Recovery of plastic packaging from mixed municipal solid waste. A case study from Austria.

Austria must recycle more packaging materials. Especially for plastic packaging waste, significant increases are necessary to reach the EU recycling targets for 2025 and 2030. In addition to improving separate collection and introducing a deposit system for specific fractions, the share of plastic packaging in mixed municipal solid waste (MSW) could be utilized. In Austria, about 1.8milliontonnes of mixed MSW are generated. This includes about 110,000 t/a of plastic packaging waste. Most of the mixed MSW (94 %) is sent directly or via residues from pre-treatment, such as mechanical-biological treatment or waste sorting, to waste incineration. While materials such as glass and metals can also be recovered from the bottom ash, combustible materials such as plastics must be recovered before incineration. This work aims to evaluate the recovery potential of plastic packaging waste in mixed MSW with automated waste sorting. For this purpose, two of the largest Austrian waste sorting plants, with a total annual throughput of about 280,000 t/a, were investigated. The investigation included regular sampling of selected output streams and sorting analysis. The results show that the theoretical recovery potential of plastic packaging from these two plants is 6,500 t/a on average. An extrapolation to Austria results in a potential of about 83,000 t/a. If losses due to further treatment, such as sorting and recycling, are considered, about 30,000 t/a of recyclate could be returned to plastic production. This would correspond to an increase in plastic packaging recycling rate from 25 % to 35 %.

Glass recovery and production of manufactured aggregate from MSWI bottom ashes from fluidized bed and grate incineration by means of enhanced treatment.

Enhanced treatment of incineration bottom ashes (IBA) from municipal solid waste incineration can contribute to a circular economy since not only metals can be recovered but also glass for recycling. Moreover, the remaining mineral fraction can be utilized in concrete as manufactured aggregate. To evaluate the effects of an enhanced treatment, three IBAs from fluidized bed combustion (FB-IBAs) and three grate incineration bottom ashes (G-IBAs) were standardly treated in a jig and further processed on a pilot scale, including improved metal recovery and sensor-based glass separation. The removed glass fractions were weighed and their composition was assessed by means of manual sorting. The manufactured aggregate was also sorted manually and its total and leachate contents were determined before and after aging. Results showed general differences between FB-IBAs and G-IBAs. For G-IBAs, higher contents of heavy metals and residual metal pieces were determined, while the share of glass removed was low compared to FB-IBA. The treated mineral fractions from G-IBA contained more mineral agglomerates, whereas FB-IBAs contained more glass. However, the glass-fractions removed from FB-IBAs need further treatment to be accepted in glass recycling. Austrian limit values for utilization in concrete were met by all manufactured aggregates produced from FB-IBA, but only by one from G-IBA. Overall, the enhanced treatment in the study performed well compared to the literature. Nevertheless, further investigations are necessary to improve the recyclability of the recovered glass fractions and to determine the technical suitability of manufactured aggregates produced from IBAs.

Comparing the quantity and quality of glass, metals, and minerals present in waste incineration bottom ashes from a fluidized bed and a grate incinerator.

Bottom ash is the primary solid residue arising from municipal solid waste incineration. It consists of valuable materials such as minerals, metals and glass. Recovering these materials from bottom ash becomes evident when integrating Waste-to-Energy within the circular economy strategy. To assess the recycling potential from bottom ash, detailed knowledge of its characteristics and composition is required. The study at hand aims to compare the quantity and quality of recyclable materials present in bottom ash from a fluidized bed combustion plant and a grate incinerator, both located in the same city in Austria and receiving mainly municipal solid waste. The investigated properties of the bottom ash are grain-size distribution, contents of recyclable metals, glass, and minerals in different grain size fractions, and the total and leaching contents of substances in minerals. The study results reveal that most recyclables present are of better quality for the bottom ash arising at the fluidized bed combustion plant. Metals are less corroded, glass contains fewer impurities, minerals contain fewer heavy metals, and their leaching behavior is also favorable. Furthermore, recoverable materials, such as metals and glass are more isolated and not incorporated into agglomerates as observed in grate incineration bottom ash. Based on the input to the incinerators more aluminum and significantly more glass can potentially be recovered from bottom ash from fluidized bed combustion. On the downside, fluidized bed combustion produces about five times more fly ash per unit of waste incinerated, which is currently disposed of in landfills.

Complete determination of the material composition of municipal solid waste incineration bottom ash.

Bottom ash from waste incineration is heterogeneous and contains different materials. Previous studies on the material composition of bottom ash provide only limited information as to composition, because large pieces present in bottom ash were not investigated nor were all materials were separated and analysed. The objective of the present study is to provide the complete and detailed composition of bottom ash encompassing and extensive range of different materials. Altogether, nine bottom ash samples with a mass of 3000 kg each were sieved to eight size fractions, whereby small particles adhering to larger pieces were separated by water and added to the respective size fractions. In the sorting analysis of all size fractions, the materials enclosed in molten mineral material and materials present as composites (e.g. transformers and batteries) were considered. The material characterisation revealed that the size fraction > 50 mm contains most of the iron (up to 50% of the total iron) and copper (about 20% of the total copper), while batteries, coins, silver and gold are almost exclusively present between 16 and 50 mm. The fractions between 8 and 16 mm show the highest share of aluminium (up to 50% of the total aluminium) and glass (up to 60% of the total glass). While the metal content is underestimated, if large pieces of material are disregarded, the multi-step approach applied in this study enables a complete determination of materials in bottom ash, which is essential for optimising material recovery in bottom ash treatment.

Legal situation and current practice of waste incineration bottom ash utilisation in Europe.

Almost 500 municipal solid waste incineration plants in the EU, Norway and Switzerland generate about 17.6 Mt/a of incinerator bottom ash (IBA). IBA contains minerals and metals. Metals are mostly separated and sold to the scrap market and minerals are either disposed of in landfills or utilised in the construction sector. Since there is no uniform regulation for IBA utilisation at EU level, countries developed own rules with varying requirements for utilisation. As a result from a cooperation network between European experts an up-to-date overview of documents regulating IBA utilisation is presented. Furthermore, this work highlights the different requirements that have to be considered. Overall, 51 different parameters for the total content and 36 different parameters for the emission by leaching are defined. An analysis of the defined parameter reveals that leaching parameters are significantly more to be considered compared to total content parameters. In order to assess the leaching behaviour nine different leaching tests, including batch tests, up-flow percolation tests and one diffusion test (monolithic materials) are in place. A further discussion of leaching parameters showed that certain countries took over limit values initially defined for landfills for inert waste and adopted them for IBA utilisation. The overall utilisation rate of IBA in construction works is approximately 54 wt%. It is revealed that the rate of utilisation does not necessarily depend on how well regulated IBA utilisation is, but rather seems to be a result of political commitment for IBA recycling and economically interesting circumstances.

Chemical composition and leachability of differently sized material fractions of municipal solid waste incineration bottom ash.

The chemical composition and leachability of municipal solid waste incineration bottom ash are important parameters determining its suitability for utilisation. The objective of the present study is to investigate the chemical composition of individual size and material fractions and their contribution to the total elemental contents of bottom ash. Nine bottom ash samples with a mass of 3000 kg each were sieved to eight size fractions and sorted into different materials. The materials (mineral material, glass, batteries) were separately analysed by inductively coupled plasma optical emission spectrometry after acid digestion. Additionally, x-ray fluorescence measurements and leaching tests were performed. Metals were further analysed by sorting analysis. The chemical analysis revealed that large particles have higher contents of Fe and Si, but lower contents of Ca and S compared to smaller particles. All mineral fractions exceed the legal limit values for utilisation in Austria mainly because of the total contents of Pb and Tl and the leachate contents of Cr and Sb. Glass from bottom ash is enriched in As, Na, Si and Tl compared to the mineral material. Although battery contents contribute only 0.2% to the total mass of bottom ash, they contribute at least 30% to the total content of Cd. Most previous studies neglected large metallic pieces and batteries, which contain most of the Cd, Cr, Cu and Ni present in bottom ash. This practice can result in an underestimation of the total contents of these elements by up to about 70%.

Combined disc pelletisation and thermal treatment of MSWI fly ash.

An environmentally friendly and cost efficient way for the management of municipal solid waste incineration (MSWI) fly ash represents its thermal co-treatment together with combustible waste. However, the safe introduction and storage of MSWI fly ash in the waste bunker is challenging and associated with severe problems (e.g. dust emissions, generation of undefined lumps and heat in case of moistened MSWI fly ash). Therefore, the aim of this study is to investigate the suitability of pelletisation as a pretreatment of MSWI fly ash. In particular, MSWI fly ash was characterised after sampling, pelletisation and thermal treatment and the transfer of constituents to secondary fly ash and flue gas was investigated. For this purpose, MSWI fly ash pellets with a water content of about 0.15 kg/kg and a diameter of about 8 mm have been produced by disc pelletiser and treated in an electrically heated pilot-scale rotary kiln at different temperatures, ranging from 450 °C to 1050 °C. The total contents of selected elements in the MSWI fly ash before and after thermal treatment and in the generated secondary fly ash have been analysed in order to understand the fate of each element. Furthermore, leachable contents of selected elements and total content of persistent organic pollutants of the thermally treated MSWI fly ash were determined. Due to the low total content of Hg (0.7 mg/kg) and the low leachate content of Pb (<0.36 mg/kg), even at the lowest treatment temperature of 450 °C, thermally treated MSWI fly ash pellets can be classified as non-hazardous waste. However, temperatures of at least 650 °C are necessary to decrease the toxic equivalency of PCDD/F and DL-PCB. The removal of toxic heavy metals like Cd and Pb is significantly improved at temperatures of 850 °C, 950 °C or even 1050 °C. The observed metal removal led to relatively high contents of e.g. Cu (up to 11,000 mg/kg), Pb (up to 91,000 mg/kg) and Zn (up to 21,000 mg/kg) in the secondary fly ash. This metal enriched secondary fly ash might represent a potential raw material for metal recovery (e.g. via acidic leaching). Due to the high content of total dissolved solids observed in the leachate of thermally treated MSWI fly ash pellets, a wet extraction procedure is suggested to enable its safe disposal at non-hazardous waste landfills.

Thermal co-treatment of combustible hazardous waste and waste incineration fly ash in a rotary kiln.

As current disposal practices for municipal solid waste incineration (MSWI) fly ash are either associated with significant costs or negative environmental impacts, an alternative treatment was investigated in a field scale experiment. Thereto, two rotary kilns were fed with hazardous waste, and moistened MSWI fly ash (water content of 23%) was added to the fuel of one kiln with a ratio of 169kg/Mg hazardous waste for 54h and 300kg/Mg hazardous waste for 48h while the other kiln was used as a reference. It was shown that the vast majority (>90%) of the inserted MSWI fly ash was transferred to the bottom ash of the rotary kiln. This bottom ash complied with the legal limits for non-hazardous waste landfills, thereby demonstrating the potential of the investigated method to transfer hazardous waste (MSWI fly ash) into non-hazardous waste (bottom ash). The results of a simple mixing test (MSWI fly ash and rotary kiln bottom ash have been mixed accordingly without thermal treatment) revealed that the observed transformation of hazardous MSWI fly ash into non-hazardous bottom ash during thermal co-treatment cannot be referred to dilution, as the mixture did not comply with legal limits for non-hazardous waste landfills. For the newly generated fly ash of the kiln, an increase in the concentration of Cd, K and Pb by 54%, 57% and 22%, respectively, was observed. In general, the operation of the rotary kiln was not impaired by the MSWI fly ash addition.