IWR Integrated Waste Recycling. Integrated System for treatment and recycling of Municipal Solid Waste

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1 IWR Integrated Waste Recycling Integrated System for treatment and recycling of Municipal Solid Waste 1

2 1. Introduction IWR is an integrated system, realised by different Italian companies, manufacturers of specific equipments for the treatment and valorisation of waste, which offer all their skills, experience, know how and support in the site realisation. The IWR system is a multipurpose plant for the treatment of waste with eco compatible processes and innovative solutions for the reduction of gas emission and lifestyle which have low environmental impact. 2

3 The treatment of waste is a very important problem that every country in the world has to face. The project propose a highly technologic and completely environmental friendly solution to all the organizations which have to face, today, the management problem of MSW. How to treat the waste and where to place it? Reusable raw material should be extracted from the waste (the so called secondary raw materials)? Could it be better to proceed in extracting energy with biological methods and/or by means of incineration? 3

4 Incineration is the easiest way to treat the garbage but it is not the answer to environmental problems. The last experiences say that the best ways to treat the waste are: reduction reusing recycling Waste that can be recycled and reused must be recycled and reused. Waste which cannot be recycled and reused must be employed in energy production. Solutions which propose physical treatment of the waste with mechanical cold treatment,, such as washing, sectioning, granulation, etc., are able to recuperate materials to be re introduced in the productive cycle, and at the same time reduce the quantity of waste going to landfill. 4

5 2. Project We have two aims: Clean technology Saving resources Environmental compatibility of the production cycles Construction of an environmental platform for the integrated treatment of the waste (at present prevalently sent to landfill or to the incinerator). Consider all the treatment of urban waste coming both from differentiated and undifferentiated collection, to obtain secondary raw material and clean energy. The plant solves the problems of a community with a waste production up to 3000 ton/day, without burning. It allows to recycle material up to 80 90% of the input waste and only a 10 20% residual go to landfill. It is able to produce energy both to be used by the plant itself and for outside sale (to provide energy to families, industrial areas, municipal common areas, etc.) The plants will be fitted with biological deodorization and all the operations will not produce polluting emissions. It is a turnkey plant, which includes civil works, offices, hangars, weighing machines, etc. 5

6 IWR platform 6

7 IWR platform 7

8 IWR platform 8

9 3. The lay out 9

10 3. The lines TIRES RECYCLING PICKING LINE RDF PRODUCTION LINE WEEE: E-SCRAP RECYCLING REFINING LINE LIGHT FERROUS SCRAP DEYDRATION MSW DRY FRACTION MSW PRESORTING LINE BIOSTABILIZATION OF DIGESTED SLUDGE ANAEROBIC DIGESTED 10

11 3. The Plant An integrated management of waste must foresee, as a strategic and priority action, the recuperation of materials from waste and the recuperation of energy from non recyclable residues. The project includes the following treatment lines: Undifferentiated MSW treatment with separation of dump fraction and RDF production (MSW) Treatment of discarded tires and of non chlorinated rubber for the production of rubber granule (various dimensions) and recovered steel and textile (rubber) Treatment of ferrous material including automobiles with automatic separation and recovery of various types of materials (ferrous material) Treatment of fridges, electric appliances and computers, etc., recovering gas and selecting different types of materials (WEEE) Energy production line 11

12 The recuperated fractions must be pre selected and treated with procedures that make them acceptable to the industrial market. The dry fraction of the MSW, by means of different treatments, is used to produce a fuel with very high caloric power without polluting materials, therefore highly ecological. Quality control will support the productive procedures. The plant can be projected and realized in different ways, both for quality and/or quantity of product. 12

13 MSW pre sorting lines ORIGIN Municipal and industrial collecting CHARACTERISTICS OF THE WASTE Paper, plastic, metals, inorganic and organic materials, glass, textile, lather and other ACTIVITY OF RECUPERATION Sorting organic fraction not organic fraction TYPE OF PLANT Primary shredder and mechanical screening separation to segregate waste in organic and not organic fraction Capacity tons/day Hours/day h. 24 Yearly potential (300 days) tons Lines n. 3 Maximum hourly potential tons 90 13

14 MAGNETIC SEPARATOR AREA OF REFUSES TROMMEL FEEDING HOPPER SHREDDER TROMMEL SCREEN AREA OF METAL 14

15 15

16 Picking lines ORIGIN Not organic fraction after MSW pre sorting line and bio dry section CHARACTERISTICS OF THE WASTE Paper, plastic, metals, inorganic and organic materials, glass, textile, lather and other ACTIVITY OF RECUPERATION Recuperation recyclables fraction paper, plastic, metals TYPE OF PLANT Mechanical screening and ballistic separation to prepare homogenous fraction for picking sorting Lines total capacity tons/day 600 Lines n. 2 Capacity of each line tons/day 300 Picking conveyor n. 6 Hours/day h. 24 Yearly potential (300/days) tons Theoretical capacity of recycling % 30

17 STOCK AREA RECYCLABLES MATERIAL BALER LINE MAGNETIC SEPARATOR REFUSE CONVEYOR FEEDING LINE PICKING CONVEYOR MECHANICAL SORTING 17

18 18

19 19

20 ORIGIN Refuse fraction to picking sorting lines RDF production lines CHARACTERISTICS OF THE WASTE Paper, plastic, rubber, wood waste and any high power calorific materials refuse sorting ACTIVITY OF RECUPERATION Production of Refuse Derived Fuel for combustion plant TYPE OF PLANT Primary and secondary shredder, metal separation, fine and heavy fraction separation Lines total capacity tons/day 600 Line n. 1 Hours/day h. 24 Yearly potential (300 days) tons RDF estimated production tons/day 500 Theoretical capacity of recycling % 80 20

21 PRIMARY SHREDDER FEEDING HOPPER MAGNETIC SEPARATOR STARS SCREEN BALLISTIC SEPARATOR RDF STORAGE 21

22 22

23 Refining line ORIGIN Organic material after bio stabilization lines CHARACTERISTICS OF THE WASTE Organic material and wood wastes mixes with paper, plastic and other small contaminants ACTIVITY OF RECUPERATION Cleaning organic material for eventually reuse bio stabilization fraction TYPE OF PLANT Mechanical and densimetric screening Lines total capacity tons/day 300 Line n. 1 Hours/day h. 24 Yearly potential (300 days) tons

24 REFUSE TROMMEL DENSIMETRIC TABLE AIR FILTER FEEDING HOPPER 24

25 25

26 Plant for anaerobic digestion of moist fraction ORIGIN Presorting line MSW or selective collection of organic fraction CHARACTERISTICS OF THE WASTE Moist fraction ACTIVITY OF RECUPERATION Production of biogas and digested sludge TYPE OF PLANT Anaerobic digestion with biogas production for combined heat and electricity production Capacity tons/day 600 Hours/day h. 24 Yearly potential (300 days) tons Lines n. 2 Digester Power capacity number for for each each line line KW n Annual energy pruduction MWh

27

28 Plant for bio stabilization of digested sludge and wood waste ORIGIN Plant for anaerobic digestion of moist fraction CHARACTERISTICS OF THE WASTE Digested sludge and wood ACTIVITY OF RECUPERATION Production of stabilized matter TYPE OF PLANT Digested sludge dehydration, mixing of solid sludge and wood, bio stabilization in closed bio cells with aerobic treatment and curing phase Solid digested sludge capacity tons/day 300 Wood waste capacity tons/day 100 Capacity tons/day 400 Hours/day h. 24 Yearly potential (300 days) tons Lines n. 2 Biocells number for each line n

29 Plant for bio stabilization of digested sludge and wood waste 29

30 Plant for dehydration of dry fraction ORIGIN Presorting line MSW or selective collection of organic fraction CHARACTERISTICS OF THE WASTE Dry fraction ACTIVITY OF RECUPERATION Production of dried matter TYPE OF PLANT Dehydration in closed biocells with aerobic treatment Dry fraction capacity tons/day 700 Hours/day h. 24 Yearly potential (300 days) tons Lines n. 1 Biocells number for each line n

31 Plant for dehydration of dry fraction

32 Light ferrous scrap ORIGIN Industrial activity, artisan, iron works, steel and non ferrous metals, differentiated collection; differentiated urban waste collection CHARACTERISTICS OF THE WASTE Ferrous discharge, steel and their alloys also constituted by falls from work shops; bulk junk material, zinc, metal sheet; packaging, barrels, empty cans of ferrous and non ferrous metals, etc. ACTIVITY OF RECUPERATION Production of secondary raw material for metal industry TYPE Iron waste, steel, non ferrous metals and their alloys, scraps or machines shop rejections of aluminum packaging and metal; parts of cars, end of life vehicles (ELV), etc. Capacity tons/h Hours/day h. 10 Yearly potential (300 days) tons / Lines n. 1 32

33 Light ferrous scrap 33

34 PFU Tires recycling plant TYPE Tires, air chambers, and other rubber waste that cannot be re utilized, production waste, dust and granule waste ORIGIN Rubber industry and production of rubber tires: other production activities, commercial activities, artisan activity: industry for the reconstruction of tires, activities of substitution and reparation of tires CHARACTERISTICS OF THE WASTE Damaged rubber and air chambers with eventual presence of superficial pollutants, rubber waste of differing dimension and shape ACTIVITY OF RECUPERATION Grinding with mechanical systems, washing with separation of occasional pollutants in order to bring the rubber to undergoing the following operations: A) recuperation in compatibility mix or in partial replacement of natural rubber; B) recuperation for production of technical articles in compatible mixes; C) recuperation for the production of modified road bitumen; D) recuperation in the production of buoys after eventual mechanical compacting. Daily potential (20 h.) tons 80 Maximum hourly potential tons 5 Yearly potential (300 days) tons Lines n. 1 Annual production of rubber granule Æ 2-4 mm tons

35 PFU Tires recycling plant 35

36 PFU Tires recycling plant

37 ORIGIN Industrial activity, differentiated collection ELV recycling plant CHARACTERISTICS OF THE WASTE Loose, bulk junk material, zinc, metal sheet; packaging, etc. ACTIVITY OF RECUPERATION Production of secondary raw material for the metal industry TYPE Scraps or machines shop rejections of aluminum packaging, plastic and metal; parts of cars, end life vehicles (ELV) Capacity tons/h Hours/day h. 10 Yearly potential (300 days) tons / Lines n. 1 37

38 ELV recycling plant 38

39 ELV recycling plant 39

40 WEEE : E scrap recycling line ORIGIN Industrial activity, differentiated collection, selection or incineration plants of MSW; differentiated urban waste collection CHARACTERISTICS OF THE WASTE Loose, bulk junk material, aluminium, plastic parts, packaging, etc. ACTIVITY OF RECUPERATION Production of secondary raw material for the metal industry TYPE Small, medium and big electric and electronic household appliances, IT & tele communications equipment, consumer equipment, toys, leisure and sports equipment, medical devices, display equipment, monitoring and control instruments, cooling appliances containing refrigerants Capacity tons/h. 5 Hours/day h. 10 Yearly potential (300 days) tons Lines n. 1 40

41 WEEE : E scrap recycling line 41

42 WEEE : E scrap recycling line 42

43 SUMMARY Integrated Waste Recycling MSW lines total capacity ton/day Other lines total capacity ton/day RDF total production ton/day 400 Recyclables total fraction ton/day 200 Refuse total fraction ton/day 300

44 SUMMARY Integrated Waste Recycling Building area m2 Total area included roads, squares and offices m2 Total employees (65 people/3 shifts /6 days a week ) 200 The IWR platform is a modular plant, that can be realized with successive steps (for example, tires treatment, or WEEE treatment or RDF production or any other plant cannot be realized if not necessary, or they can be realized later). The indicative management cost for the waste treatment can change from 15 to 35 Euro/ton, in accordance with the country standards and values and following the investment capacity of the client. The civil works of the IWR platform will be realized in co operation with local companies.

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