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End-Of-Life Vehicle Recycling : State of the Art of Resource Recovery From ANL/ESD/07-8 End-of-Life Vehicle Recycling: The State of the Art of Resource Recovery from Shredder Residue Energy Systems Division About Argonne National Laboratory Argonne is a U.S. Department of Energy laboratory managed by UChicago Argonne, LLC under contract DE-AC02-06CH11357. The Laboratory’s main facility is outside Chicago, at 9700 South Cass Avenue, Argonne, Illinois 60439. For information about Argonne, see www.anl.gov. Availability of This Report This report is available, at no cost, at http://www.osti.gov/bridge. It is also available on paper to the U.S. Department of Energy and its contractors, for a processing fee, from: U.S. Department of Energy Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831-0062 phone (865) 576-8401 fax (865) 576-5728 [email protected] Disclaimer This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor UChicago Argonne, LLC, nor any of their employees or officers, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of document authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof, Argonne National Laboratory, or UChicago Argonne, LLC. ANL/ESD/07-8 End-of-Life Vehicle Recycling: The State of the Art of Resource Recovery from Shredder Residue by B.J. Jody and E.J. Daniels Energy Systems Division, Argonne National Laboratory work sponsored by the Office of FreedomCAR and Vehicle Technologies Automotive Lightweighting Materials Advanced Materials and Processes U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy September 25, 2006 CONTENTS ACKNOWLEDGMENTS ........................................................................................................ ix NOTATION.............................................................................................................................. x SUMMARY.............................................................................................................................. 1 1 INTRODUCTION AND BACKGROUND ....................................................................... 3 1.1 The Automobile Industry........................................................................................... 5 1.2 The Metals Recycling Industry.................................................................................. 6 1.3 Methods for Disposal of Shredder Residue ............................................................... 7 1.4 Regulatory Issues....................................................................................................... 9 2 RECYCLING INFRASTRUCTURE AND STRATEGIES............................................... 13 2.1 Recovery of Materials for Recycling into Primary Products..................................... 13 2.2 Recovery of Materials for Recycling into Secondary Products................................. 14 2.3 Chemical Recycling................................................................................................... 15 2.4 Combustion for Energy Recovery ............................................................................. 15 3 THE PROCESS OF RECYCLING DURABLE GOODS.................................................. 17 3.1 Recycling Automobiles.............................................................................................. 17 3.1.1 Dismantling for Direct Resale ....................................................................... 17 3.1.2 Shredding ....................................................................................................... 28 3.2 Recycling White Goods............................................................................................. 28 4 SHREDDER RESIDUE...................................................................................................... 31 4.1 Composition of Shredder Residue ............................................................................. 31 4.2 Recycling Shredder Residue...................................................................................... 33 4.2.1 Recyclable Materials from Shredder Residue................................................ 33 4.2.2 Separation of Materials from Shredder Residue............................................ 34 5 TECHNOLOGIES FOR CONCENTRATING RECYCLABLES FROM SHREDDER RESIDUE ......................................................................................... 37 5.1 Argonne’s Mechanical Separation System ................................................................ 37 5.2 Salyp Mechanical Separation System........................................................................ 39 5.3 The WESA-SLF Process............................................................................................ 40 5.4 Compaction and Solidification Technology .............................................................. 40 5.5 The Witten Process for the Separation of an Organic Fraction from Shredder Residue ....................................................................................................... 41 iii CONTENTS (CONT.) 5.6 The Sortec Process..................................................................................................... 42 5.7 Other Mechanical Equipment for Separating Solid Mixtures.................................... 42 5.7.1 Gravity Separators......................................................................................... 42 5.7.2 Electrostatic Separators.................................................................................. 43 6 COMBUSTION OF SHREDDER RESIDUE FOR ENERGY RECOVERY ................... 47 7 THERMOCHEMICAL CONVERSION METHODS TO PRODUCE FUELS ................ 57 7.1 Pyrolysis..................................................................................................................... 57 7.2 Gasification................................................................................................................ 60 7.3 Changing World Technologies Process..................................................................... 64 8 TECHNOLOGIES FOR SEPARATING AND RECOVERING PRODUCTS FROM SHREDDER RESIDUE ................................................................... 67 8.1 The Argonne Process for the Separation and Recovery of Flexible Polyurethane Foam ...................................................................................... 67 8.2 The Salyp Process for the Separation and Recovery of Flexible Foam..................... 72 8.3 The Argonne Process for the Separation and Recovery of Plastics........................... 72 8.4 The Recovery Plastics International Process ............................................................. 76 8.5 The Salyp Process for the Separation of Mixed Plastics ........................................... 76 8.6 The Volkswagen-SiCon Recycling Process............................................................... 77 8.7 The Galloo Process for Recovering Plastics.............................................................. 78 8.8 The MBA Polymers, Inc., Process............................................................................. 79 8.9 The Toyota Process.................................................................................................... 80 8.10 Centrifugation Processes............................................................................................ 81 8.10.1 The Delphi Process........................................................................................ 82 8.10.2 The Result Technology AG Process.............................................................. 81 8.10.3 Recovery of Nylon from Post-Consumer Carpet Using Centrifugal Technology ................................................................................. 82 8.11 Rapid Identification and Separation Automated Processes ....................................... 83 8.11.1 Infrared Separators......................................................................................... 83 8.11.2 Color Sorters.................................................................................................. 84 8.11.3 X-Ray Separators........................................................................................... 84 8.11.4 UV-Fluorescence for the Separation of Nylon-PC Mixtures......................... 84 9 CHEMICAL PROCESSES FOR RECYCLING SHREDDER RESIDUE........................ 85 9.1 Methods Using Organic Solvents .............................................................................. 85 9.1.1 Rensselaer Polytechnic Institute Process....................................................... 85 9.1.2 Argonne Process............................................................................................ 85 iv CONTENTS (CONT.) 9.1.3 Solvay Process............................................................................................... 86 9.1.4 Delphi Process..............................................................................................
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