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Chapter:5 Resource Recovery

Er. Sunil Rakhal

B.E civil /Msc in Environmental Engineering
I.O.E pulchowk campus
Lecturer, Coordinator K.E.C kalimati
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Introduction
• A materials recovery facility is a specialized plant that receives,
separates and prepares recyclable materials for marketing to end-user
manufacturers. There are two types of MRF:
• Clean MRF
• Dirty MRF

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Material Recovery facility

Principle of Material Recovery Facility

• Mixed solid waste are separated based on their source for recovery of
materials.
• The process depends on degree of source separation of waste.
• The nature and design of each unit process accommodate the physical
and chemical characteristics of the source material.
• Resource recovery plays an important role in the economies of
developing nations

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Process involved in MRF Techniques

• Manual methods

• Mechanical methods
➢Electromagnetic separation
➢Fluid dynamics
➢Pneumatics
➢Others

• Processes: • Size reduction • Air classification • Screening

Manual Processing
• Bulky items (appliances, furniture, etc.) and specified contaminants (e.g., hazardous waste)
• Manual separation is applicable to the removal of contaminants from source-separated materials
• Equipment involved in manual separation of materials usually includes a sorting belt or table, which
contains a mixture of materials
• Hoppers or other receptacles for receiving removed items are positioned within easy reach of the sorters.
Manual Processing
• Newspaper (700 to 4,500kg/hr/person)
• Corrugated (700 to 4,500kg/hr/person)
• Glass containers (mixed colour) (400 to 800kg/hr/person)
• Glass containers (by colour) (200 to 400 kg/hr/person)
• Plastic containers (PET, HDPE) (140 to 280 kg/hr/person)
• Aluminum cans

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Mechanical Separation
• Size reduction
• Glass separation
• Air classification
• Non-ferrous separation
• Screening
• Densification
• Magnetic separation
• Conveyors

Size reduction Technique

• The term “size reduction” has a number of synonyms in solid waste
management, including “shredding” and “grinding”.
• Reduces bulky items to particles, the sizes of which are compatible with the
processing equipment.
• This uniformity is a requirement of some mechanical sorting systems Size
reduction Technique
• The hammer mill is a type of high-speed shredder frequently used for size
reducing solid waste.
• Low-speed, high-torque; flail mill-type shredders; and shear shredders are
also used in some cases for size reducing solid waste.
• On the basis of orientation of the rotor -- namely, horizontal and vertical

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Shear shredders
• Shear shredder is also used to size
reduce mixed waste. This size
reduction device is characterized by
its high torque and low rpm. The unit
consists of two horizontal, counter
rotating shafts. Each shaft contains
cutters to tear and shear the material.
In shear shredders, shear and
deformation are the primary
mechanisms of particle size reduction.
The cutters typically operate within a
range of 20 to 70 rpm
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AIR classification
• Air classification is a process of separating categories of materials by
way of differences in their respective aerodynamic characteristics.
• The aerodynamic characteristic of a particular material is primarily a
function of the size, geometry, and density of the particles.
• The suspended fraction conventionally is referred to as the “air
classified light fraction” and the settled fraction is termed “air-
classified heavy fraction”.
• The confined volume in which the separation takes place is called an
“air classifier”.

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Screening
• Screens are used for achieving efficient
separation of particles through dependence
on differences between particle sizes with
respect to any two dimensions.
• Screening process: Oversized feedstock,
Undersized feedstock
Types of Screening
1.Trommel Screening: The trommel has
proven to be quite effective and efficient for
processing mixed waste and other mixtures
where large, flat particles (e.g., paper) and
aggregate-type particles (e.g., crushed glass)
must be separated.
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Disc screen:
• Disc screens have been employed in many waste processing facilities.
The predominant applications to date are effecting the separation of
inorganic materials from refuse-derived fuel fractions, from paper
materials, or from wood waste.

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Magnetic Separation
• Magnetic separation is a process used to segregate magnetic (i.e.,
ferrous) metal from a mixture of different types of materials, e.g.,
mixed waste or commingled metal, glass, and plastic containers. The
process is technically simple and of relatively low cost.

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Aluminium and Glass Separation

• The predominant non-ferrous metal represented in the waste stream is
usually aluminium, and it is oftentimes a target for recovery.
• In the case of aluminium, heavy media and eddy current separation are
possibilities.
• Eddy current separation is, at present, the more commercially feasible.
• Separation is brought about by the ejection of aluminium particles
from a moving waste stream due to the force exerted on the metallic
particles as they pass through an electromagnetic flux generated by the
equipment.

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Conclusion
• By Material recovery facility the Waste management system functions
efficiently.
• MRF methods provides recycling of raw materials for Industrial uses

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What are Conversion Technologies?

• Conversion technologies refer to a wide array of state-of-theart technologies
capable of converting unrecyclable solid waste into useful products, such as green
fuels and renewable energy, in an environmentally beneficial way. These
technologies may be thermal, chemical, biological, mechanical, or a combination
of processes, but do not include incineration (waste combustion).
• Energy recovery is the process by which solid waste is converted into feedstock
materials or renewable energy. Energy recovery is happening right now, powering
homes and businesses, and it’s helping to address our growing population’s
biggest challenges: energy independence, waste diversion, and climate change.
Conversion technologies
• Most conversion technologies can be described as having three separate and
distinct components: (1) front-end MSW preprocessing, (2) the conversion unit,
and (3) the energy/chemicals production system. Frontend preprocessing is used to
prepare the solid waste for treatment by helping to separate and remove any
recyclables.

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Utilizing conversion technologies

Utilizing conversion technologies to recover solid waste from disposal
can:
• reduce greenhouse gas emissions and other criteria pollutants;
• reduce dependence on land filling and imported fossil fuels;
• enhance recycling efforts; and
• exceed California's strict environmental standards.

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Conversion technologies
• Conversion technologies are an integral process in achieving a zero-
waste goal.
• These technologies not only create a beneficial product but also
potentially reduce greenhouse gas emissions and other air pollutants
This reduction is achieved through disposal and transportation
avoidance, as well as through fuel/electricity offsets.

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Vermicomposting
• Vermicomposting or worm composting
is a simple technology for converting
biodegradable waste into organic
manure with the help of earthworms.
• Vermi composting is essentially the
consumption of organic material by
earthworms. This speeds up the
process of decomposition and provides
a nutrient-rich end product, called
vermi compost, in the form of ‘worm
castings’.

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• Earthworms have been used for centuries as a means of decomposing wastes and
improving soil structure.
• Increasing numbers of businesses worldwide are successfully employing
vermiculture technology and marketing vermicompost as an excellent soil
conditioner, to farmers and gardeners.
• For instance, Japan imports millions of tonnes of earthworms per annum for waste
conversion.
• Worms are odourless and free from disease.
• Vermiculture looks set to emerge as a significant waste management technology
Why vermin compost?
• keep valuable resources out of the landfill
• grow better veggies
• having fun looking at tiny critters in the worm bin
• feeling good at recycling nutrients that don't need to be wasted
• making a few bucks now and then, selling worms to new composters
vermicomposting

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Vermicomposting
• Two species of red earthworms have consistently been used for
commercial composting or worm farming, due to their relatively high
tolerance of environmental variations:
• a) Eisenia foetida The Red Wiggler;
• b) Lumbricus rebellus The Red Worm.
• Earthworms are hermaphroditic - that is, each worm is both male and
female and each can produce eggs and fertilise the eggs produced by
another worm. Under perfect conditions a mature breeder will produce
an egg capsule every 7 to 10 days, each containing over 1 dozen
hatchlings. Development takes 14-21 days and, once hatched, the
newly-emerged worms reach maturity in approximately four to six
weeks, meaning that the worm population may double each month.
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• In theory, 1 kilo of worms can increase to 1,000 kilos (approximately

one million worms) in a year.
• However, in working conditions 1 kilo may produce a surplus of 10
kilos in one year, because hatchlings and capsules (cocoons or eggs)
are usually lost when the vermicompost is harvested.
• This rapid breeding rate means the worm population easily adjusts to
environmental conditions, feed supply and the proportion of worm
casts to feed and bedding.

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To Begin vermicomposting need five basic

ingredients
1. container
2. bedding
3 water
4. worms
5. non-fatty kitchen scraps.

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Recommendations of key design/operating parameters for small-scale intermittent

incinerators
Type Parameters Recommendation
Capacity Destruction rate, District/subdistricts in Taylor (2003) that regularly used incinerators
safety boxes destroyed an average of 58 safety boxes per month, about 14 per week,
capacity equivalent to ~12 kg/week. Remote areas may only generate 1 kg per
month. Proper sizing is important. Ideally, unit should burn for long
periods (~4 hrs) to save fuel. (De Montfort units are not suitable for
short sharp burns without a warm up period, though this appears to be
common practice).
Temperatures Primary chamber 540 to 980 C
Secondary 980 to 1200 C (EPA 1990 recommendations) >850/1100* C (S. African
chamber and EU standards) >1000/1100* C (Indian and Thai standards) * more
than 1% chlorinated organic matter in waste, 1s
Gas entering air
pollution control
devices if any
Residence Gas (secondary >1 s
times chamber) 28

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Air flows ➢ Total combustion air ➢ 140 – 200% excess

➢ Supply and ➢ Adequate
distribution of air in ➢ Good mixing
the incinerator
➢ Mixing of ➢ Minimize by keeping moderate
combustion gas and air velocity to avoid fluidization
air in all zones of the waste, especially if high
➢ Particulate matter (>2%) ash waste is burned.
entrainment into
flue gas leaving the
incinerator
Controls & Monitoring Temperature and many Continuous for some, periodic for
other parameters others

Waste Waste destruction >90% by weight

efficiency 29

Enclosure Roof A roof may be fitted to protect

the operator from rain, but only
minimum walls.
Chimney Height At least 4 – 5 m high, needed for
both adequate dispersion plus
draft for proper air flow
Pollution control Installing air pollution Most frequently used controls
equipment control devices (APCD) include packed bed, venturi or
other wet scrubbers, fabric filter
typically used with a dry
injection system, and
infrequently electrostatic
precipitator (ESP). Modern
emission limits cannot be met
without APCD. 30

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TYPES OF INCINERATORS
1. ROTARY KILN.
2. FLUIDIZED BED
3. LIQUID INJECTION
4. MULTIPLE HEARTH
5. CATALYTIC COMBUSTION
6. WASTE-GAS FLARE
7. DIRECT-FLAME. Hemant

ROTARY KILN INCINERATOR

Rotary kiln incinerators, like the other types, are designed with
• A primary chamber, where the waste is heated and volatilized, and
• A secondary chamber, where combustion of the volatile fraction is completed.
• The primary chamber consists of a slightly inclined, rotating kiln in which waste materials migrate from the feed
end to the ash discharge end.
• The waste throughout rate is controlled by adjusting the rate of kiln rotation and the angle of inclination. Volatiles
and combustion gases pass from the primary chamber to the secondary chamber.
• The secondary chamber operates at excess air. Combustion of the volatiles is completed in the secondary chamber.
• Due to the turbulent motion of the waste in the primary chamber, solids burnout rates and particulate entrainment in
the flue gas are higher for rotary kiln incinerators than for other incinerator designs. As a result, rotary kiln
incinerators generally have add-on gas cleaning devices 32

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FLUIDIZED BED INCINERATOR

• Fluidized bed incinerators are used both the industrial and sewage sludge incineration processes.
The principle of fluidization is the process where a granular material in a solid state is turned into a
fluid-like state by passing a fluid (liquid or gas) through it.

LIQUID INJECTION INCINERATOR

Commonly used system that relies on high pressure to prepare liquid wastes for incineration by
breaking them up into tiny droplets to allow easier combustion.

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MULTIPLE HEARTH INCINERATOR

• A Multiple Hearth Furnace consists of a series of circular hearths,
positioned in a column and enclosed in a refractory-lined steel shell. A
vertical rotating shaft through the center of the furnace has rabble arms
which moves the feed material in a spiral path across each hearth, until
it passes through drop holes to the hearth below. After it passes through
each hearth, the final product is discharged through an outlet.

CATALYTIC COMBUSTION INCINERATOR

• Catalytic combustion is a chemical process which uses a catalyst to
speed desired oxidation reactions of a fuel and so reduce the formation
of undesired products, especially pollutant nitrogen oxide gases (NOx)
far below what can be achieved without catalysts. The process was
discovered in the 1970s.
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WASTE-GAS FLARE INCINERATOR

• Gas flaring is a combustion device to burn associated, unwanted or excess
gases and liquids released during normal or unplanned over-pressuring operation
in many industrial processes, such as oil-gas extraction, refineries, chemical
plants, coal industry and landfills. Gas flaring is a significant source of
greenhouse gases emissions. It also generates noise, heat and provided large
areas uninhabitable.

DIRECT-FLAME INCINERATOR
The direct flame incinerator is comprised only of the combustion chamber.

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Advantages of incineration
➢Incineration causes a significant reduction in the volume of waste. The
reduction in the original volume and weight 95% and 75% respectively.
➢It helps providing a renewable source and conserving valuable raw
materials.
➢Bottom ash can be reused – as secondary aggregates for parking lots, paved
roads etc.
➢Due to incineration, a large proportion of the organic compounds including
putrescible and hazardous waste is destroyed.So there is a net reduction in
the quantity of toxicity.
➢Incineration does not generate methane gas and reduces methane from
landfills.
➢It provides better control over odor and noise.
➢ It occupies small land.

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DISADVANTAGES OF INCINERATION
➢It causes atmospheric pollution if incinerators are not well maintained.
➢Incinerators are costly to construct, operate and regulate. Stringent
emission for incinerators increase the cost of construction, operation
and maintenance.
➢It lacks system flexibility. The demand for recycled and recovered
material for different treatment methods is likely to change overtime.
➢Incineration process produces ash and waste water from pollution
control devices.
➢A huge amount of money required to purchase a foreign made
incinerator.
➢Low income countries often lacks of adequately trained labor to
operate and maintain incinerator systems.
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