Air Classifier Zig-Zag

Air classifier: Zig-zag
Copyright Anders Damgaard & Morton A. Barlaz, NC State University
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Material settling velocity
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Optical sorting
Glass
can sort crushed glass by color
can remove ceramic
role will be at an intermediate processor collecting glass from
multiple MRFs
Plastic
PET
HDPE (translucent/pigmented)
http://www.youtube.com/watch?v=CUmHDH7C-e8
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Paper Sorting
A lot of activity on sorted office pack (SOP)

Tradeoff between quality and diversion
high quality: 10 - 20% diversion
SOP up to 75% of office waste
What is the market for sorted vs. mixed paper?
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Paper Sorting
What can be done at a MRF?
Labor intensive as mechanized sorting can only do so much
Disc/star screens separate OCC from other paper
Waterfall conveyors that flip stacks of paper every 30
contaminants are more visible to sorters
Pneumatic suctions ducts over picking lines
eliminate workers bending and turning
reduces contamination
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Star Disc Screen
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Disc screen
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Manual sorting:
Positive and Negative sorting
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Technology: Compaction
Hydraulic compaction and containment (hydraulic plate or screw

compacting against a wall in a container)
Baling: hydraulic compaction and containment by wires, plastic or
other wrapping
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Balers (Densification)
The major piece of equipment at many MRFs

Used to prepare recyclables for market
In some (rare) cases used to bale refuse prior to disposal
Expensive, complex, and crucial to continuous operation
Can be used for plastics, cans, fiber
Size: 30 x 30 x 42 to 72 x 46 x 42
Moved by forklift
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Balers (Densification)
Vertical balers
Small capacity - 5 - 20 TPD
Horizontal baler
Large capacity - 50 - 80 TPD
2 balers are desirable due to potential for downtime
Specifications are critical!!!
Materials to be baled
Volume per day
Size of largest material
ONP, OCC, OFF > Al, plastics, ferrous
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Inspector could be placed here
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Can Compaction
Crushers
Crush cans between two rotating wheels
Al: 250 lb/yd3
May drop onto a conveyor or pneumatically blow them into a
trailer
Shredders (for Al)
Shred and blow them into a trailer
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Perforators
Device to punch holes in plastic in order to facilitate flattening

Can be mounted inside chutes
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50
Wood grinders
Primary use is upstream of a yard waste composting facility of for a

C&D MRF
Could be used to generate a fuel supplement from pallets, scrap
lumber
Tub grinder
large tub with a revolving upper section, followed by a hammer
mill
Fed by a conveyor, front end loader or bucket
May be portable and operated on diesel
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Conveyors
Transfer waste from one location to another - vertical and horizontal

Vertical: < 40 degree angle to avoid accumulation of heavies
(glass); use of flights
On a picking line
Wastes dropped onto conveyors by front end loaders tends to
add to wear and tear
require maintenance due to dusty environment
adjustable speed to spread waste
Also used to feed balers, ECS, screens, etc.
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Pneumatic Conveyors
used to convey materials large distances across a plant
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Copyright: Anders Damgaard & Morton A. Barlaz, NC State University
55
Conveyor Feed Pit
Photo Source: Ken Mills Engineering, Ltd. (www.kenmills.co.uk)
56
Pit Length
The higher the desired throughput the longer the pit

Bulkier materials require longer pits
At 5 tons/hr: pit length - 15 ft for OCC
pit length - 10 ft for paper
Throughput of conveyor/end point machinery is limited most by
loading capability (the ability to keep material on the belt)
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Picking Line 1
Well lighted and ventilated
room enclosure for fresh air, noise protection
dust control using misters at point where material drops vertically
sort high volume materials first
as number of materials goes up, so does residual
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Picking Line 2
Adjustable speed 15 - 90 ft/min
Used to control material thickness, thinner is optimal for recovery
efficiency
60 ft/min typical.
Must have sufficient material for worker to maximize material
recovery
number of people on a material
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Picking Line 3
Width 3 - 4 ft depending on whether there is access from both sides
typically hand picked waste will be discharged to a chute which
drops into a bin on a lower level (in line glass crusher)
the bin may be the shipping container or an intermediate container
(labor cost implications)
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Picking Line 4
Negative Sorts
All facilities must be designed to minimize repetitive
motion injuries (ergonomics)
pushing versus pulling material
head on sorting off of a shaking table
lets workers see an item coming longer and use both hands
more efficiently
61
Sorting Line Considerations
Double vs Single side sorting
Photo source: www.hustler-conveyor.com
Photo source: www.nexgenbalers.com
Is single side preferable over double side?
- Double side: need at least 2 people for good efficiency; higher

throughput
- Single side: need only 1 sorter with no loss in efficiency
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Sorter Line Ergonomics

Angled sideboards for armrest & protection
Width: Single side = 24 typ. (36 max.)
Double side = 48 60 typ. (72 max.)
Burden depth = 6
Speed adjust for sort
efficiency & # workers
Length based on
# workers, space, etc.
Negative sort for

heavier items
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This is an enclosed picking room

so workers are insulated from the
general plant noise. Picked
materials are dropped in here.
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dust curtain at entrance

to enclosed picking room
Vacuum supply
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This is an
example of head
on sorting
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Other Requirements
Scales
Typically trucks are weighed on entering and leaving
May need smaller scales to weigh bins of materials as are prepared
for shipment
Storage
May be in roll off containers, boxes, tractor trailers, piles, bales
Must allow for storage between collection and sale
Depending on the material, the market and the flow rate, this could
be 1 - 5 weeks (or higher if small portions)
Vehicles
Forklifts
Bobcats/loaders
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Other Requirements 3
Office space
Flexibility!!
Increase the number of shifts
Leave room for another processing train
Movable chutes and bins to vary materials recovered
Heat and ventilation
Fire protection
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Other Requirements 4
Traffic patterns and size of tipping floor to minimize unload time and
congestion
Public access
Separate commercial haulers from pickup trucks
Material Purification
second sort of materials sorted from mixed waste, or,
a picking line for checking recyclables sorted at point of
collection (negative sort)
Some MRFs may cater to commercial waste/ office waste only
72
MRF Design
The design process
1. Formulation of a design basis
What will be delivered and from where?
How much will be delivered?
2. Recovery factor
How reliable are people in source curbside programs?
(lb/house-wk)
How good are pickers in a mixed waste MRF?
Optimize personnel vs. efficiency
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MRF Design 2
3. Development of a process flow diagram
4. Material balance
All material must be accounted for at each step
5. Size equipment
Operating hours
Allow for cleanup time
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MRF Design 3
6. Specify equipment
Interaction with vendors
Demonstrations, site visits
Write performance specifications and send out for bid
Performance guarantees
MSW is more abrasive than many other solid materials
7. Equipment and facility layout
Traffic pattern
Minimize backing up
Number of trucks to be accommodated at one time
Typically will not be spread evenly
75
MRF Design
8. OSHA
Personnel on the tipping floor moving around heavy equipment
Noise levels
Gloves/respirators
Repetitive motion
Lifting
Dedicated dust control
Ventilation for dust/bacteria
Curtains where waste falls on conveyors
Around trommel
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MRF Economics 1
MRFs typically require a tipping fee
Fee may vary by type of load
Presorted vs. Commingled
Commercial vs. Residential
Recyclables vs. mixed refuse
MRF profitability versus total system cost
Many companies will build a MRF and then recruit business
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MRF Economics 2
Citys perspective
Additional collection plus MRF operation costs money
Write contracts carefully so city is not trapped in a bad situation
Contract can include revenue sharing between the city and MRF
owner which protects both parties from price fluctuations
Is there a cost savings by not using landfill?
Refuse plus recyclables costs are not linear
78
C&D Waste Recycling

Material
Dirt/Fines
Brick
Concrete
Asphalt
OCC
Ferrous Metal
Non-Ferrous Metal
Wallboard
Wood
Miscellaneous
Composition (%)
25
5
10
6
7
3
2
8
22
12
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C&D Waste Recycling
Separate from a traditional MSW MRF

Special Equipment
excavator with a permanent magnet head used to

scavenge metal on receipt
finger screen to do a size split
small material (<12) to a trommel
large air suction for paper removal
larger material hand sorted
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C&D Waste Recycling
Trommel:
<2 fines landfill cover

2-4 magnet, rock and bricks
>4 hand sorting for:
Rugs
Wood
Tires
Plastic buckets
OCC
wallboard
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C&D Waste Recycling
Rock and brick is crushed, passed under a

magnet and sized for use in gravel
can be processed by sink/float system to remove

small pieces of wood
Wallboard causes significant dust problems
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Typical Flow Diagram
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Air classifier: Zig-zag

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Material settling velocity

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

A lot of activity on sorted office pack (SOP)

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Star Disc Screen

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Hydraulic compaction and containment (hydraulic plate or screw

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

The major piece of equipment at many MRFs

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Inspector could be placed here

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Shredders (for Al)

Shred and blow them into a trailer

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Device to punch holes in plastic in order to facilitate flattening

Primary use is upstream of a yard waste composting facility of for a

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Transfer waste from one location to another - vertical and horizontal

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

used to convey materials large distances across a plant

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright: Anders Damgaard & Morton A. Barlaz, NC State University

Conveyor Feed Pit

Photo Source: Ken Mills Engineering, Ltd. (www.kenmills.co.uk)

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

The higher the desired throughput the longer the pit

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Sorting Line Considerations

Double vs Single side sorting

Photo source: www.hustler-conveyor.com

Photo source: www.nexgenbalers.com

Is single side preferable over double side?

- Double side: need at least 2 people for good efficiency; higher

Sorter Line Ergonomics

Negative sort for

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

This is an enclosed picking room

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

dust curtain at entrance

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright: Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University

Copyright Anders Damgaard & Morton A. Barlaz, NC State University