located about 10 km south-west of Addis Ababa at 2300 metres above sea level and with average temperatures of 14-25°C, the project presents some unique challenges. But at only 7 km from the African Union (AU) headquar-ters and in the city home to the United Nations Economic Commission for Africa (UNECA), Reppie forms a key part of Ethiopia’s Climate Resilient Green Economy strategy.

Under the terms of this strategy, the Ethiopian government plans to be a car-

FACTS

US$120 MILLIONTotal cost of the government- backed project.

100,400 TONNES Bottom ash is expected to be produced annually.

102.37 MILLION Ethiopia’s population, 19.5% of whom live in an urban environment.


WASTE TO ENERGY

Keppel Seghers Belgium N.V. • Hoofd 1, 2830 Willebroek, Belgium • [email protected] • www.keppelseghers.com

Leading environmental technology and engineering

solutions provider for the Waste-to-Energy industry

bon neutral economy by 2025. This is a huge challenge. According to the World Bank, Ethiopia has experienced rapid eco-nomic growth in recent years, with GDP expanding at an average of close to 11% between 2004 and 2014.

Rural migration into Addis Ababa has resulted in a high rate of population growth and the city is expected to have some six million residents within 20 years. Indeed, Dr Tewolde Berhan Gebre Egziabher, director general of Ethiopia's Environmental Protection Authority, re-portedly noted that when the Koshe site was created decades ago it was well be-yond the city limits; today it is home to many, becoming part of the city's land-scape due to expanding urbanisation. This has had tragic results. In mid-March it was reported that a ‘landslide’ of hun-dreds of tonnes of rubbish at the Koshe site killed more than 110 people with dozens more still missing.

CLEANING UP AFRICA’S ENVIRONMENTThough Ethiopia’s domestic electricity demand is currently relatively modest - according to USAID figures the country only has an installed generation capacity of approximately 2300 MW for its popu-lation of above 95 million people – urban-isation is set to change that. Furthermore, government investment in infrastructure has been significant.

Waste to energy plants like Reppie are expected to make a significant con-tribution, not just to Addis Ababa’s bur-geoning electricity demand, but also in reducing greenhouse gas emissions such as carbon dioxide and methane, as well as improving water quality by preventing leachate entering the water course.

This project is just one step in Ethiopia’s clean energy supply plan, but it is a huge leap for Africa’s waste manage-ment story.

FACTS

LAND LOCKEDEthiopia is the most populous landlocked country in the world.

6000Towns and cities in the country which have been electrified.


ISWA World Congress & WASTECON 2017: Time for Adventures — Even Fun!

For the first time in decades, the International Solid Waste Association’s World Congress is co-locating with the Solid Waste Association of North America’s WASTECON 2017 in Baltimore, Maryland, this September. These international events will feature the latest in topics such as climate change, resource management, marine litter, en-ergy recovery, and more, through tech-nical sessions, facility tours, exhibits and global networking opportunities.The co-location of the events will attract thousands of solid waste professionals from around the world. In addition, it will promote important international in-formational and educational exchange, as well as promoting some local fun that only the Baltimore-area has to offer.You’re attending for solutions to your day-to-day issues at work, but we promise you’ll have a great time, too.

TIME TO MEETMonday, September 2518:30 – 21:00 in the Exhibit HallJoin us on your tour of the U.S. and Canada through the sights and sounds of the “Taste of North America” ISWA World Congress Welcome Reception. The Exhibit Hall will be filled with lo-cal food specialties and entertainment stations from all different parts of North America, so attendees can expe-rience all different regional fares and cultures.

TIME TO CELEBRATE Tuesday, September 2619:00 – 23:00Enjoy a truly American experience as the ISWA World Congress’ Tuesday Night Networking Gala takes you to Oriole Park at Camden Yards. Join us for food, fun and dancing — American-style — at the official home of the major-league Orioles baseball team in historic downtown Baltimore.Dress is casual but be ready for an epic evening celebrating the solid waste industry.

TIME TO MEET MONDAY, SEPTEMBER 25

TIME TO CELEBRATE TUESDAY, SEPTEMBER 26

SHOW YOUR HOMETOWN SPIRIT— WEAR YOUR FAVORITE SPORTS TEAM’S JERSEY OR HAT!

TEE TIME THURSDAY, SEPTEMBER 28


Visit www.iswa.org for more information

ISWA INFORMATION

TEE TIME The Mid-Atlantic SWANA Chapter in-vites you to join us for the ISWA World Congress & WASTECON 2017 Golf Tournament.Don’t miss this unique opportunity for networking while you hit the links on a scenic journey through a world of tall, hardwood trees that guard the lush Bent Grass fairways and large, undulating greens of the course's enjoyable, yet chal-lenging 18 holes.Location: The Woodlands Golf CourseAddress: 2309 Ridge Rd, Windsor Mill, MD 21244Time/Date: Shotgun start at 8:00 Thursday, September 28Includes: Continental Breakfast and LunchCost: $70 per personTravel: Bus transportation from confer-ence hotel not currently available.Clubs: Rental Clubs are available at the course. Contact the Club House for pric-ing and availability. Email: [email protected] to reserve equipment.

TIME FOR FUN & SUPPORTING A GREAT CAUSERace Date: Sunday, September 24Check In Time: 17:30Registration Fee: $35SWANA is thrilled to invite you to par-ticipate in the ISWA World Congress & WASTECON 2017 5K Fun Run/Walk with proceeds supporting ISWA Scholarship Programme, an international charity that offers scholarships to children who have been working at trash dumps in Guatemala.The Fun Run/Walk is great for all skill lev-els - the route will be an easy route through Baltimore Harbor and will end at a local brewery for cold refreshments.New This Year: Team ChallengeEnlist your co-workers to join and show your company spirit. Create a team of walkers/runners to participate in the ISWA World Congress & WASTECON 2017 5K Fun Run/Walk.

TIME FOR EXPERIENCESPrepare to enjoy a truly American adven-ture: Visit Baltimore & Washington, D.C. Fall in love with ‘Charm City’— enjoy the world-famous Inner Harbor; renowned

museums and historic attractions; award-winning restaurants featuring Maryland’s famous blue crabs; a locally loved music scene, and stroll through the hip and time-honored neighborhoods around the city.Then take a 45-minute train ride to the National’s Capital to see monuments and memorials, eclectic neighborhoods, and true local flavor - Washington, D.C. is a place unlike any other. Take advantage of the city’s many free museums and other attractions to complete your visit.

TIME FOR FUN SUNDAY, SEPTEMBER 24


ISWA Calendar

20 17

For more events and details please go to www.iswa.org or scan the QR code.

18–23 JUNISWA Study Tour Waste to EnergyGermany & Austria

7–18 AUGISWA - UM Summer School on Landfill in Developing CountriesKuala Lumpur, Malaysia

4–8 SEPISWA Study Tour on Collection Sorting & Recycling 2017Amsterdam, Netherlands

11–14 SEPPractitioner Training Course on Bio-Waste ManagementVienna, Austria

25–27 SEP ISWA World Congress 2017Baltimore, MD, United States

COUNTRY SPOTLIGHT

UK: POSITIVE PROSECUTIONS

Following the launch of Keep Britain Tidy's #crimenottocare

campaign the government recently pub-lished its ‘Litter Strategy for England’ report. In addition to current Local Authority pow-ers to investigate, prosecute and deal with small fly tips on public land, the Strategy suggested (amongst other initiatives): · A consultation to increase the amount

for which fixed penalty notices can be issued

· The introduction of civil charges when rubbish is thrown from a car

· The publishing of new guidance on en-forcement for Local Authorities.

Whether the strategy results in policy, enforcement, or legal changes remains to be seen. It does, however, highlight the government's commitment to tackling en-vironmental crime.The Strategy did also raise the claim that some Local Authorities were underesti-mating offences, and dealing with small fly tipping incidents as littering. It is important for Local Authorities to consider the Code for Practice on Litter and Refuse before is-suing fixed penalty notices or prosecuting. The maximum amount of a Fixed Penalty Notice is far lower for littering than fly tip-ping, the sentences for littering are far less than for fly tipping, and the Magistrates do not have the benefit of any specific sentencing guidelines for littering offences, unlike for fly tipping.In terms of the current law, the Environmental Protection Act 1990 ("the Act"), makes it an offence for any person to

“IT IS IMPORTANT TO ENSURE THAT PROPER EVIDENCE IS COLLECTED TO JUSTIFY A PROSECUTION TO ACHIEVE A SUCCESSFUL CONVICTION.”

In recent months, fly tipping has become an increa-singly a hot topic in the UK with the agricultural sector growing more vocal about the difficulties of clearing waste deposited on private land.

By Jeremy Asher and Stephen Sadler

While Local Authority budget cuts mean that not as many resources not

be available to deal with fly-tipping as might be liked, costs for bringing a

prosecution can often be recovered fully or partially from the offender.

deposit controlled waste, knowingly cause or knowingly permit controlled waste to be deposited where they act otherwise than in accordance with a valid environmental permit. Household, industrial and commer-cial waste all come under the definition of controlled waste. To deal with these offences, the Act pro-vides the Local Authority with useful powers to attempt to prevent fly-tipping before it occurs, including powers to search and take a vehicle they reasonably believe have, will or are being used to commit certain waste offences. In addition, Local Authorities are able to issue fixed penalty notices for offences. These notices can be issued for amounts between £150 to £400. The Court also has options at its disposal to deal with fly tipping. These can involve the seizing of vehicles used for the offence, or of property used to commit the offence, as well as imposing costs against the defend-ant. For individuals who offend, the Court may make orders banning them from hold-ing directorships, or disqualifying them from driving.It is important to ensure that proper evi-dence is collected to justify a prosecution to achieve a successful conviction. So long as care is taken in this regard, Local Authorities can continue to be successful in prosecut-ing these types of waste offences, which according to DEFRA's statistics, currently result in a 98% conviction rate.In spite of budget cuts it is important to remember that prosecutions are often suc-cessful and act as an effective deterrent.

Jeremy Asher is a Senior Associate and Stephen Sadler Trainee Solicitor


Babcock & Wilcox Vølund's DynaGrate® is one of the

most advanced combustion grates available to service the

waste-to-energy and biomass markets. Its design is based

on more than 40 years of R&D and provides excellent fuel

flexibility and performance, with the added benefit of low

operational and maintenance costs. Designed to process

ever changing waste streams, it can efficiently combust all

types of untreated waste, so you will find it difficult to find

any waste left after the combustion process.

B&W Vølund has a significant amount of operational

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These are all significant cost benefits for your project.

There’s much more to be said. Find out by contacting us at

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