Lecture No.

9
Separation and Processing and Transformation of Solid Waste
Chapter 9, p. 247
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Issues in this lecture:

Recovery of separated materials.
Separation and processing of solid waste components
Transformation processes
1. General
Methods used to recover source separated material:
- Curbside collection
- Homeowner delivery to drop-off centers
Further separation of source separated material as well as separation of commingled
waste
- MRF's Material Recovery Facilities
- MR/TFs Material Recovery/Transfer Facilities, a facility of the future which may include:
-drop-off center
-materials separation facility
- composting
- bioconversion
- production of refuse derived fuel (DRF)
- transfer and transport facility

2. Reuse and Recycling Opportunities

Lecture No. 9: Separation and Processing and Transformation of Solid Waste, Page
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A.

Opportunities for reuse include: (T9-1, p.249)(T9-2)

Direct reuse as a raw material, 55 gal. drums, furniture, bicycles. Thrift shops.
Raw material for re manufacturing. Must meet material specifications, e.g.
- glass: color, no label or metal, degree of cleanliness
- plastics: type (PETE/1, HDPE/2 etc.) moisture content
Feed stock for the production of compost and other processes. If used as an intermediate
cover the compost can be fairly contaminated. However, compost for sale must be
free of contaminants.
Fuel Source: (perhaps the greatest value of MSW)
- Direct burn of the organic fraction. Dirt, ashes, metal, refrigerators will not burn and
perhaps other constituents such as plastics and tires should not be burned.
- Converting MSW to fuel.
Land reclamation. Enormous opportunity to reclaim land such as strip-mines or areas
below sea level as in the Netherlands, or create new green areas such as golf courses,
ball fields, equestrian centers.

B.

Drop-off, Buy-back Centers

Drop-off centers may be a wooden bin for newspapers to a thrift shop. Participation
can be low because the material must be stored by the homeowner and there is not an
economic incentive. Convenience, next to a supermarket, may be critical.
Buy-back centers may be a vending type machine in front of Lucky's to a large
commercial venture, such as the Holt Boulevard operation.

3. Unit Operations for Separation and Processing (T9-3, p.256)

A.

B.

Purpose
Modify the physical characteristics to facilitate removal of desired component.
Remove specific components or contaminants.
Prepare the material for subsequent uses.
Size Reduction
Size reduction is the process by which as collected materials are mechanically reduced
in size.
Object is to obtain a uniform final product that is reduced in size potentially reducing
storage and shipping course. Size reduction does not necessarily mean volume
reduction. Shredded paper occupies more space than the parent stock.
Shredders include hammer mill, flail mill and shear shredder and usually involve metal
parts revolving against one another.
Glass crushers.

Lecture No. 9: Separation and Processing and Transformation of Solid Waste, Page
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C.

Wood grinders include chippers, such as local tree cutters use, to reduce the branches
to chips and tub grinders. Once the wood is broken up, the finer pieces can be used as
raw material for composting and the larger pieces can be used as a fuel.
Screening

Screening is a unit operation used to separate mixtures of materials of different sizes

into two or more size fractions by means of screen surfaces.
Object is to:
- Remove oversized material
- Remove undersized material
- Separate into light (combustible, paper) and heavy (non-combustible, glass) fractions.
- Screening devices include: (Fig. 9-8, p. 260)
- Vibrating screens
- Rotary screens
- Disc screens

D.

Other Processes

- Density Separation (Air Classification) is the unit process used to separate light materials
such as paper and plastic from heavy materials such as metals based on weight difference
in the air stream. In solid waste the light fraction is typically organic while the heavy
fraction is typically inorganic. Used to separate glass from plastic in a commingled
situation.
- Magnetic Separation is the operation by which ferrous metals are separated from the
waste stream utilizing magnetic principals. Used to separate tin cans from aluminum in a
commingled situation.
- Densification (compaction) is a unit operation used to increase the density of the material
so that it can be stored and transported more cheaply and as a means of preparing
densified refuse-derived fuels (dRDR) and include balers and can crushers.
4. Facilities for Handling, Moving and Storing MSW

Conveyors (Fig. 9-14, p.265). Transfer wastes from one location to another and
include hinge, belt drag and pneumatic. Conveyors are used in the manual sorting of
MSW. Belt is 4' wide and move at 15-90 ft./min. with a thickness of waste of 6".

Example
Given: A recycling operation of commingled wastes.
Find: The Chief of Public Works of Pomona wants to know how many sorters, jobs, will be
needed on the sorting conveyor line. You know the population is 120,000.
From T6-3, p.138 3.82 lb./capita.day
Weekly tonnage = 120,000 residents x 3.82 lb./capita.day x days/week x 1 ton/2000 lb.

Lecture No. 9: Separation and Processing and Transformation of Solid Waste, Page
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Weekly tonnage = 16,044 tons/week
From T9-4, p.268 2.5 ton/person.hour, Assume a work week of 40 hours
Persons required = 16,044 tons/week x x 1 week/40 hours
Persons required = 160 people not including augmentation because of sickness, vacation,
holidays, absenteeism etc. An analysis of the economic advantages of the recycling operation
seems in order.

Movable Equipment - front end loaders, fork lifts

Weighing facilities
Storage facilities

5. Development and Implementation of MRF's

A.

Engineering Considerations

Function of MRF. Depends on role of MRF, type of materials, how the material will
be delivered and how it will be presented to the buyer.
Selection of materials to be separated. Depends on the program set up in the
community, e.g. commingled, 3 recycle containers and 1 for waste.
Material specifications.
Flow diagrams(Fig. 9-20, p. 276). Would consider:
- Characteristics of the waste material to be processed.
- Material specifications.
- Available equipment.
- Example: Refrigerators must be removed, plastic bags must be burst open, brown bags
are moved from the paper to the cardboard section where they command a higher
price. Paper may be baled which weigh 1400 lb. and are 30x40x60 inches.
Example
**Problem 9-6, p. 320
Estimate Quantities and Loading rates. Mass balance. Usually expressed in tons/hour.
Based on 1820 operating hours year.

Loading rate, ton/h =

Layout and design. Would consider:

- Waste deliveries, ingress.
- Material delivery rates.
- Loading rates including storage for peak times.
- Material flow and handling patterns
- Performance criteria for equipment selection
Equipment
Environmental controls
Aesthetics

Lecture No. 9: Separation and Processing and Transformation of Solid Waste, Page
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B.

Planning and Design Process for MRF's

Feasibility analysis. Technical and economic merits.

- The coordination of the MRF into the overall IWM (integrate waste management) plan.
- What kind of MRF and what kind of materials will it process.
- Economics, capital and operating costs. A sensitivity analysis of the effects of fluctuating
prices is particularly important.
- Ownership and Operation. Public, private, combination.
Preliminary design.
Final design.

C.

Issues for MRFs

Siting. Remote locations, as much buffer as possible, NIMBY inevitable.
Environmental issues. Traffic, noise, dust, odor, vector control, airborne litter, looks
terrible.
Public health and safety. General public and employees. For the employees,
protective clothing, puncture-proof gloves, air filters, showers, perhaps a radio.
Economics. Sensitive to market prices. Must be environmentally correct or be shut
down.

6. Combustion
A.

General

Object:
- Reduce the volume (85-95% reduction) and weight of wastes.
- Recover conversion products and energy.
Major concerns:
- Air pollution.
- Siting, NIMBY.

B.

Description of Combustion Process (Fig. 9-31, p. 293)

- Unload into a storage pit, usually a 2 day volume. The tipping area should minimize
unloading waiting time with reason.
- An overhead crane drops material into a charging chute which directs the wastes to the
furnace. The operator tries to get an even mix and remove non-combustible items such as
mattresses or engine blocks.
- The waste falls on grates and is mass fired. Air is typically introduced.
- Gases and small particles rise to the combustion chamber and burn at 1600F.
- Heat is recovered from the gases using water-filled tubes in the combustion chamber and
a boiler that produces steam which is converted to electricity in a generator.
- Air pollution is controlled including NOx, SO2 and particulates.

Lecture No. 9: Separation and Processing and Transformation of Solid Waste, Page
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- Clean gases are discharged to the stack.
- Ash and unburned material are quenched (cooled with water). The water and residue
must be properly disposed of. See p.641 for an excellent discussion of air pollution
systems.
C.

D.

E.

F.

Types of Combustors
Mass fired. Use unseparated, commingled MSW. Predominate in US, 68%. Pick out
the bicycles and refrigerators, burn the rest. The energy content is probably extremely
variable.
RDF (Refuse Derived Fuel) fired. 23%. Produced from the organic fraction and can
be made with consistency to meet energy, moisture, ash content specifications. Forms
include: shredded, fluff, pellets or cubes. Also, since metals, plastics etc. are not
burned, air emissions are cleaner.
Volume Reduction (T9-8, p.299)
Typically 90% volume reduction of the materials that were combusted. Demolition
wastes, white goods, cars etc. were never considered.
Always a residue and ash left over after combustion consisting of glass, tin cans, iron
and steel.
Issues With Combustion Facilities
Siting. As with MRF's, a remote location with plenty of buffer zone.
Air Emissions. May exceed the cost of the combustion facilities. Most pressing issue in
the LA area. Important consideration in the decision between mass-fired and RDF
systems.
Disposal of residues, bottom ash, fly ash, scrubber product. Typically disposed of in
land fill.
Liquid Emissions. Sources: ash removal, wet scrubbers.
Economics. Standardized life cycle costing.
Example Problem

**Problem 9-16, p. 321

7. Composting
A.

General
The organic fraction of MSW (less plastic, rubber and leather) is converted into an
earthy, humus-like, material by the action of bacteria and other microbes.

Lecture No. 9: Separation and Processing and Transformation of Solid Waste, Page
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P r o t e in s
A m in o a c id s
L ip id s
C a rb o s
+ O 2 + N u t r ie n t s + M O s
C e llu lo s e
L ig n in
A sh

C o m p o s t + N e w C e lls + D e a d C e lls +
C O 2 + H 20 + N O 3 + SO 4 +heat

Objectives:
- Convert the MSW into a biologically stable material which is reduced in volume.
- Destroy unwanted biologicals: pathogens, weeds, insect eggs.
- Retain the maximum nutrient (N, K, pH).
- To produce a valuable, soil amendment product. Not a fertilizer. Lousy C:N ratio.

B.

Process Description

Howard et al in India in 1930.

Three basic steps:
- Preprocessing MSW
- Segregating degradable matter, removing engine blocks, tin cans.
- moisture content.
- fertilizer content perhaps by adding sewer sludge
- Decomposition
- windrow
- static pile
- in-vessel
- Preparation for market.
- grinding
- screening
- blending
- additives
- bagging

C.

Design and Control

- Particle size
- Seeding, mixing and turning
- Oxygen requirement (aerobic process)
- Moisture content
- C:N ratio
D.

Composting Techniques
Agitated and Static. With agitated, the material is turned; with static, air is blown
through the material.
Windrow composting.

Lecture No. 9: Separation and Processing and Transformation of Solid Waste, Page
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- Most common agitated method.
- The material to be composted is shredded into 1-3" pieces and the moisture is adjusted
between 50-60%.
-The material is formed into triangular shapes called windrows which may be 6-7' high and
1`4-16' at the base.
- The windrows are tuned twice a week to maintain aerobic decomposition and the
temperature is maintained at 131F (55C).
- Takes 3-4 weeks and cured for an additional 3-4 weeks without turning.
Aerated Static Pile (Fig. 9-40, p. 307) (also Beltville or ARS process)
- MSW is placeed on top of exhaust piping in mounds 7'-8' high.
- Each pile has its own blower to deliver air, oxygen.
- 3-4 weeks of processing with an equal period for curing.
In-Vessel. Inside an enclosed vessel. Proprietary.(Fig. 9-41, p. 309)
- Plug flow and dynamic systems.
- Takes 1-2 weeks and 4-12 weeks of curing.
E. What Can Be Composted (Applications)

F.

Yard wastes T9-9, T9-10 and T9-11, p. 310. Ranges from minimal which may take 3
years to high level in container which can be done in several weeks.
MSW (organic fraction). Metals or household hazardous waste can easily contaminate
the compost. If a high quality product is desired, source separation is a must.
MSW (commingled, partially processed). Not suitable as a gardener's compost; use as
an intermediate cover if allowed.
MSW (with sewer sludge). May avoid sludge dewatering. Increases the nutrient and
moisture contents of the mix; may also contain heavy metals. A 2:1, MSW: sludge is
recommended as a starting point.

Issues With Composting Facilities

Odors. Usually caused by:

- Low C:N ratios
- Poor temperature control
- Excessive moisture
- Poor mixing
- Can be controlled with various towers and facilities and odor-masking agents and
enzymes.
Pathogens. Usually destroyed by normal composting parameters of 55C for 15-20
days
Heavy metals. Particles are created when the waste is shredded and these particles may
become attached to the lighter fractions.
Definition of acceptable compost

Lecture No. 9: Separation and Processing and Transformation of Solid Waste, Page
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G.

Example Problem

**Problem 9-18, p. 322

8. Impact of Source Reduction and Recycling on Combustion
and Composting
see example 9-4, p. 318
EXAMPLES
9-6, 9-16, 9-18
HOMEWORK
Read Chapter 9, Separation and Processing and Transformation of Solid Waste, PP. 247323
Problems, p. 320, 9-2, 9-8, 9-13, 9-17, 9-20

Lecture No. 9: Separation and Processing and Transformation of Solid Waste, Page
No. 10
LECTURE NO. 9...........................................................................................................................................1
SEPARATION AND PROCESSING AND TRANSFORMATION OF SOLID WASTE........................1
1. GENERAL..................................................................................................................................................1
2. REUSE AND RECYCLING OPPORTUNITIES...................................................................................2
A.
B.

OPPORTUNITIES FOR REUSE INCLUDE: (T9-1, P.249)(T9-2)................................................................2

DROP-OFF, BUY-BACK CENTERS.........................................................................................................2

3. UNIT OPERATIONS FOR SEPARATION AND PROCESSING (T9-3, P.256).................................2

A.
B.
C.
D.

PURPOSE.............................................................................................................................................2
SIZE REDUCTION.................................................................................................................................2
SCREENING.........................................................................................................................................3
OTHER PROCESSES..............................................................................................................................3

4. FACILITIES FOR HANDLING, MOVING AND STORING MSW...................................................3

5. DEVELOPMENT AND IMPLEMENTATION OF MRF'S..................................................................4
A.
B.
C.

ENGINEERING CONSIDERATIONS.........................................................................................................4
PLANNING AND DESIGN PROCESS FOR MRF'S....................................................................................5
ISSUES FOR MRFS...............................................................................................................................5

6. COMBUSTION..........................................................................................................................................5
A.
B.
C.
D.
E.
F.

GENERAL............................................................................................................................................5
DESCRIPTION OF COMBUSTION PROCESS (FIG. 9-31, P. 293).............................................................6
TYPES OF COMBUSTORS......................................................................................................................6
VOLUME REDUCTION (T9-8, P.299)...................................................................................................6
ISSUES WITH COMBUSTION FACILITIES..............................................................................................6
EXAMPLE PROBLEM............................................................................................................................7

7. COMPOSTING..........................................................................................................................................7
A. GENERAL............................................................................................................................................7
B. PROCESS DESCRIPTION.......................................................................................................................7
C. DESIGN AND CONTROL.......................................................................................................................8
D. COMPOSTING TECHNIQUES.................................................................................................................8
E. WHAT CAN BE COMPOSTED (APPLICATIONS).........................................................................................8
F.
ISSUES WITH COMPOSTING FACILITIES..............................................................................................9
G. EXAMPLE PROBLEM............................................................................................................................9
8. IMPACT OF SOURCE REDUCTION AND RECYCLING ON COMBUSTION AND
COMPOSTING..............................................................................................................................................9