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End-Of-Life Vehicle Recycling: State of the Art of Resource Recovery from Shredder Residue

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End-Of-Life Vehicle Recycling: State of the Art of Resource Recovery from Shredder Residue ANL/ESD/10-8 End-of-Life Vehicle Recycling: 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 and its pioneering science and technology programs, 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/10-8 End-of-Life Vehicle Recycling: State of the Art of Resource Recovery from Shredder Residue by B.J. Jody, E.J. Daniels, C.M. Duranceau, J.A. Pomykala, Jr., and J.S. Spangenberger Center for Transportation Research Energy Systems Division, Argonne National Laboratory September 2010 CONTENTS ACKNOWLEDGMENTS ........................................................................................................ xiii NOTATION .............................................................................................................................. xiv SUMMARY .............................................................................................................................. xix 1 INTRODUCTION .............................................................................................................. 1 1.1 Background ................................................................................................................ 1 1.2 The Automobile Industry ........................................................................................... 3 1.3 Automotive Material Recyclers ................................................................................. 7 1.4 Recycling Supports Sustainability ............................................................................. 8 1.5 The Metals Recycling (Shredding) Industry .............................................................. 9 1.6 Impact of Using Lightweighting Materials On the Recyclability of Vehicles .......... 11 1.7 Life-Cycle Analyses of Different Recycling Methodologies .................................... 14 1.8 Methods for Disposal of Shredder Residue ............................................................... 17 1.9 Regulatory Issues ....................................................................................................... 19 1.9.1 United States Regulations .............................................................................. 19 1.9.2 European Regulations .................................................................................... 21 1.9.3 Japanese Regulations ..................................................................................... 25 1.9.4 Russian Regulations ....................................................................................... 26 1.9.5 Canadian Regulations .................................................................................... 26 1.9.6 Chinese Regulations....................................................................................... 27 1.10 Recycling Barriers and Recycling Strategies ............................................................. 27 2 RECYCLING INFRASTRUCTURE AND STRATEGIES ............................................... 30 2.1 Recovery of Materials for Recycling Into Primary Products ..................................... 30 2.2 Recovery of Materials for Recycling Into Secondary Products ................................. 30 2.3 Chemical Recycling ................................................................................................... 31 2.4 Combustion for Energy Recovery ............................................................................. 32 3 THE PROCESS OF RECYCLING DURABLE GOODS .................................................. 33 3.1 Recycling Automobiles .............................................................................................. 33 3.1.1 Dismantling for Direct Resale ....................................................................... 33 3.1.2 Shredding ....................................................................................................... 45 3.2 Recycling White Goods ............................................................................................. 46 v CONTENTS (CONT.) 4 SHREDDER RESIDUE...................................................................................................... 48 4.1 Composition of Shredder Residue ............................................................................. 48 4.2 Recycling Shredder Residue ...................................................................................... 50 4.2.1 Recyclable Materials from Shredder Residue................................................ 50 4.2.2 Separation of Materials from Shredder Residue ............................................ 51 5 TECHNOLOGIES FOR CONCENTRATING RECYCLABLES FROM SHREDDER RESIDUE...................................................................................................... 53 5.1 The Argonne Mechanical Separation System ............................................................ 53 5.2 The Salyp Mechanical Separation Process ................................................................ 55 5.3 The Wesa-Slf Process ................................................................................................ 56 5.4 Compaction and Solidification Technology .............................................................. 56 5.5 The Witten Process for the Separation of an Organic Fraction from Shredder Residue ....................................................................................................... 57 5.6 The Sortec Process ..................................................................................................... 58 5.7 The Nimco Shredding Process ................................................................................... 58 5.8 Other Mechanical Equipment For Separating Solid Mixtures ................................... 58 5.8.1 Gravity Separators ......................................................................................... 59 5.8.2 Electrostatic Separators .................................................................................. 59 6 COMBUSTION OF SHREDDER RESIDUE FOR ENERGY RECOVERY ................... 62 7 THERMOCHEMICAL CONVERSION METHODS TO PRODUCE FUELS ................ 72 7.1 Pyrolysis ..................................................................................................................... 72 7.2 Gasification ................................................................................................................ 75 7.3 Changing World Technologies Process ..................................................................... 80 8 TECHNOLOGIES FOR SEPARATING AND RECOVERING PRODUCTS FROM SHREDDER RESIDUE...................................................................................................... 83 8.1 The Argonne Process for the Separation and Recovery of Flexible Polyurethane Foam .................................................................................................... 83 8.2 The Salyp Process for the Separation and Recovery of Flexible Foam ..................... 88 8.3 The Argonne Process for the Separation and Recovery of Plastics ........................... 88 8.4 The Recovery Plastics International Process ............................................................. 92 8.5 The Salyp Process for the Separation of Mixed Plastics ........................................... 92 8.6 The Volkswagon Ag-SiCon Recycling Process ........................................................ 93 8.7 The Galloo Process for the Recovery Plastics ........................................................... 94 8.8 The MBA Polymers Process ...................................................................................... 95 8.9 The Toyota Process .................................................................................................... 96 vi CONTENTS (CONT.) 8.10 Centrifugation Processes ............................................................................................ 97 8.10.1 The Delphi Process .......................................................................................
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