EU End-of-life-Vehicles recycling simplified material ‘flow’

1. Shredder waste in the EU with respect to Directive 2000/53/EC and the EFR-ESG formation7 September 2001 – 08.30 to 09.10 hrs.Mr Thorvald Isager, Chief of Environmental Issues, HJ Hansen Recycling IndustriesMember of the EFR -European Shredder Group EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

2. The identification and implementation of practical and economic solutions to (1) minimise and (2) properly dispose of shredder waste are the most important actions that will determine the success of the EU End-of-life Vehicles Directive EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

3. EU End-of-life-Vehicles recycling simplified material ‘flow’ “Second hand car” exports last holder/Owner Collectors / scrap yards Dismantler Shredder Second hand parts De-pollution / dismantling De-pollution / dismantling Shredding Aspirated dust / fluff steel To metal works Non-magnetic shredder fraction New technologies non-metals Media & Metal Separation Non-ferrous metal Products Non-metallic waste EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

4. The Shredding process – terminology Aspirated dust (obsolescent terms - “fluff” or “light fraction”) Magnetic separation Eddy current separation Non-magnetic fraction - (“heavy fraction” obs..) EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

5. Media & Metal Separation process - terminology Dense media separation sg2.0 Dense media separation - sg3.0 MM3 MM1 MM2 Eddy current separation Eddy current separation and glass EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

6. End-of-life-Vehicles Recycling current EU infrastructure The term recognised refers to economic operators either acknowledged by Governments( by licence, permit etc) or in Voluntary agreements. Where there is an obligation to de-pollute , the recognised dismantlers are assumed to carry out de-pollution EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

7. here Where waste arises • Materials entering a shredder • End-of-life vehicles • Other metal containing scrap • Materials exiting a shredder • Recovered steel scrap • Non-magnetic shredder fraction • Aspirated dust / fluff • Materials entering a Media separation plant • Non-magnetic shredder fraction • Materials exiting a Media separation plant • Recovered non-ferrous metals • Recovered non metals • Non-metals destined for energy recovery • Materials going for final disposal • Incineration without energy recovery • Landfill • Materials utilised by other industries here EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

8. End-of-life-Vehicles arising and therefore volumes arising as shredder aspirated dust (fluff) and non-metallic wastes Non-metallic shredder wastes and shredder aspirated dust (fluff) arisings estimated between: 1,654,000 (LOW) - 3,032,000 (HIGH) tonnes This range is due to the loss of ELVs because of exports of second hand cars, these exports are expected to increase on EU enlargement. EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

9. Aspirated dust (fluff) and non-metallic waste issues • volumes represent <0.3% of overall EU waste arisings - the European Environment Agency reports that the EU produces 250 million tonnes of Municipal waste and 850 million tonnes of industrial waste per annum. • If ELVs are not de-polluted – waste may test as hazardous • European Waste list entries (Chapter 16 01 - ELVs; Chapter 16 02 - WEEE; Chapter 17 C&D waste; Chapter 19 10 - waste from shredding of metal-containing wastes; Chapter 19 12 - wastes from the mechanical treatment of wastes) • Fluff and non-metallic wastes are a burden to shredders and to MMS plantA negative cost – landfill – hazardous vs. non-hazardousA negative cost – incineration – hazardous vs. non-hazardous • Environmental taxes and charges are not harmonised in the EU. Gate prices of landfill sites and incinerators also vary EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

10. Aspirated dust (fluff) and non-metallic waste issues - Reducing the burden on the environment - • Reduce the volumes arising by:- • Design ( reduce the amount of non-metals – or reduce the types of non-metals – select recyclable non-metals) • Dismantling before shredding • Separation for material recovery after shredding • Reduce the hazardous nature of arisings • design (reduce hazardous components in vehicles) • depollute ELVs before shredding • Increase re-use and recycling as alternatives to landfill and incineration EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

11. Parts per million (logarithmic scale) Year of analysis (Danish example) EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

12. PPM 7000 6500 6000 5500 5000 4500 4000 3500 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 Lead content in shredder waste 1990 - 2001 (Danish example) EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

13. Alternatives to landfill and incineration of non-metals • re-use • recovery for material recycling • recovery for energy use The case of tyres:- An estimated 250 million worn tyres arise in the EU annually, of which around 60 million from ELVs arrive at dismantlers, scrap yards and shredders. Of these about 18 million are fit for re-use (some for retreading) and are sold on, leaving 42 million tyres or 336,000 tonnes for material recovery (30,000tpa), energy recovery or incineration since the EU Landfill Directive bans from landfilling whole tyres from 2003 and shredded tyres from 2006. Though tyres may still be used in landfill engineering as a leachate drainage blanket in the construction of new landfill cells. EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

14. Re-use • Design for re-use? • Hand-stripping by dismantlers • safety issues • quality issues • age related issues (obsolescence) EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

15. Non-metallic material recovery options • Sorting • dismantling - by plastic type • automated sorting ( e.g. glass separation by screening … / ... foam recovery ) • the need for a sustainable markets for recovered materials • recovered material specifications could help, but quality issues arise? • other • pyrolysis • Melting cyclone • Cokeless cupola • Blast furnace reductant? • Microwave technology • Cryogenic technology • what is the status of each of these technologies ?? • Which of the Directive’s targets do they contribute to ?? • Reminder… no legal certainty = no investment EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

16. Energy recovery options • Incineration with energy recovery • Use in cement kilns • Iron oxide contributes to cement manufacture • Substitute fuels EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

17. End-of-life-Vehicles Directive targets • For vehicles produced before 1 Jan 1980 - may use targets Re-use & Recovery 75% Re-use & Recycling 70% • 1 Jan 2006 for all ELVs Re-use & Recovery 85% Re-use & Recycling 80% • 1 Jan 2015 for all ELVs Re-use & Recovery 95% Re-use & Recycling 85% EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

18. Timeline of Directive • On October 21, 2000………. Directive published in OJ • from October 21, 2000…….. MSs may immediately implement Free take back • by April 21, 2002………..…. MSs to bring into force laws, regulations and administrative provisions to comply with the Directive • from July 1, 2002…………… Free take back for Vehicles put on the market from this date One may conclude that there is not much time in which to organise systems in EU members states that presently have under-developed infrastructure for: de-polluting ELVs; for recycling non-metals; or for data-capture EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

19. EFR-ESG work • improve understanding of the directive ( Interpretation by Member States-vs.-European Commission ) • influence and participate in the transposition into National Legislation • influence and participate in the practical and feasible implementation in Member States • To move forward on these issues EFR-ESG formed two Committees • Legal & Technical Committee • Committee for liaison with car dismantlers and car manufacturers EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

20. ESG Legal & Technical Committee • Monitoring data on Members State legislation and new technologies; compilation of statistics • to promote shredder capabilities to other stakeholders – particularly through good public relations. To reinforce the European Shredders Group as the 'point of contact' on ELV issues in Europe. • EFR website to promulgate information: (www.efr2.org) • translations of the animation of the shredder and media separation operations provided in Danish, English, French, German, Italian, Spanish - available through the BIR website EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

21. ESG Committee for liaison with car dismantlers and car manufacturers • Liaison with car manufacturers at the top level to arrive at the best practical & economic solution to achieving the ELV Directives environmental objectives • Liaison with the dismantlers at the top level to arrive at the best practical & economic solution to achieving the ELV Directives environmental objectives • To discuss cost recovery and finance options; • To promote shredder capabilities to other stakeholders – particularly through good public relations. To reinforce the European Shredders Group as the 'point of contact' on ELV issues in Europe. EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

22. Impediments to progress • Interpretation of the Directive – vs. – harmonisation (e.g. Fuel substitutes/Energy Recovery/Pyrolysis) • Implementation timescale – vs. – harmonisation • Financial problems - vs. - harmonisation - vs.- competition (ELV funding; landfill costs; incineration costs; infrastructure costs) • Competitivity issues – access to information • Waste shipment issues - limitations imposed by the EU legislation EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

23. <0.3 - 0.6 0.3 - 0.6 Capacity needed doubles 0.6 - 1.2 Million tonnes 0.3 - 0.6 >1.3- 2.4 0.6 - 1.2 1.0 - 1.8 A  rd reduction 0.3 - 0.6 estimated 1995 2006 2015 Re-use and/or Material recycling (or by using: Pyrolysis; Melting cyclone; Cokeless cupola; Microwave technology; Cryogenic technology; or as a blast furnace reductant ? ) Energy recovery Incineration and/or Landfill What are the tonnages of and likely solutions to attaining the Directives targets 2006 - 2015 for the non-metallic wastes? Capacity needed doubles A combination of activities/technologies will be required. EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

24. The enormous increase in the Re-use and Energy Recovery capacities required raise questions of... • which technology contributes to which target? • Will the answer to this be science based or a political decision and at which level EU or Member State? • Legal certainty of the status of technologies is required by operators and investors • how to develop and support the combination of economically sustainable processes, not yet in place but required to meet these targets? • Perhaps a funding system - an annual fee collected with the car insurance as in Denmark - will be essential to develop infrastructure and support the processing of non-metallic waste? EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

25. Examples of activities from two of the EU Members States.. EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

26. Activities in Germany: A Pilot plant for Shredder residue • Operated by:- R-plus Recycling GmbH, Eppingen • Technology: WESA-SLF-Verfahren • Project time table: December 1999 - December 2002 • Project funding: Dm 1,000,000 from ARGE-Altauto • Scientific evaluation by: Steinbeis-Transferzentrum, Verfahrens-, Energie- und Umwelttechnik, Heilbronn • Project aim: To separate the organic and inorganic fractions from the shredder residue by a dry recycling process • Expected products: • a magnetic ferrous fraction • copper chips • a mix of non-ferrous metals and minerals • a homogeneous organic fraction of specific quality EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

27. Recovery process Recovery type Capacity Available: SVZ (Gasification: Product Methanol) Recovered material 50.000 tonnes/annum of untreated shredder residue 70.000-100.000 tonnes/annum of treated shredder residue Potential: Blast furnace use Power station use Household incineration plants Recovered material Recovered energy Recovered energy no further information available Activities in Germany: Shredder residue valorisation • To recover between 340.000 t and 740.000 tonnes per annum of Shredder residue by 2015 • Recovery capacities of Shredder residue EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

28. Activities in France : Shredder residue recovery RESEARCH & DEVELOPMENT • Shredding & sorting of shredder residues : • Optimization of sorting process • Plastics sorting & recovery • inerting of the non-recoverable part • Partners of the different studies (1990-1997) : CFF Recycling - Eco-VHU - Elf ATO - CGEA - Renault - Peugeot - Gifam - Galloo - Eco Emballage - ECR - MTB - MEWA - Steinert - … • Remarks : 1990 - 1997 : Many studies about the sorting & recovery of the shredder residue were carried out Since 1998 : Studies are rather discreet : Industrial strategies in context of waiting for ELV Directive give a confidential nature to the studies, so that further information is currently not available. EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

29. Activities in France : Shredder residue valorisation • To recover around 200.000 tonnes per annum of Shredder residue by 2015 • Recovery capacities for shredder residues : EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION

30. Discussions and questions... EUROPEAN FERROUS RECOVERY & RECYCLING FEDERATION