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Wendt Corporation Ex. 1003, P. 1 Wendt Corporation Ex Wendt Corporation Ex. 1003, p. 1 Wendt Corporation Ex. 1003, p. 2 Wendt Corporation Close Dec., Ex. A HANDBOOK OF .· RECYCLING TECHNIQUES Alfred Arn. Nijkerk and Wijnand L. Dalmijn The Hague, March 1998 Fourth printing .. Wendt Corporation Close Dec., Ex. A First printing, November 1995 Second printing, February 1996 Third printing, September 1996 Fourth, revised and expanded printing, March 1998 The Royal Library of The Hague Cataloguing-in-Publication Data Nijkerk, A.A Handbook of Recycling Techniques I A.A. Nijkerk. - The Hague Nijkerk Consultancy. - Ill. Published at the request of NOVEM/NOH. - With bibliography and index ISBN 90-802909-2-0 NUGI 841 Keyword: recycling © copyright: Nijkerk Consultancy 1998 All rights reserved. No part of this book may be reproduced and/ or transmitted, by means of print, photocopy, microfilm or otherwise, in total or in part, without the written permission of the copy­ right holder or the publisher. Cover photo: Demolition of a 25-year-old Sabena Boeing 747 at Brussels Zaventhem airport. The airplane was scrapped by a hydraulic LaBounty MSD 116 crane-attached shear of 650 tonnes cutting force, with a Verachtert/ Veratech connecting arm and a Verachtert/Veratech, crane-attached shear. The excavators are Hitachi EX 400s. PHOTOGRAPH BY COURTESY OF VAN LEEUWEN RECYCLING, ROTTERDAM, THE NETHERLANDS. 2 -· Wendt Corporation Close Dec., Ex. A Handbook of Recycling Techniques by Alfred Arn. Nijkerk and Wijnand L. Dalmijn This book was written within the framework of the Dutch National Reuse of Waste Research Programme (NOH). Project number: NOH/353293/0710 Management and co-ordination of the NOH programme rest with: NOVEM Netherlands Agency for Energy and the Environment RIVM National Institute of Public Health and Environmental Protection The authors can give no guarantee of the accuracy and/ or comprehensive nature of information, designs, constructions, products or production methods arising or described in this book, nor of their suitability for any given specific application. Published by Nijkerk Consultancy, Ruychrocklaan 202, NL-2597 EC The Hague, The Netherlands. Tel: +31 70 324 33 34 - Facsimile +31 70 324 29 92 Distributed in North America by 'Scrap', a bi-monthly magazine published by ISRI, the Institute of Scrap Recycling Industries, 1325 G-Street NW, Washington DC 20005-3104. Tel.: +(202) 662 8540, Facsimile: +(202) 626 0940. 3 -· Wendt Corporation Close Dec., Ex. A 'Design for Recycling' in practice. The Dutch Ministry of the Environment, equivalent of the US EPA, moved to new premises in The Hague in 1990. The building is fully recyclable and contains among other things 2000 tonnes of recycled concrete, derived from six demolished viaducts around Rotterdam. The internal walls are fire-resistant and made from paper stock mixed with gypsum and fly-ash from a power station. A total of 3100 civil servants work in this building. 4 Wendt Corporation Close Dec., Ex. A I Table of contents Foreword 8 Methodology 10 Chapter I Cycle of materials 11 1 Primary and secondary materials 11 2 Complexity threatens the cycle 11 3 Design for recycling can restore the cycle 13 Chapter II Concepts and terminology 14 1 No uniformity - primary or secondary 14 2 Recovery, recycling, reclamation or re-use 14 Chapter III Recycling through the ages 18 1 Eleven thousand years of melting 18 2 Metals for warfare and knives 18 3 Recycling and the seven wonders of the world 21 4 Was the Roman Empire ruined by (old) lead? 21 5 The nineteenth century 23 6 Ships, a new source for recovery 25 Chapter IV Early techniques 27 1 De-riveting and beating, nineteenth century dismantling 27 2 Dismantling with fire and frost; hacking 28 3 Remelting 29 Chapter V Current processing techniques 31 1 Introduction 31 2 Drop-ball breaking or 'tupping' 32 3 Cutting torches 34 A Ring conduit, batteries or a tank 36 B Limitations 37 C Gas cutting - the technique 38 D Pros and cons of cutting torches 38 E Powder, plasma and laser-beam torches 40 1 Powder torches 40 2 Plasma torches 40 3 Laser cutting of metals, plastics etc. 41 4 Water-jet cutting 42 5 Abrasive-disc cutting 43 6 Shears 44 A Alligator shears 45 1 Hydraulically-driven alligator shears 47 B Special shears 47 C Crane-attached shears 48 1 Variations in crane-attached shears 49 D Hydraulic guillotine shears 53 1 Cut-throat history 53 2 Concrete and steel foundations or trailer mounted 56 3 Push, hold-down, side-compress and cut 59 4 Variations in hydraulic guillotine shears 63 7 Balers 65 A From horizontal to vertical and back again 65 B Metal balers and loggers 66 5 Wendt Corporation Close Dec., Ex. A 1 Metal baling, the system 67 C Balers for paper stock, textiles, plastics, cans and drums 69 1 Essential differences from metal presses 69 2 Downstroke balers 71 3 Horizontal paper balers 73 4 Single-ram and two-ram balers 75 5 The closed-end baler 76 6 Accessories 76 7 Safety 77 8 Manufacturers 77 D Briquetters 77 8 Car flatteners 79 9 Cable strippers 80 10 Rotary shears I shredders 82 11 Shredders 85 A Types of shredder 85 B History and development 87 1 Ore and turnings crushers first' 87 2 1958, the year of the first automobile shredders 88 3 Complete automobile and non-ferrous yield as a bonus 92 4 Shredders, mainly from the US, Germany and Japan 93 C Method 95 D The automobile shredder 95 1 Feed and types; costs and personnel 98 2 Automobile shredder-process description 99 a The input or feed 99 b Shredding 101 c The dust collection system 105 d The heavy metallic fraction 106 e The non-magnetic fraction and shredder waste/fluff 107 E Other types. Zerdirators, Kondirators and Mills; HD and SHD shredders 108 1 The Zerdira tor 108 2 The Kondirator 110 3 The Henschel Mill 110 F 'Wet' shredders 111 1 Advantages 112 2 Disadvantages 113 G Accessories and peripherals 114 H Pre-shredders/rippers 117 1 Return after 25 years 117 2 Advantages 117 3 Disadvantages 120 4 Considerations 120 5 Three kinds of ripper 121 I Cryogenic shredders 122 J Cable shredders and wire choppers 123 1 Various types 123 2 Burning, stripping or shredding 124 3 Shredding is fast, but not without problems 125 4 Shredding of plastic-sheathed cable 126 5 Shredding of armoured cable, 'warm' or 'cold' 127 K Aluminium shredders 127 L Rubble crushers 129 1 Not real shredders 129 2 Crushing in two stages 129 3 Fixed or mobile installations 131 4 High throughput 132 6 Wendt Corporation Close Dec., Ex. A 5 The infeed 132 6 Pre-crushing 133 7 Types of rubble crusher 134 8 Cleaning the material 135 9 Microwaves assist rubble crushing 135 M Paper shredding 137 1 Safety 140 N Tyre shredding 140 0 Shredders for 'green' waste 142 Chapter VI Ancillary equipment 144 1 Introduction 144 2 Aids to collection 145 A Collection from citizens 146 B Collection at offices, catering establishments and institutions 150 C Collection - and internal transport - at companies 151 3 Aids to storage at companies 154 4 Ancillaries for transport of secondary raw materials 156 A Special containers 156 B Loading and unloading 157 1 Magnets 158 2 Grapples for loading and unloading 161 5 Ancillaries for motor vehicle dismantling 163 6 Weighing aids 165 Chapter VII Identification, sorting and separation 168 1 Increasing complexity demands additional action 168 2 Sorting and separation - the essentials 170 3 Identification and sorting 171 4 Visual identification; colour, weight, shape and application still reveal too little 171 5 Mechanical identification - radiation detection 175 6 Mechanical processing by sorting/separation 178 A Dismantling 179 B Processing by dry separation 181 1 Gravity separation 181 a Industrial screening 181 b Centrifuges and cyclones 182 c Air classification 182 d Friction separators and shaking tables 185 2 Dry separation with electro magnetics 187 a Magnetic separation 187 b Eddy current separation 188 3 Electrostatic separation 194 4 Particle for particle sorting 196 a Metal detection 196 b Sensing systems based on light 198 5 Image processing 202 C Processing by wet separation 204 1 Rising current and hydro-cyclone methods 204 2 Sink-float method 205 3 Jigging 207 4 Flotation methods 207 D Melt separation 208 Bibliography 211 Index 212 7 Wendt Corporation Close Dec., Ex. A Foreword " ... And they shall beat their swords into ploughshares, and their spears into pruning hooks ... " (Isaiah 2:4) Recycling techniques, even in their most simple forms, are at least 50 centuries old, but scientific interest in them remained limited. Literature on the subject is exceedingly scarce, even today. In the light of the overwhelming interest which recycling has enjoyed in recent years, this is very surprising. It is possibly a consequence of the fact that hardly any­ where are there organised courses on recycling and recovery techniques, let alone at academic levels. Over the last decade recovery techniques have taken off - particularly identification, sorting, processing and separation - un­ doubtedly stimulated by political and economic factors. Political stimulus came mainly from gov­ ernment authorities, which saw that only through prevention and re-use would it be possible to counteract the growing moun­ tain of waste. 'From swords to ploughshares.' On the economic/technical side the recy­ This sculptural interpretation of the Biblical text cling sector took the lead. It was compelled stands in front of the United Nations building in New to develop new techniques to be able to York. A gift from the Russian people, it is the work of recycle the fast-growing stream of ever­ Yevgenii Vuketich. more complex consumer goods, which furthermore had ever shorter economic and technical life-spans.
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