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Eco-Industrial Park

Eco-Industrial Park. Long-term strategy to utilize the Midwest’s post-consumer carpet supply. Necessary Components of a Carpet Eco-Industrial Park. Collection infrastructure Process to denisify resin Manufacturing facilities that use either post-consumer carpet or densified resin as feedstock.

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Eco-Industrial Park

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  1. Eco-Industrial Park Long-term strategy to utilize the Midwest’s post-consumer carpet supply

  2. Necessary Components of a Carpet Eco-Industrial Park • Collection infrastructure • Process to denisify resin • Manufacturing facilities that use either post-consumer carpet or densified resin as feedstock

  3. Collection Infrastructure

  4. Collection Infrastructure • Minnesota disposes of 77,000 tons of carpet annually, not including C & D waste carpet • Purpose would be to collect, identify, sort, and bale (and possibly grind) post-consumer carpet as specified by the manufacturers • Would collect from state vendors, general contractors, C & D contractors, commercial management firms, flooring contractors, etc. • Possibly could densify the resin on site • Would sell the baled carpet/fiber or resin to manufacturers (on- and off-site) for processing

  5. Post Consumer Carpet Carpet is Identified and Sorted by fiber type/backing Wool,PET Other Urethane Backed Floor Tile PVC Backed Floor Tile Polyolefin Backed Carpet Nylon 6,6 Nylon 6 PP WTE or Flood Bags Refurbished Floor Tile Milliken New Floor Tile (Interface C & A, Shaw) Deconstruction of Carpet Depolymerzation BASF Waste Carpet Needle Punch Carpet Pad Bales of Face Fiber Separated from Backing with Low Calcium Carbonate Content Bales of Whole Ground Carpet with Backing High Calcium Carbonate Content Densified Nylon Carpet Backing Whole Carpet Extruded into Construction Sheeting by Nylon Board Manufacturing Other Products Injection Grade Resin Wood Plastic Composite Landfill

  6. Items for Consideration • State vendors • Willing to explore collection options and offer a certificate guaranteeing recycling • Willing to alter their de-installation process to fit specifications required by the end-user or collection center • Commercial management firms, C & D contractors and other carpet installers expressed interest in carpet recycling • DuPont, C & A, Interface, and Milliken have expressed interest in working w/ OEA on a collection issues

  7. Issues/Barriers • Landfilling of carpet is currently cheaper than recycling it in the Metro area • There is no ban on landfilling carpet • Carpet manufacturers (fiber?)are paying NBM to take post-industrial carpet • Other manufacturers (i.e. Winnebago) is also paying NBM take material or giving it to them for free • There is plenty of carpet-with not many outlets currently

  8. Continuation of Issues/Barriers • NBM refuses to pay for material (since they are getting paid to take material or are getting it for free)-how to keep that from occurring? • Needs justification to collect and recycle (i.e. DuPont)

  9. Positive Aspects of Collecting Post-Consumer Carpet • Central Collection allows economy of scale • NBM has to use either post-consumer or post-industrial feedstock-virgin resin too expensive • Collection is a non-issue if there are markets for the material

  10. Next Steps • Determine whether NBM is planning on starting up their own collection infrastructure. • Conduct discussions with manufacturers on how a collection center could be designed to fit their needs. • Come to agreement with manufacturers that they will take material to the center, rather than to NBM, once center is started. • Conduct discussions with manufacturers to gauge their interest in being part of a central collection system and what their commitment is to an eco-industrial park.

  11. Continuation of Next Steps • Conduct discussions with manufacturers about their goals with producing recycled content resin, recycled content carpet, etc. • Require all public agencies to recycle all their post-consumer carpet to be recycled by inserting a standard specification in bid packages to general contractors.

  12. Items to be Determined • Identification tool? • Which carpet manufacturers will be involved? • Which facilities will the post-consumer carpet be sent to for processing? • What standards for removal will be required to ensure clean material is brought to the collection center? • Costs for collection, handling, and transportation of post-consumer carpet? • Grant opportunity?

  13. Timeline (Collection)

  14. Resin

  15. Recycled Resin • Could be produced in a manufacturing facility • Manufacturer densifies the resin in-house to extrude into a composite profile or use it as an injection grade resin. • Could be produced in a vertically integrated collection system • The collection center would then collect, identify, sort, and densify the resin to be sold to manufacturers in the eco-industrial park.

  16. Post Consumer Carpet Carpet is Identified and Sorted by fiber type/backing Wool,PET Other Urethane Backed Floor Tile PVC Backed Floor Tile Polyolefin Backed Carpet Nylon 6,6 Nylon 6 PP WTE or Flood Bags Refurbished Floor Tile Milliken New Floor Tile (Interface C & A, Shaw) Deconstruction of Carpet Depolymerzation BASF Waste Carpet Needle Punch Carpet Pad Bales of Face Fiber Separated from Backing with Low Calcium Carbonate Content Bales of Whole Ground Carpet with Backing High Calcium Carbonate Content Densified Nylon Carpet Backing Whole Carpet Extruded into Construction Sheeting by Nylon Board Manufacturing Other Products Injection Grade Resin Wood Plastic Composite Landfill

  17. Recycled Resin is a marketable product if: • ASTM tested • UL tested (electrical) • Feedstock is available • Cost of recycled resin is comparable or cheaper than virgin resin • Board products or other high value product(s) made with recycled resin are successful

  18. Recycled nylon will not be CHEAPER unless: • Petroleum prices decrease • Engineers take a chance • A more efficient system to recycle resin is designed and implemented (i.e. Honeywell)

  19. Resin Producers • DuPont • Wellman • Solutia • BASF • Honeywell/DSM

  20. Issues and Barriers in Mainstreaming Recycled Resin • Must convince manufacturers to use post-consumer carpet as a feedstock • Currently fiber manufacturers are selling OEM manufacturers and tier I & tier II suppliers virgin nylon • Cheaper to de-bottleneck a plant to increase capacity than to produce recycled resin • Recycled nylon hinders virgin nylon sales-don’t make much profit selling recycled nylon

  21. Continuation of Issues & Barriers • Recycling process starts with dirty material-costs money to handle it and make it homogenous; cheaper to produce virgin nylon, rather than clean dirty fiber. Dirty Fiber Virgin/Clean Product Recycled Nylon Cost to handle and clean

  22. Next Steps • Identify what steps need to be taken to perform ASTM and UL testing of recycled resin. • Ask fiber manufacturers to donate their current recycled resin to perform tests (ASTM and UL). • Continue to explore and facilitate partnerships with manufacturers currently using recycled resin or with manufacturers that have the potential to incorporate recycled resin in their product(s) (i.e. Marvin Windows, Ford, etc.)

  23. Timeline (Resin) 2002 Engage Fiber Manufactures & Partners to Take Next Certification Steps March 2003 Develop Workplan and Apply to CARE for Grant Funding Complete Workplan Secure Funding and Start Project Interim Report Complete Initial Testing and Modify Plan If Needed 2004 Complete Testing and Market Resin November 2002 March 2003 July 2003 2003 July 2003 December 2004

  24. Composites

  25. Potential Composite Manufacturers • Nylon Board Manufacturing • Marvin Windows • Weyerhauser A.E.R.T

  26. Main Incentive for Composite Manufacturers The product will be able to successfully compete in the marketplace • Composites (wood-plastic or wood-nylon) are high performance materials that outlast wood products. Since consumers demand convenience and low-maintenance lifestyles, these composite products will be viable in the marketplace.

  27. Inconsisteny of resin & supply available. What is right mix of fiber types? Who will supply resin? Will manufactures want to use recycled resin in their composite product? Issues and Barriers to Producing Composites with Recycled Resin

  28. Next Steps to Begin Composite Manufacturing • Validate recycled resin through ASTM and UL testing • Identify a manufacturing partner • Product design and validation • Marketing of product

  29. Timeline (Composites) 2002 Engage composite manufactures/ partners to take next R & D Steps December 2002 Develop Workplan and Findings for Grant Funding Complete Workplan Funding and Start Project First Interim Report Complete Initial Testing and Modify Plan as Needed Second Interim Report 2004 Complete Product Testing and Market Product 2002 Dec 31 2003 July 2003 2003 July 2003 2004

  30. Eco-Industrial Layout • Sell • Baled Carpet • Baled Fiber • Resin • Collection Center • Bale Material • Grin Material • Identify Material • Fiber/Resin (possible) • Additional • Manufacturer • Wood/Plastic • Composites • Extruded Board • Pay for: • Baled Carpet • Baled Fiber • Resin • Vendors • Contractors • Manufactures • Pay to take • Post-consumer • & Post-industrial • carpet • Pay for: • Baled Carpet • Baled Fiber • Resin Excess Manufacturing Capacity Traded • Nylon Board • Manufacturing • Extruded Board Goal:Utilize Manufacturing Capacity @ 100%

  31. Why an Eco-Industrial Park Makes Economic Sense • Economies of Scale • Lower Production Costs • Lower Material Costs • Lower Infrastructure Costs • Greater Access to Financial Resources

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