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TN  296 

■ULI 

IC.  8711 

1976 

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Bureau  of  Mines  Information  Circular/1976 


I 


4-1MAY2C 
Copy  1 1976 


Recycling  Trends  in  the  United  States: 
A  Review 


UNITED  STATES  DEPARTMENT  OF  THE  INTERIOR 


Information  Circular  8711 

Recycling  Trends  in  the  United  States: 
A  Review 


By  Max  J.  Spendlove 

College  Park  Metallurgy   Research  Center,  College  Park,  Md. 


UNITED  STATES  DEPARTMENT  OF  THE  INTERIOR 

Thomas  S.  Kleppe,  Secretary 

BUREAU  OF  MINES 

Thomas  V.  Falkie,  Director 


This  publication  has  been  cataloged  as  follows: 


.Of 

11% 


Sp< 

?ndlove,  Max 

Jones 

Recycling 

trends   in  the 

United  States:     a 

review. 

[Wash- 

ington]  U.S. 

Bureau  of  Mines  [1976] 

25  p«     illus 

.,  tables.     (U.S. 

Bureau  of  Mines. 

Information  circu* 

lar  8711) 

Includes  bibliography. 

1.     Recycling  (Waste,  etc.) 

I.     U.S.  Bureau  of 

Mines.     II. 

Title. 

(Series) 

TN23.U71 

no.  8711        622.06173 

U.S.  Dept.  of 

the   Int.   Library 

CONTENTS 


Page 


Abstract 1 

Introduction 1 

Mineral  supply  and  recycling  system 3 

Mineral  deficits 5 

Origin  of  mineral  wastes 7 

Relative  values  in  wastes 8 

Urban  ore 10 

Refuse  processing 12 

Collection 12 

Composting 12 

Common  refuse  disposal  options 12 

Incineration 13 

Resource  recovery  from  raw  refuse 14 

Product  recycling 16 

Recycling  problems 18 

Areas  for  research  and  development 20 

The  future  of  recycling 21 

References 23 

ILLUSTRATIONS 

1.  Mineral  supply  and  recycling  systems  in  the  U.S.  economy 4 

2.  Production,  recycling,  and  waste  disposal  in  the  metal  supply  system  7 

3 .  Products  extracted  from  municipal  incinerator  residues 15 

4 .  Products  extracted  from  municipal  raw  refuse 15 

5.  Typical  items  made  from  products  recovered  from  municipal  refuse....  16 

6 .  Conventional  and  product  recycling  systems 17 

TABLES 

1.  Estimated  tonnage  of  copper,  lead,  and  zinc  in  use  in  the  United 

States 10 

2.  Average  composition  and  estimated  value  of  raw  refuse  and  municipal 

incinerator  residues 11 

3.  Estimated  amount  and  value  of  recovered  products  from  raw  refuse  and 

incinerator  residue 12 


RECYCLING   TRENDS    IN    THE    UNITED    STATES:    A    REVIEW 

by 

Max  J.  Spendlove 1 


ABSTRACT 

This  Bureau  of  Mines  publication  reviews  current  recycling  trends  in  the 
United  States.   Although  near -term  prospects  are  poor  for  recycling  most 
present  wastes,  urban  refuse  is  an  important  exception.   Such  wastes  comprise 
a  mine  above  ground,  and  much  less  processing  energy  is  normally  required  to 
recycle  the  constituents  of  urban  ore  than  to  obtain  them  in  equal  amounts 
from  natural  raw  materials. 

INTRODUCTION 

This  review  of  U.S.  recycling  arises  from  the  Bureau  of  Mines  research  in 
this  area,  which  has  been  in  progress  since  the  Bureau's  foundation  in  1910. 
Although  the  problems  are  complex,  achievements  to  date  are  significant  and 
there  appears  to  be  no  practical  alternative  to  the  present  high  costs  of 
refuse  disposal  and  the  waste  of  mineral  and  energy -related  resources  involved 
in  disposing  wastes  without  recycling. 

Raw  materials  of  mineral  origin  comprise  the  most  vital  ingredients  for 
building  or  maintaining  the  economy  of  any  industrialized  nation.   The  wealth 
and  economic  viability  of  the  entire  industrialized  world  are  determined 
primarily  by  the  availability  of  mineral  resources.   Their  importance  is 
emphasized  by  the  fact  that,  in  addition  to  our  supplies  of  direct  mineral 
origin,  many  of  our  nonmineral  products,  such  as  meat  and  vegetables,  are 
indirectly  of  mineral  origin.   For  example,  fertilizers  and  other  chemicals 
are  used  extensively  in  many  parts  of  the  world  to  grow  the  vegetation 
essential  for  raising  domestic  animals  and  poultry.   Furthermore,  owing  to 
technological  advances  during  the  past  few  decades,  agriculture  has  become 
highly  energy  intensive  in  connection  with  fertilizer  production  and  the 
manufacture  and  use  of  heavy  equipment  in  growing,  marketing,  and  processing 
farm  products . 

Some  nations  possess  relatively  abundant  resources  and  others  have 
virtually  none,  but  no  industrialized  nation  can  develop  and  maintain 
economic  growth  and  viability  without  a  continuous  and  adequate  supply  of 

•"•Metallurgist  (now  retired)  . 


many  raw  materials  of  mineral  origin.   In  recent  years,  most  nations  have 
become  more  intensely  concerned  with  their  long-range  supply  of  mineral 
reserves,  believing  that  the  natural  resources  of  the  entire  world  are  finite 
and  therefore  will  eventually  be  totally  consumed  as  the  needs  of  society 
continue  to  mount. 

In  a  somewhat  different  approach,  Brooks  and  Andrews  (J5)   discuss  a  view 
that  natural  resources  are  not  actually  being  depleted  as  commonly  believed. 
Instead,  they  appear  to  be  vanishing  only  because  the  industrial  world  cannot 
yet  afford  the  high  cost  of  exploiting  the  more  abundant  but  lower  grade 
resources.   Typical  of  such  a  resource  is  the  average  uppercrust  of  the  earth. 
One  cubic  kilometer  is  said  to  contain  2  X  10a  tons  of  iron,  800,000  tons  of 
zinc,  and  200,000  tons  of  copper  (J5)  .   As  an  ore,  the  average  grade  of  this 
crust  is  very  low  indeed,  and  the  cost  of  extracting  and  refining  the  market- 
able constituents  is  unquestionably  prohibitive.   In  most  cases,  the  cost  of 
processing  natural  minerals  increases  generally  exponentially  as  the  average 
grade  diminishes.   This  simply  means  that,  regardless  of  their  apparent  great 
abundance,  the  metals  and  minerals  in  the  average  crust  of  the  earth  are  not 
yet  within  economic  reach,  nor  will  they  likely  be  reachable  in  the  foresee- 
able future  without  profound  technological  advances  in  extraction  processes 
and/or  in  energy  conversion.   The  same  applies  to  the  low -value  or  negative - 
value  industrial  waste  materials. 

At  this  point,  it  is  important  to  note  the  difference  between  resources 
and  reserves.   Resources  refer  to  our  natural  fuel  and  nonfuel  mineral 
deposits  and  other  natural  entities  such  as  forests,  rivers,  and  geothermal 
wells.   Reserves  comprise  only  that  part  of  a  resource  that  can  be  extracted 
and  marketed  economically  under  prevailing  prices  and  marketing  conditions. 
Reserves  are  thus  conditional  quantities  the  magnitude  of  which  depends  on 
nearly  all  factors  affecting  the  national  economy.   Given  appropriate  economic 
conditions  they  may  include  materials  currently  discarded  as  waste;  for 
example,  in  municipal  refuse. 

The  U.S.  aluminum  situation  can  be  cited  as  an  example  of  this  resource- 
reserve  relationship.   Although  the  United  States  has  unbelievably  large 
deposits  of  anorthosite,  clay,  and  shale  which  contain  aluminum  in  tremendous 
quantities  (resources) ,  it  has  no  significant  domestic  reserves  of  aluminum 
minerals  because  there  are  no  processes  that  will  extract  aluminum  from  our 
domestic  resources  in  economic  competition  with  the  Bayer  and  Hall  processes 
now  employed  for  treating  imported  bauxite.   In  fact,  our  greatest  domestic 
aluminum  reserves  are  the  secondary  materials  which  we  have  been  recycling 
for  many  years  from  the  reservoir  of  recoverable  materials  still  in  use  by  the 
consumers,  the  goods -in -use  reservoir. 

In  the  future  many  other  materials  besides  aluminum  may  be  recovered  from 
municipal  refuse.   Today  this  refuse  is  at  best  a  resource;  when  recovery  can 
be  done  economically,  it  will  become  a  large  manmade  reserve  of  many  raw 
materials . 

2 Underlined  numbers  in  parentheses  refer  to  the  reference  list  at  the  end  of 
this  paper. 


MINERAL  SUPPLY  AND  RECYCLING  SYSTEM 

Support  for  recycling  in  the  United  States  is  indicated  by  the  growing 
deficits  in  the  national  economy  originating  primarily  in  the  mineral  supply 
system.   The  demand  for  goods  and  services  of  mineral  origin  has  increased 
markedly  in  unison  with  the  national  economic  growth.   Concurrently,  the 
Nation's  ability  to  supply  these  growing  demands  from  domestic  resources 
has  faltered  seriously.   On  a  value  base  of  current  U.S.  dollars,  the  1971 
gross  national  product  (GNP)  of  $1,055  billion  was  accompanied  by  a  national 
mineral  deficit  of  $4  billion.   At  the  end  of  1974,  the  GNP  had  reached 
$1,397  billion,  and  the  mineral  deficit  was  $24  billion.   The  relatively  low 
probability  of  meeting  future  deficits  by  discovering  large  new  domestic 
resources  or  by  significantly  improving  minerals  supply  and/or  energy  con- 
version technologies  in  the  near  future  emphasizes  the  importance  of  recycling. 

The  following  discussions  dwell  almost  exclusively  with  situations  and 
systems  in  the  U.S.  mineral  supply  economy.   Although  no  data  on  other  coun- 
tries are  readily  available,  there  is  little  doubt  that  similar  if  not 
identical  parallels  can  be  drawn  for  any  other  of  the  more  advanced  nations. 

Referring  to  figure  l,3  minerals,  crude  oil,  gas,  coal,  and  water  valued 
at  $55  billion  were  taken  from  the  U.S.  reserves  in  1974  by  extraction 
industries  such  as  mining,  crude  oil,  and  gas  producers.   The  U.S.  import  of 
mineral  raw  materials  in  1974,  valued  at  $20  billion,  came  mainly  from 
foreign  mineral  operations  of  U.S.  and/or  foreign  firms.   Reclaimed  materials 
of  mineral  origin  from  the  recycling  industries  were  valued  at  $4  billion. 
Accordingly,  the  U.S.  mineral  processing  industries  such  as  smelters,  refiners, 
and  fuel  producers  consumed  these  total  raw  materials  valued  at  $79  billion  to 
produce  energy  and  processed  materials  valued  at  $210  billion.   The  manufac- 
turing and  services  industries  in  turn  consumed  these  to  generate  a  gross 
national  product  in  1974  of  $1,397  billion.   Exports  from  this  sector  of  the 
economy  amounted  to  $18  billion,  but  imports  from  foreign  firms  amounted  to 
$22  billion.   Thus,  the  net  value  of  goods  and  services  consumed  in  1974 
by  the  U.S.  population  was  $1,401  billion.   A  total  of  more  than  4  billion 
tons  of  new  materials  of  mineral  origin  was  supplied,  amounting  to  40,000 
pounds  for  each  U.S.  citizen.   More  than  18,000  pounds  of  this  was  for  energy 
materials  (19) . 

We  have  now  arrived  at  what  may  be  considered  the  headwaters  of  the  small 
but  important  recycling  channel  of  the  mineral  supply  system.   First,  note 
that  some  consumer  products  such  as  gasoline,  electric  power,  and  fertilizers 
are  totally  consumed  and  therefore  lost  from  the  recycling  channels  forever, 
but  that  very  large  quantities  of  other  consumer  goods  continue  to  be 
accumulated  by  all  sectors  of  society.   This  accumulation  was  previously 
referred  to  as  the  goods -in-use  reservoir.   Although  attempts  have  been  made 
to  develop  reliable  data  on  the  magnitude,  composition,  and  location  of  this 
growing  reservoir,  no  conclusive  data  are  yet  available  on  all  materials 
entering  into  it.   However,  the  total  quantities  involved  are  undoubtedly 
tremendous.   As  the  goods  in  use  become  obsolete,  worn  out,  and  discarded, 

3Figure  1  is  a  modification  of  graphic  information  presented  in  reference  19. 


U.S.  RESERVES 
Minerals,  crude 
oil,  coal,  gas, etc 


ENERGY    AND 
PROCESSED 
MATERIALS 
$210   BILLION 
Fuels,  metals, 
nonmetals.etc 


I 


PRODUCTS    LOST 
OR  TOTALLY 
CONSUMED 


EXTRACTION    INDUSTRIES 
Mining,  oil-gas  production 


MINERAL  PROCESSING 

INDUSTRIES 
Milling,  smelting,  power 


CONSUMER    PRODUCTS 

AND    SERVICES 

INDUSTRIES 

Manufacturing, 

transportation,  services, 

other 


PRODUCT   CONSUMING 
SECTOR   OF    ECONOMY 


RESERVOIR  OF 
GOODS    IN   USE 

1 

I 

WASTES   AND 

POSTCONSUMER 

GOODS 


SECONDARY    MATERIALS 

INDUSTRIES 
Collecting  and  processing 


RAW   MATERIALS  OF 
MINERAL   ORIGIN    ^^^ 
$55  BILLION 
Ore,  petroleum, coal,  sand 

( I M PORTS  $20  BILLION) 


$79   BILLION   TOTAL 
RAW   MATERIALS 


(EXPORTS,  $18  BILLION) 


GROSS  NATIONAL 
PRODUCT,  1974 
$1,397   BILLION 
Goods  and   services 


(IMPORTS,  $22  BILLION 


$1,401  BILLION   NET 
1974 


($4    BILLION) 
RECLAIMED 
MATERIALS 
Junk,  scrap, 
wastes 


*J 


FIGURE  1.  -  Mineral  supply  and  recycling  systems  in  the  U.S.  economy,  estimated  values 
for  1974. 


substantial  quantities  are  channeled  into  the  secondary  materials  industries 
that  produced  the  previously  cited  $4  billion  worth  of  raw  materials  sub- 
sequently channeled  to  the  mineral  processing  industries  in  1974. 

An  analysis  of  figure  1  reveals  several  points  that  strengthen  the 
arguments  for  drastically  improving  the  recycling  sections  of  this  complex 


system.   For  example,  it  will  be  noted  that  in  1974  imports  of  mineral  raw 
materials  and  processed  materials  of  mineral  origin  exceeded  exports  by 
$24  billion.  This  is  a  very  sizable  mineral  deficit  in  the  balance  of  trade 
and  contributes  to  an  unfavorable  imbalance  in  the  U.S.  economy.   Such  a 
large  mineral  deficit  indicates  that  the  United  States  is  not  self-sufficient 
in  many  of  its  mineral  materials  needs  by  a  very  significant  margin.   Also 
note  that  only  $4  billion  worth  of  materials  was  recycled  from  a  total  raw 
materials  consumption  of  $79  billion. 

The  nature  of  the  mineral  deficit  is  indicated  by  the  fact  that,  to 
supply  its  total  1974  mineral  demands  (19)  ,  the  United  States  imported  nearly 
90  percent  of  its  raw  materials  for  producing  aluminum;  more  than  75  percent 
of  its  needs  for  titanium,  tin,  mercury,  bismuth,  nickel,  and  potassium; 
more  than  50  percent  of  its  silver,  tungsten,  zinc,  and  gold;  and  more  than 
25  percent  of  its  iron,  cadmium,  vanadium,  and  lead.   Even  with  its  tremen- 
dously large  copper  resources,  the  United  States  imported  about  6  percent  of 
its  1974  copper  demand. 

While  there  has  been  a  sizable  increase  in  U.S.  mineral  demands  and  a 
parallel  increase  in  product,  the  demand  for  materials  of  mineral  origin  has 
grown  rapidly  worldwide.   Concurrently,  ever  larger  quantities  of  waste  are 
being  generated  and  waste  disposal  costs  have  reached  an  alltime  high.   Super- 
imposed upon  the  unfavorable  trade  deficit  situation  are  the  growing  environ- 
mental problems  in  the  minerals  and  minerals -related  fields.   Establishment  of 
more  rigid  regulations  calling  for  cleaner  air,  water,  and  land  no  doubt  will 
add  new  production  costs  in  nearly  every  segment  of  the  goods  and  services 
industries  so  that  future  mineral  deficits  may  be  greater  than  expected.   In 
addition,  grades  of  our  most  important  resources  such  as  copper  and  iron  are 
steadily  declining.   The  underlying  question  behind  all  of  this  is,  "What  can 
be  done  about  the  present  and  future  U.S.  mineral  deficits?" 

MINERAL  DEFICITS 

There  are  numerous  suggestions  for  a  partial  solution  of  deficit  problems, 
one  of  the  most  obvious  being  to  find  more  natural  resources  for  those  mate- 
rials in  greatest  short  supply.   Many  proposals  have  been  made  for  doing  this, 
but  at  the  present  or  foreseeable  rate  of  development  in  mineral  exploration 
technology,  it  does  not  appear  that  any  significant  breakthrough  is  likely  in 
the  near  future.   One  solution  that  has  been  suggested  is  to  control  the  use 
of  mineral  commodities  in  short  supply  by  some  type  of  governmental  rationing 
based  on  the  potential  for  maximum  national  benefit.   However,  with  a  large 
shortage  of  so  many  different  materials,  the  rationing  system  would  have  to  be 
widespread,  expensive,  and  difficult  to  manage,  and  might  lead  to  unprece- 
dented black  marketing. 

Another  partial  solution  to  the  deficit  problem  would  be  to  improve  the 
efficiency  of  extraction  processes  or  to  develop  new  ones  applicable  to  the 
more  abundant  lower  grade  resources.   It  should  be  remembered,  however,  that 
a  very  great  effort  to  do  this  has  continued  for  many  years  in  government  and 
private  laboratories  and  plants  around  the  world.   Many  extraction  technolo- 
gists point  with  pride  to  the  fact  that  it  is  possible  to  produce  copper 


economically  from  ores  that  contain  only  0.5  percent  copper.   It  is  possible, 
in  fact,  to  economically  extract  some  metals  from  process  solutions  containing 
only  1,000  parts  or  less  of  metal  per  million  parts  of  solution.   Every  effort 
should  be  made  to  continue  extractive  research  and  development  at  an  accel- 
erated rate,  but  progress  in  this  area  of  technology  is  difficult,  tradi- 
tionally slow,  and  often  underfunded.   Accordingly,  we  cannot  depend  heavily 
on  this  approach  to  meet  many  of  our  immediate  mineral  demands. 

Common  experience  shows  that  processing  costs  per  unit  of  additional 
product  will  normally  increase  almost  exponentially  as  the  extraction 
efficiency  achieved  approaches  100  percent.   For  example,  if  the  assumed  cost 
of  producing  a  pound  of  aluminum  is  28  cents  in  the  conventional  processing 
of  a  50 -percent  aluminum  ore,  we  would  expect  to  extract  90  percent  of  the 
aluminum  contained  in  1  ton  of  ore,  or  900  pounds,  at  a  total  cost  of  $252. 
The  process  residues  would  still  contain  100  pounds  of  aluminum,  some  of  which 
might  be  recovered  in  a  more  sophisticated  and  more  efficient  process.   How- 
ever, the  residues  would  comprise  a  5 -percent  ore  and  the  additional  sophis- 
tication needed  to  extract  an  additional  90  percent  (90  pounds)  of  aluminum 
from  such  low-grade  materials  may  well  exceed  the  cost  of  recovering  the 
first  900  pounds.   Even  at  the  same  total  cost  per  ton  of  ore,  each  of  the 
additional  90  pounds  would  cost  $2.80. 

If  abundant  cheap  energy  should  become  available  in  the  near  future, 
it  would  not  alter  our  extraction  capabilities  significantly,  but  it  would 
bring  them  well  within  the  range  of  economic  application  on  many  low-grade 
resources.   There  is  no  firm  evidence,  however,  that  the  mineral  situation 
will  change  significantly  in  the  foreseeable  future  unless  a  major  and 
unexpected  breakthrough  is  made  in  either  extraction  or  energy -conversion 
technology  or  both.   A  breakthrough  in  energy  conversion  would  probably  offer 
the  greatest  ultimate  benefit  because  present  extraction  capabilities  of 
85  to  98  percent  or  better  are  common.   Although  the  chances  for  greatly 
improved  energy-conversion  processes  within  the  next  several  decades  are 
a  highly  controversial  subject,  recent  reliable  reports  are  not  profoundly 
optimistic  (1_,  _16)  .   Many  of  those  engaged  in  the  development  of  new  atomic 
energy  processes  predict  that  the  breeder  reactor  will  provide  the  best 
practical  solution  to  the  growing  national  energy  demands,  but  others  claim 
that  the  problems  of  radioactive  waste  disposal  and  safeguards  against 
potential  radiation  accidents  will  keep  development  in  this  field  to  a 
minimum  (9^)  . 

It  has  happened  that  critical  mineral  shortages  have  occurred  con- 
currently with  widespread  pollution  and  fears  of  inundation  by  our  own  wastes. 
These  shortages  and  the  general  deterioration  of  the  environment  have  focused 
our  concerted  attention  more  directly  on  one  of  the  best  opportunities  for 
reducing  large  and  uncomfortable  national  mineral  deficits --simply  by  improv- 
ing and  extending  the  age-old  practice  of  recycling  to  its  fullest  possible 
proportions . 

The  potentials  of  wastes  as  a  renewable  resource  are  not  easy  to  analyze 
because  recycling  within  the  complex  systems  of  mineral  supply  and  demand  is 
influenced  by  a  host  of  interdependent  and  seemingly  uncontrollable  variables. 


The  most  important  of  these  factors  include  inflation,  environmental  regula- 
tions, poor  recycling  incentives,  tax  structures,  import -export  policies, 
embargoes  and  property  acquisitions  by  other  nations,  the  quantity,  grade, 
and  distribution  of  domestic  reserves,  the  state  of  pertinent  technology,  and 
the  great  divergence  of  recycling  concepts  and  opinions  among  national,  State, 
and  urban  officials,  the  engineering  and  scientific  communities,  and  the 
general  public.   Based  on  personal  discussions  with  informed  people  from  the 
major  mineral -consuming  areas  of  the  globe,  it  appears  that  many  of  these 
variables  are  essentially  identical  in  all  industrialized  nations.   In  general, 
however,  a  critical  examination  of  mineral  resource  supply  and  demand  cycles 
reveals  waste  disposal  practices  that  could  be  modified  to  improve  recycling. 

ORIGIN  OF  MINERAL  WASTES 

The  potentials  for  recycling  can  best  be  determined  by  considering  the 
makeup  of  the  system  which  generates  the  bulk  of  wastes. 


MINING 


Overburden 


Ore 


Figure  2  illustrates  how  wastes  are  generated  in  metal  production,  but 

the  process  of  making  almost 
any  one  of  the  millions  of 
items  used  in  modern  society 
leaves  a  trail  of  wastes 
along  the  routes  of  produc- 
tion all  the  way  back  to  the 
very  origin  of  all  constit- 
uents.  This  trail  of  wastes 
occurs  in  much  the  same  man- 
ner for  all  consumer  prod- 
ucts --from  straw  hats  to 
automobiles . 


Secondary  raw 
motenals 


MILLING 

1 

Concentrates 

4l_ 


Tailings,  dusts, 
solutions 


SMELTING 


Slags,  goses, 
particulates 


Secondary  raw 
materials 


Residues,  scraps, 
drosses,  rejects 


Rejects,  scraps, 
metallic  dusts 


Crude  metal 


REFINING 


Slogs,  goses, 
particulates 


Refined   meta  I 


FABRICATION 

1 

Supplies  and  parts 


MANUFACTURING 


1 

Consumer  products 

_i_ 


MARKETING 

1 

Products  distribution 


Grindings,  residues, 
dusts,  drosses,         « 
residues 


Sludges,  drosses, 
dusts,  smokes,      ^^~ 
tumes,  discords 

Spent  fuels,  gases 
and    particulates    ^^ 
containers  and 
advertising  materials 


CONSUMER 
GOODS  IN  USE 


y- 


Spent  products 
Packaging,  spoilage 


LPostconsumer  goods 
,      *      , 
Reclaimed  goods  ___    RECYCLING    — 
and  wastes  I . 


Slags,  drosses, 
dusts,  solutions 


J 


FIGURE  2.  -  Production,  recycling,  and  waste  disposal  in 
the  metal  supply  system. 


The  relative  amounts  of 
wastes  generated  are  nearly 
always  greatest  at  those 
operations  in  the  supply 
channel  nearest  the  natural 
resource,  such  as  mining, 
dredging,  and  quarrying.   In 
the  production  of  most 
metals  and  nonmetallic 
mineral  products,  mountains 
of  overburden  are  moved 
literally  from  one  point  to 
another  (29) .   In  Utah  and 
other  Western  States, 
gullies  and  canyons  have 
been  filled  to  the  brim  with 
copper  mine  overburden  and 
subgrade  rock  rubble  that 
was  moved  only  to  gain 
access  to  the  underlying  or 


adjacent  ore  bodies.   In  Minnesota,  enormous  piles  of  iron -mine  rubble  rise 
high  above  the  flat  countryside  near  cavernous  iron-mine  pits.   Similar,  but 
perhaps  smaller,  quantities  of  mine  wastes  are  produced  at  phosphate  mines, 
coal  mines,  marble  quarries,  gravel  pits,  and  similar  operations  (6,  29) . 

Having  moved  the  overburden  at  the  mine  site,  mining  companies  extract 
the  ore  that  is  delivered  to  beneficiation  mills,  where  a  very  large  fraction 
of  the  unwanted  matrix  minerals  is  removed  and  sent  to  tailing  ponds  or  banks. 
The  fraction  that  is  ultimately  discarded  as  tailings  varies  according  to  type 
and  grade  of  incoming  ore  and  the  efficiency  of  beneficiation  operations.   Con- 
centrates produced  in  the  beneficiation  mills  are  sent  to  smelters  that  pro- 
duce rather  large  fractions  of  slag  wastes  along  with  waste  stack  gases  and 
solid  particulate  matter.   The  smelter  produces  crude  metal,  which  is  sent  to 
metal  refining  plants  where  more  slag  and  stack  wastes  are  generated.   Refined 
metals  are  sent  to  fabricators  where  still  more  wastes  are  generated.   Some 
scrap  is  sent  back  to  the  smelters  or  used  elsewhere  in  the  fabrication 
plants.   Worthless  materials  are  usually  piled  in  dumps  or  covered  in  landfill 
operations.   In  the  vast  majority  of  production  operations,  waste  disposal 
restrictions  are  rapidly  becoming  more  rigid,  and  the  disposal  of  such  wastes 
is  one  of  the  most  pressing  problems  in  nearly  every  industry  in  the  United 
States . 

RELATIVE  VALUES  IN  WASTES 

Updating  earlier  data  (14,  23,  30) ,  the  total  of  all  solid  wastes 
generated  in  the  United  States  in  1974  is  estimated  at  4.7  billion  tons,  of 
which  the  greatest  amount  (2.5  billion  tons)  was  of  agricultural  origin.   The 
mineral  industry  wastes  totaled  1.8  billion  tons.   Municipal,  urban,  indus- 
trial, and  institutional  solid  wastes  accounted  for  at  least  another  300  mil- 
lion tons;  this  figure  includes  garbage,  trash,  demolition  debris,  utility  fly 
ash,  and  other  such  solid  wastes,  but  excludes  sewage  sludge.   Although 
agricultural  wastes  are  far  greater  than  the  others,  they  are  not  considered 
here  except  incidentally. 

Of  all  the  mineral  wastes,  it  was  determined  (6)    that  only  8  of  the 
80  mineral  industries  were  generating  80  percent  of  the  total  mineral  wastes 
prior  to  1970.   The  copper  industry  generated  the  greatest  amount,  iron  and 
steel  industries  ranked  second,  and  bituminous  coal  and  phosphate  rock 
producers  were  third  and  fourth,  respectively.   Most  of  the  mineral  wastes 
generated  by  the  mining  and  milling  industries  (fig.  2)  are  very  large  in 
quantity  and  very  low  in  value.   This  happens  simply  because  our  most  capable 
industries  consistently  extract  nearly  all  values  of  importance  from  their 
raw  materials;  consequently  the  wastes  are  worthless  or  of  negative  value. 
The  slags,  drosses,  and  fumes  generated  in  the  smelting  and  refining  indus- 
tries are  considerably  less  in  total  quantity  than  wastes  from  mining  and 
milling,  and  they  usually  contain  higher  levels  of  potentially  valuable  con- 
stituents.  Nevertheless,  the  levels  are  often  much  too  low  for  economic 
processing. 

It  is  now  important  to  note  the  consecutive  concentration  of  values  that 
occurs  within  the  entire  supply -recycling -disposal  system.   In  every  industry 


nearly  all  of  the  valuable  constituents  are  extracted  from  incoming  raw 
materials  and  transferred  to  an  outgoing  product.   Thus,  nearly  all  of  the 
constituents  of  greatest  value  are  eventually  transferred  to  product 
materials  that  eventually  end  up  in  consumer  goods  or  services.   Even  though 
vast  amounts  of  nonrecoverable  wastes  are  generated  in  the  metal  supply  system 
(fig.  2),  most  such  wastes  have  virtually  no  economic  importance  in  the 
present  technological  climate.   These  wastes  comprise  a  liability,  and  the 
environmental  aspects  of  disposal  are  becoming  paramount.   In  the  United 
States,  disposal  of  such  mineral  wastes  has,  in  the  past,  affected  the 
environmental  quality  of  the  land,  lakes,  and  streams.   Although  measures 
are  being  taken  to  correct  polluted  conditions  in  lakes  and  streams,  it  is 
likely  that  most  of  the  affected  lands  cannot  be  returned  to  their  original 
condition  in  the  near  future  because  the  cost  would  be  so  much  greater  than 
the  net  environmental  benefit.   The  present  approach  to  the  problem  appears 
to  be  based  on  improving  future  disposal  practices  and  regulations.   In  this 
regard,  it  has  been  suggested  that  the  best  disposal  of  very  low-  or  negative- 
value  wastes  generated  in  the  future  would  be  to  send  them  back  to  the  site 
of  their  natural  origin,  such  as  vacated  mine  sites.   But  even  this  apparently 
simple  solution  would  cause  overwhelming  new  problems  in  nearly  every  segment 
of  the  supply  and  recycling  channels,  problems  far  beyond  the  scope  of  this 
paper. 

Some  of  the  wastes  generated  in  the  system  (fig.  2)  are  currently  being 
recycled  by  the  secondary  metals  industry.   There  is  also  inplant  and  intra- 
industry  recycling  in  which  wastes  of  one  industry  are  used  to  make  the  prod- 
ucts of  another.   The  importance  of  recycling  metals  in  the  United  States  has 
been  described  previously  in  considerable  detail  (14,  23-24).   Therefore,  it 
is  sufficient  to  state  here  that  the  U.S.  recycling  industries  are  now  supply- 
ing 25  percent  of  all  the  aluminum  and  zinc  consumed,  40  percent  of  the  copper, 
45  percent  of  the  iron,  and  50  percent  or  more  of  the  lead. 

The  rate  at  which  copper,  lead,  and  zinc  are  accumulating  in  the  goods - 
in-use  reservoir  is  shown  in  table  1.   The  three  metals  in  table  1,  together 
with  many  other  metals  and  nonmetallic  materials  such  as  plastics  and  paper, 
comprise  a  very  valuable  reserve.   It  is  most  difficult,  however,  to  determine 
the  real  potential  of  this  reserve  because  of  the  very  wide  range  of  material 
types  entering  the  reservoir  and  the  exceedingly  long  time  lapse  between  entry 
and  exit  dates.   For  goods  such  as  copper  pipe,  electrical  conductors,  and 
brass  ornaments,  the  in-use  time  often  exceeds  50  years.   For  other  goods, 
such  as  automobile  radiators  and  batteries  and  machinery  parts,  the  average 
time  lapse  may  only  be  2  to  10  years.   In  either  case,  the  secondary  materials 
industries  presently  recycling  materials  of  this  type  are  quite  as  efficient 
as  the  primary  producers  of  the  same  or  equivalent  commodities.   It  is  likely, 
therefore,  that  the  quantities  of  materials  entering  or  leaving  the  goods -in- 
use  reservoir  will  not  be  changed  significantly  by  any  anticipated  improvements 
in  extraction  technology,  so  this  reserve  will  continue  to  grow. 


10 


TABLE  1 .  -  Estimated  tonnage  of  copper,  lead,  and  zinc 
in  use  in  the  United  States,  1940-741 

(Thousand  short  tons) 


Year 


Copper3  Lead3  1  Zinc 


1940, 

1945, 

1950, 

1955 

1960, 

1965, 

1968, 

1969, 

1970, 

1971, 

1972, 

1973, 

1974, 


14 
19 
24 
28 
32 
37 
40 
41 
42 
43 
44 
46 
47 


,735 
,933 
,169 
,615 
,630 
,346 
,333 
,447 
,509 
,615 
,927 
,242 
,437 


180 
873 
1,674 
2,490 
3,052 
3,587 
4,030 
4,137 
4,234 
4,405 
4,701 
4,992 
5,242 


264 
1,173 
1,722 
2,525 
3,085 
3,928 
4,477 
4,677 
4,841 
5,025 
5,249 
5,478 
5,685 


information  gathered  from  Bureau  of  Mines,  Office  of 
Mineral  Resource  Evaluation. 
1907  base  of  reference. 
31939  base  of  reference. 


URBAN  ORE 

The  mass  of  materials  discarded  by  the  urban  society  of  the  United  States 
is  commonly  known  as  urban  refuse.   The  Bureau  of  Mines  refers  to  these  wastes 
as  urban  ore.   In  contrast  with  many  natural  resources,  urban  ore  is  growing 
in  abundance,  rich  in  grade  and  variety  of  value,  and  comparatively  simple  to 
process  (14,  26) .   It  is  also  very  costly  to  dispose  of  by  conventional 
methods,  but  the  overall  economics  of  recovering  large  quantities  of  minerals, 
metals,  and  organic  materials  of  significant  value  are  favorable  (17 ,  25-26) . 
Ultimately,  many  successful  demonstrations  of  recovery  and  recycling  systems 
will  not  only  increase  domestic  mineral  and  energy  material  supplies  signif- 
icantly, but  will  also  offer  a  variety  of  answers  to  the  growing  dilemma  of 
evaluating  waste  disposal  options. 

Urban  ore  is  conspicuously  heterogeneous,  comprising  an  astounding 
variety  of  postconsumer  items.   Although  speeches  and  publications  on  refuse 
disposal  and  utilization  number  in  the  thousands,  municipal  officials  have 
been  hampered  in  their  long-range  planning  for  new  waste  disposal  or  process- 
ing facilities  by  lack  of  firm  decisionmaking  information.   Only  recently  has 
meaningful  information  begun  to  emerge.   This  probably  stems  from  the  fact 
that  each  municipal  entity  is  unique  and  every  proposed  system  must  be 
evaluated  under  a  wide  variety  of  conditions  corresponding  to  a  wide  range 
of  local  situations . 


About  210  million  people  in  the  United  States  are  presently  generating 
about  145  million  tons  of  residential -commercial -institutional  urban  ore 
annually.   The  average  combined  refuse  collection  and  disposal  cost  in  the 


11 


United  States  now  exceeds  $20  per  ton.   The  cost  in  some  of  the  major  cities 
approaches  $40  per  ton  (31) .   All  but  about  30  million  of  the  145  million  tons 
collected  goes  directly  to  landfills.   The  remaining  30  million  tons  is  incin- 
erated, a  process  which  reduces  the  volume  by  about  90  percent  and  reduces  the 
weight  by  about  80  percent.   The  remaining  residues  after  incineration  are 
landfilled. 

Other  refuse,  amounting  to  untold  millions  of  tons,  does  not  enter  munic- 
ipal  collection  systems.   This  type  of  refuse,  such  as  utility  fly  ash,  demo- 
lition wastes,  and  industrial  wastes,  is  disposed  of  in  private  dumps  or 
abandoned  where  it  originates.   Some  of  this  refuse  is  taken  to  the  dumps  by 
private  collectors,  but  much  of  it  becomes  widely  scattered  litter.   The  aver- 
age composition  of  U.S.  municipal  refuse  (145  million  tens)  and  municipal 
incinerator  residues  (7.5  million  tons)  is  given  in  table  2,  and  values  of  the 
products  from  both  sources  are  shown  in  table  3.   The  estimated  values  shown 
are  based  on  products  and  processing  costs  obtained  during  the  Bureau  of  Mines 
pilot  plant  operations  and  process  development  and  cost  evaluation  studies  in 
two  different  pilot  plants  (12  -13 ,  17 ,  25  -26)  .   Others  (_2)  have  investigated 
the  economics  of  prototype  processes  for  extracting  values  from  municipal 
refuse  based  on  a  conceptual  arrangement  of  mostly  conventional  equipment  to 
yield  products  of  assumed  grade  and  values.   A  comparison  is  made  (2)    of  eco- 
nomic benefits  in  resource  recovery  systems  that  recover  only  noncombustible 
materials  (metals  and  glass)  with  those  that  recover  both  noncombustibles  and 
energy.   It  was  concluded  that  favorable  economics  must  be  based  on  more  than 
one  source  of  revenue,  and  the  addition  of  energy  recovery  systems  would  bene- 
fit most  communities.   It  was  also  concluded  that  other  uncertain  factors, 
such  as  location  of  markets,  quantities  of  wastes,  and  composition  of  wastes, 
could  alter  the  overall  economics  unpredictably.   It  is  thus  evident  that 
municipal  waste  disposal  problems  are  different  in  each  municipality  and  each 
one  should  consider  its  own  situation  as  unique. 

TABLE  2 .  -  Average  composition  and  estimated  value  of  raw 
refuse  and  municipal  incinerator  residues 


Material 


Glass 

Aluminum 

Copper -zinc 

Ferrous  metals 

Ash  and  slag 

Paper 

Food  waste 

Yard  waste 

Plastic 

Leather,  rubber.... 

Wood 

Textiles 

Dirt,  ceramics,  etc 


Raw  refuse, 

Incinerator  residue, 

percent1 

percent2 

9.7 

30.0 

.6 

1.4 

.3 

.6 

8.5 

20.0 

- 

48.0 

31.3 

- 

17.6 

- 

19.3 

- 

3.4 

- 

2.6 

- 

3.7 

- 

1.5 

- 

1.5 

_ 

1Lowe,  R.  A.   Energy  Conservation  Through  Improved  Solid 
Waste  Management.   U.S.  Environmental  Protection 
Agency,  1974. 
Bureau  of  Mines,  College  Park  Metallurgy  Research  Center. 
Resource  Recovery  Group.   Work  sheets,  1974. 


12 


TABLE  3 .  -  Estimated  amount  and  value  of  recovered  products  from  raw  refuse 

and  incinerator  residue 


Incinerator  residue 


Amount  generated  annually million  tons.. 

Gross  values1 per  ton.  . 

Total  gross  values millions  .  . 


7.5 
$23.25 

$174 


1Product  value  at  the  plant;  does  not  include  transportation  or  marketing 
costs . 

REFUSE  PROCESSING 

Collection 

Only  a  small  number  of  innovative  refuse  collection  methods  have  been 
studied  in  recent  years,  and  only  a  few  of  these  are  now  in  use  on  a  practical 
scale.   The  two  most  interesting  are  the  pneumatic  transport  system  and  the  one- 
man  collection  truck  equipped  for  automatic  pickup  and  dumping  of  special 
roadside  refuse  containers  into  the  collector  truck.   As  yet,  however,  there 
is  no  practical  substitute  for  general  use  to  replace  the  common  packer  truck 
with  its  pickup  crew. 

Composting 

Little  or  no  effort  was  made  in  the  United  States  to  develop  large  - 
capacity  systems  to  recover  values  from  municipal  refuse  prior  to  enactment 
of  the  Solid  Waste  Disposal  Act  of  1965  (28) .   Immediately  thereafter,  com- 
posting was  among  the  first  large-scale  processes  considered  (_7,  2_2)  .   Now 
it  is  among  the  least  attractive  utilization  methods,  particularly  in  the 
United  States.   Of  18  composting  operations  started  in  the  United  States  since 
1966,  only  2  are  still  operating,  and  as  yet  there  are  no  records  to  show 
that  composting  is  economical.   Except  in  a  very  few  unique  situations,  the 
interest  in  composting  must  certainly  continue  to  decline  in  the  United  States 
because  the  percentage  of  putrescibles  in  the  average  municipal  refuse  is 
steadily  decreasing,  and  there  is  no  evidence  that  a  significant  demand  for 
compost  of  municipal  origin  as  a  soil  amendment  can  develop  in  competition 
with  available  commercial  fertilizers. 

Common  Refuse  Disposal  Options 

There  are  only  six  general  types  of  refuse  disposal  practiced  in  the 
United  States.   Included  are  (1)  ocean  dumping,  (2)  open-land  dumping, 
(3)  open -dump  burning,  (4)  landfilling,  (5)  incineration,  and  (6)  resource 
recovery  disposal  systems.   The  first  three  are  now  banned  in  the  vast 
majority  of  municipalities,  and  a  total  ban  will  probably  be  enforced  in  the 
near  future . 


Landfilling  is  the  most  extensively  practiced  refuse  disposal  method, 
and  incineration  is  next  with  200  or  more  incinerators  now  in  operation. 


13 


Although  there  were  few  attempts  to  recover  valuable  constituents  from 
refuse  before  1965,  by  1974  both  the  scope  and  diversity  of  recycling  methods 
under  consideration  increased  markedly.   It  now  appears  that  the  number  of 
basically  different  concepts  has  reached  a  maximum,  but  the  level  of  develop- 
ment on  several  types  of  systems  continues  to  increase.   This  trend  is  likely 
to  continue  during  the  next  decade. 

Incineration 

There  are  only  three  basic  incineration  systems,  as  follows -- 

1.  Incineration  and  disposal  of  residues. 

2.  Incineration  with  energy  recovery  only. 

3.  Incineration  with  energy  and  resource  recovery. 

In  the  first  method,  refuse  is  delivered  to  a  holding  pit  at  the 
incinerator  plant  and  charged  at  a  uniform  rate  to  the  incinerator  combustion 
chamber.   Resulting  combustion  gases  and  some  particulates  are  discharged  into 
the  stack,  and  the  ashes  and  noncombustible  materials  are  discharged  into 
water  quenching  pits.   Some  stacks  are  equipped  with  electrostatic  precipita- 
tors to  remove  most  of  the  particulates  from  the  stack  gases.   The  precipi- 
tated solids  and  the  quenching  pit  residues  are  hauled  to  disposal  dumps  or 
landfills.   In  some  cases,  ferrous  metals  are  magnetically  recovered  from  the 
residues  prior  to  dump  disposal. 

The  same  basic  operations  are  performed  in  the  second  method  (energy 
recovery) ,  except  that  in  this  case  the  hot  combustion  gases  generated  in 
the  incineration  section  are  conducted  through  a  boiler  system  where  steam 
energy  is  recovered.   In  some  energy -recovery  systems,  bulky  ferrous  metals 
are  magnetically  recovered  from  the  raw  refuse  before  it  is  incinerated. 
Since  Europe  encountered  the  problems  of  high -cost  energy  and  refuse  dis- 
posal much  earlier  than  the  United  States,  refuse  energy  plants  are  more 
common  in  Western  Europe.   For  example,  about  16  West  German  plants  currently 
generate  power  from  refuse-fueled  systems  (8) ,  and  the  Netherlands  produces 
6  percent  of  its  total  electrical  energy  from  refuse.   The  United  States  is 
only  now  entering  this  area  of  energy  supply. 

The  third  method  (energy  and  resource  recovery)  is  much  more  com- 
plicated if  it  is  performed  for  total  recovery  of  contained  values.   In 
this  method,  energy  is  recovered  essentially  the  same  as  in  the  second 
method,  but  the  residues  are  sent  through  first -stage  separation  units  to 
produce  crude  fractions  of  glass,  metals,  organic  materials,  and  residuals. 
Upgrading  of  the  crude  products  is  performed  in  second-  and  third -stage 
operations  to  produce  high-grade  metal  fractions  (ferrous,  aluminum,  and 
copper-zinc),  and  a  high-grade  glass  fraction  (mixed  flint,  amber,  and  green). 
A  small  part  of  the  incoming  residues  (sand,  ceramics,  dirt,  and  unburned 
organics)  is  hauled  to  the  dumps  or  used  for  other  purposes. 


14 


Resource  Recovery  From  Raw  Refuse 
The  five  basic  methods  for  recovering  values  from  raw  refuse  are-- 

1.  Incineration  with  direct  energy  conversion. 

2.  Recovery  of  combustibles  for  direct  use  as  fuel. 

3.  Recovery  of  combustibles  and  conversion  to  fuel  products  (solid  fuel, 
oil,  and  methane). 

4.  Recovery  of  combustibles  and  separation  into  fuel  and  nonfuel 
products  (paper  for  fiber  or  fuel,  putrescibles  for  fuel  or  direct  conversion 
to  animal  food,  plastics,  and  other  combustibles  for  fuel). 

5.  Maximum  recovery  of  all  values  (paper,  plastics,  and  organics  for 
fuel  or  recycling;  and  ferrous  metals,  copper -zinc  metals,  aluminum-base 
metals,  flint  glass,  and  amber  and  green  glass  for  recycling). 

The  first  method  (incineration)  has  been  described  under  the  incineration 
grouping.   It  is  included  here  only  because  it  has  raw  refuse  input. 

In  the  second  raw  refuse  method  (combustibles  for  direct  use  as  fuel) , 
the  common  procedure  is  to  first  shred  the  refuse  to  liberate  all  constituents 
and  reduce  them  to  some  convenient,  uniform  size.   This  is  usually  followed  by 
air  classification  to  separate  lightweight  constituents  (paper,  light 
fabrics,  and  plastics)  from  the  heavy  constituents  such  as  metals,  glass, 
stones,  heavy  plastics,  and  rubber.   The  light  fraction  may  then  be  reduced 
in  size,  or  it  may  be  used  as  is  for  supplemental  fuel. 

The  third  method  (conversion  of  combustibles  to  fuel  products)  follows 
essentially  the  same  procedures  as  the  second  except  in  the  use  of  light - 
fraction  materials.   In  this  case,  the  light  fraction  can  be  dried  and 
pulverized  to  produce  an  improved  solid  fuel  material.   Alternatively,  it 
can  be  processed  in  a  reactor  to  produce  a  low-sulfur  oil  fuel,  or  it  can 
be  treated  by  a  hydrogasification  process  to  produce  substitute  natural  gas. 

The  fourth  general  raw  refuse  process  (recovery  of  combustibles  and 
separation  into  fuel  and  nonfuel  products)  is  simply  a  slight  modification 
of  the  third  process.   It  provides  optional  methods  for  utilizing  the 
recovered  combustible  materials  to  better  satisfy  a  wider  range  of  marketing 
situations.   Some  of  the  paper,  for  example,  may  be  recovered  either  as  a 
paper  fiber  product  or  as  a  solid  fuel  product.   It  might  also  be  converted 
to  oil  or  fuel  gas,  as  in  the  third  method.   The  putrescibles,  if  present  in 
sufficient  amounts,  may  be  converted  to  animal  food  (11) . 

The  fifth  (maximum  recovery)  process  is  essentially  the  same  as  the 
fourth  except  that  it  includes  additional  systems  for  recovering  the  non- 
combustible  values.   In  this  system,  several  consecutive  stages  follow  the 
initial  air  classification.   The  light  fractions  are  processes  as  in  the 
third  and  fourth  methods,  but  the  heavy  fraction  of  the  initial  classification 


15 


FIGURE  3t  -   Products  extracted  from  municipal  inciner- 
ator residues. 


is  subjected  to  further  pro- 
cesses such  as  secondary 
shredding  and  air  classify- 
ing, secondary  magnetic  sep- 
aration, jigging,  screening, 
and  froth  flotation.   Obvi- 
ously, the  combination  of 
such  unit  operations  and  the 
degree  of  upgrading  products 
are  optional,  depending  upon 
the  quality  of  product  needed 
for  optimum  marketability. 

The  literature  is 
replete  with  information  on 
various  research  and  devel- 
opment activities  in  the 
development  of  refuse  pro- 
cessing systems  (3_,  1_5,  20, 
31) ,  and  the  number  of  pub- 
lications is  growing  rapidly 
(18). 

When  the  Solid  Waste 
Disposal  Act  (28)  became  law 
in  1965,  the  Bureau  of  Mines 
was  already  deeply  involved 
in  recycling  research,  which 
it  had  been  conducting  since 
1910,  when  it  was  founded. 
Since  passage  of  the  act, 
the  Bureau  has  conducted  a 
number  of  investigations, 
most  of  which  have  produced 
positive  and  often  surpris- 
ing results  (15)  .   The 
resource  recovery  program 
(18,  27)  has  included  a  very 
diverse  list  of  projects 
ranging  from  the  conversion 
of  animal  manure  to  oil  and 
fuel  gases,  to  the  extrac- 
tion of  gold  from  electronic 
scrap.   The  program  has 
included  pilot  plant  investi- 
u  w5»'  w^  *  „   gations  of  municipal  refuse 
Products  extracted  from  municipal  raw     recovery  and  utilization  sys- 
refuse,  terns  since  1970.   Interested 

organizations  and  individuals  from  around  the  world  have  visited  these  plants 
and  received  the  most  detailed  data  available  on  system  options,  equipment  per- 
formance, processing  efficiency,  product  quality  analysis  and  control,  eco- 
nomic evaluations,  and  product  use  options.  The  systems  demonstrated  in  the 


FIGURE  4. 


16 


FIGURE  5.  -  Typical  items  made  from  products  recovered  from  municipal  refuse. 

Bureau  of  Mines  pilot  plants  have  been  adopted  in  whole  or  in  part  in  many 
of  the  commercial -scale  systems  under  construction  or  in  the  planning  stage. 

Typical  products  from  incinerator  residue  processing  plants  are  shown 
in  figure  3.   Similar  products  from  raw  refuse  processing  are  illustrated 
in  figure  4.   Several  typical  end  uses  for  products  extracted  from  municipal 
refuse  are  illustrated  in  figure  5. 

PRODUCT  RECYCLING 


The  most  widely  recognized  recycling  channel  originates  in  the  waste 
collection  and  disposal  industries  where  postconsumer  goods  and  wastes  are 
processed  for  salvage  or  disposal  (fig.  6).   The  most  common  practice  is  to 
sort  incoming  materials  and  prepare  selected  or  sorted  materials  for  the 
secondary  materials  industries.   The  secondary  materials  industry  output 
comprises  raw  materials  that  are  used  by  the  primary  materials  industries 
with  substantial  supplies  from  natural  reserves.   Here  the  recycled  materials 
lose  their  identity,  except  statistically.   For  example,  there  is  no  way  to 


17 


Natural    raw 
materials 


1 


BULK 

MATERIAL 

INDUSTRIES 


Secondary 

i        raw       ■ 

materials 


SECONDARY    MATERIALS 
INDUSTRIES 


i« H 

i 
i 

i 


PRODUCTS  RECYCLING 
INDUSTRY 


Repaired  parts 

and  units 

I 


M.»__  Recycled^ _ Jf 

parts  | 

Supplies  I 

I 


I 


Waste 


PRODUCER   OF 

GOODS  AND 

SERVICES 


I 
I 

Recycled 
units 


Consumer 
products 


I 


i- 


MARKETING 
INDUSTRIES 


,Goods  and 
services 


h 


Scrap 


Scrap  and 
salvaged    items 


MATERIALS 

DISPOSAL   AND 

SALVAGE 

INDUSTRIES 


T 


Postconsumer 
materials 


CONSUMER 


J 


FIGURE  6,  -  Conventional  and  product  recycling  systems. 


distinguish  the  part  of  a  new  aluminum  lawnmower  housing  derived  from  second- 
ary aluminum  from  the  part  derived  from  virgin  aluminum.   This  type  of 
recycling  provides  hundreds  of  thousands  of  tons  annually  of  secondary 
products  for  the  buyers  of  bulk  minerals,  metals,  and  other  raw  materials. 
The  methods  employed  are  relatively  efficient  and  well  established  in  the 
U.S.  economy. 

The  other  basic  recycling  channel ,  which  has  not  received  the  attention 
it  deserves,  involves  the  recovery  and  reconditioning  of  postconsumer  items 
such  as  electric  motors,  car  generators ,  carburetors,  and  bumpers.   A  compari- 
son of  the  economics  in  the  two  channels  suggests  an  immediate  need  for 
greater  attention  to  the  potentials  of  product  recycling  through  the  recondi- 
tioning channels.   Recycling  automobile  scrap  in  the  United  States  provides 
a  typical  case  in  point.   The  average  new  automobile,  which  sells  for  about 


18 


$4,000,  is  only  worth  about  $30  at  the  junkyard  after  8  to  10  years.   Most 
junk  autos  are  now  processed  in  huge  shredding  machines  which  grind  them  up 
into  fist-size  nuggets  of  metal  and  nonmetallic  debris.   The  metal  is  cleaned, 
sorted,  and  marketed.   After  shredding,  if  all  of  the  constituent  metals  are 
separated  into  individual  lots,  the  combined  value  of  the  iron,  copper,  alu- 
minum, zinc,  lead,  and  other  materials  increases  to  about  $200  per  junked 
automobile. 

Consider  now  that  we  start  with  an  identical  junk  automobile  and  first 
remove  the  starter  motor,  the  alternator,  the  carburetor,  and  the  two  bumpers. 
We  can  recondition  these  five  items  to  be  as  good  as  new  or  better.   Their 
total  reconditioned  value  will  then  be  about  $261.   In  this  case,  the  five 
reconditioned  parts  are  worth  $61  more  than  the  value  of  the  shredded  compo- 
nents of  the  entire  automobile.   Obviously,  the  amount  of  energy  required  to 
recondition  articles  of  this  type  is  several  orders  of  magnitude  less  than  the 
total  energy  required  to  produce  the  same  articles  from  natural  resource 
materials .   It  is  reported  that  even  the  normal  methods  of  recycling  already 
save  enormous  amounts  of  energy  (4,  21_) .   Recycled  copper  saves  32,700 
kilowatt -hours  per  ton  over  that  required  for  the  production  of  primary  copper, 
Recycling  a  ton  of  aluminum  saves  62,000  kilowatt -hours ,  a  ton  of  recycled 
steel  saves  7,500  kilowatt -hours ,  and  even  a  ton  of  recycled  paper  saves 
3,500  kilowatt -hours .   Still  greater  energy  savings  could  be  achieved  by 
reconditioning  units  and  parts  for  recycling  without  the  conventional  need 
for  remelting,  refining,  fabrication,  and  manufacturing. 

Reconditioned  items  are  presently  sold  by  repair  shops  where  the  demand 
is  somewhat  limited;  hence,  only  a  small  fraction  of  repairable  postconsumer 
goods  (mostly  automotive  parts)  is  being  recycled  through  that  channel.   It  is 
thus  clearly  evident  that  tremendous  quantities  of  materials  and  energy  could 
be  saved  in  any  industrialized  nation  if  it  could  simply  develop  the  full 
potential  of  product  recycling.   This  effort  could  be  helped  considerably  if 
manufacturers  would  design  more  products  for  reconditioning  and  establish  a 
practice  of  accepting  a  maximum  number  of  reconditioned  items  for  factory  use 
rather  than  limiting  their  use  to  maintenance  and  repair  shops  only. 

RECYCLING  PROBLEMS 

The  technology  for  processing  urban  refuse  has  developed  rapidly  during 
the  past  decade.   Several  different  systems  are  currently  being  demonstrated, 
and  others  will  be  demonstrated  in  the  near  future.   However,  the  number  of 
problems  involving  the  selection  and  successful  application  of  any  system  is 
too  great  to  discuss  in  depth  here,  so  only  the  most  important  general 
problems  are  considered. 

The  greatest  problem  is  that  of  marketing  the  recovered  products, 
particularly  those  recovered  from  municipal  refuse.   In  most  cases  the 
questions  of  product  quality  and  geographical  location  are  paramount. 

Although  the  commercial  value  of  such  products  can  be  estimated,  it  is 
very  difficult  to  negotiate  firm  long-term  sale  contracts  based  on  a  few 
thousand  pounds  of  pilot  plant  products.   Before  they  can  agree  to  long-term 


19 


purchase  agreements,  prospective  buyers  first  want  a  large  supply  of  product 
materials  provided  over  a  reasonably  long  period  of  operation  in  order  to 
evaluate  the  consistency  of  product  quality  and  the  stability  of  the  supply. 
This  unfortunate  situation  is  complicated  by  the  fact  that  no  such  large-scale 
supplies  can  be  produced  until  large-scale  demonstration  plants  are  producing 
at  full  capacity.   A  dilemma  then  arises  when  it  is  found  that  only  limited 
funds  are  likely  to  be  available  for  large-scale  demonstration  plants  until 
after  a  satisfactory  market  survey  of  products  is  completed.   The  difficulty 
in  these  cases  stems  from  the  fact  that  the  market  surveys  are  not  conclusive 
because  without  large  quantities  of  real  products  available  for  evaluation, 
the  surveys  must  be  based  on  hypothetical  plant  productivity  and  products 
and  hypothetical  market  prices,  all  of  which  lead  to  many  other  questions 
that  cannot  be  answered  completely. 

Another  major  problem  appears  to  be  in  the  eventual  need  to  consume 
large  quantities  of  glass,  metals,  paper,  and  plastic  that  are  to  be  produced 
at  great  distances  from  locations  where  they  are  normally  needed  as  raw 
materials.   Many  municipalities  are  so  remote  from  potential  markets  that 
transportation  costs  preclude  the  sale  in  the  common  marketplaces  of  products 
recovered  from  refuse.   This  means  that  unconventional  uses  must  be  found  for 
the  recovered  products.   Paper  that  cannot  be  sent  to  distant  markets  must  be 
used  locally  as  fuel,  for  making  roofing  felt,  for  thermal  insulating  material, 
for  wallboard,  for  conversion  to  oil,  or  perhaps  for  other  uses  not  yet  con- 
ceived. Glass  that  cannot  be  shipped  to  a  distant  bottle  plant  must  be  used 
locally  for  making  brick,  tile,  glass  wool,  poultry  grit,  aggregate,  and 
other  products. 

Before  any  of  these  possibilities  can  become  a  reality,  some  individual 
or  firm  must  first  decide  to  become  involved  in  the  local  recycling  effort  by 
establishing  new  plants  to  consume  the  refuse  plant  products  in  new  ways. 
Here  again,  it  is  essential  that  large  amounts  of  refuse  products  are  avail- 
able so  that  the  new  uses  can  be  developed  with  real  rather  than  hypothetical 
products.   If  materials  are  made  available  in  sufficient  quantity,  new  uses 
will  probably  develop  almost  automatically. 

The  third  most  distressing  problem  lies  in  the  unusually  large  number 
of  authorities  that  inevitably  become  involved  with  Federal,  State,  county, 
and  city  participation  in  municipal  refuse  problems.   In  many  local  cases, 
for  example,  it  is  difficult  for  city  councils  to  arrive  at  a  firm  decision 
on  what  needs  to  be  done  with  waste  disposal  problems  or  how  to  do  it.   If 
there  should  be  any  agreement,  new  problems  are  usually  encountered  with 
county,  State,  or  Federal  authorities  and  regulations.   In  view  of  these 
problems,  it  is  gratifying  that  any  significant  progress  has  been  made  in 
the  many  persistent  efforts  to  conserve  resources  and  increase  recycling. 
It  is  remarkable  that  more  private  and  industrial  capital  is  moving  into  the 
development  and  operation  of  recycling  systems.   Now  that  it  has  begun,  this 
trend  should  continue  as  more  demonstration  plants  are  completed  and  the 
economics  of  the  various  systems  are  found  to  be  favorable. 


20 


AREAS  FOR  RESEARCH  AND  DEVELOPMENT 

If  our  atomic  scientists  should  successfully  develop  systems  for  con- 
trolled fusion  reactions,  the  U.S.  minerals  deficits  would  melt  away  and 
probably  be  gone  forever.   With  virtually  unlimited  cheap  power,  we  could 
afford  to  process  abundant  resources  that  are  presently  far  beyond  economic 
processing  parameters.   With  fusion  energy,  not  only  would  there  be  a  limit- 
less supply  of  fuel  (deuterium  and  tritium)  in  sea  water,  but  both  the  reactor 
heat  and  the  fast  neutron  product  of  fusion  could  be  used.   The  former  would 
generate  power,  and  the  latter,  a  "fusion  torch,"  is  reported  to  perform  a 
long  list  of  remarkable  feats  such  as  "...vaporize  garbage,  turning  it  into 
its  basic  elements  for  recycling"  (10) .   It  is  also  believed  that  the  torch 
could  be  employed  to  produce  methane,  synthetic  natural  gas,  and  methanol  from 
abundant  resources  and  thus  eliminate  our  need  for  imported  fossil  fuel.   For 
the  present,  however,  we  must  view  this  as  a  possible  dream  and  remain  alert 
to  present  realities. 

Most,  if  not  all,  of  the  basic  systems  for  reclaiming  values  from  urban 
wastes  have  been  conceived,  and  the  exchange  of  technology  has  been  extensive. 
Most  of  the  basic  concepts  have  been  demonstrated,  at  least  on  the  pilot  plant 
scale.  This  suggests  that  future  research  in  this  field  should  be  concentrated 
on  the  problems  of  increasing  the  efficiency  of  unit  operations  and  devices 
such  as  shredding,  air  classification,  and  sorting  of  mixed  colored  glass  and 
nonferrous  metals. 

Research  on  heavy  media  separation  should  continue  toward  better  methods 
and  devices  for  separating  mixed  plastics,  mixed  metals,  and  glass.   Much  more 
work  should  be  done  on  electrostatic  and  other  methods  for  separating  mixed 
papers,  plastics,  particulate  metals,  and  minerals. 

The  tremendous  opportunities  for  recycling  repaired  consumer  goods  have 
received  little  or  no  attention.   The  field  of  product  design  for  recycling 
is  indeed  essentially  a  virgin  area. 

Another  area  in  which  little  or  no  research  has  been  conducted  is  the 
separation  of  the  high -value  components  from  home  appliances  and  similar 
bulky  postconsumer  goods. 

The  potential  of  designing  landfills  for  eventual  methane  recovery  should 
be  conducted  with  concurrent  extensive  studies  on  the  recovery  of  gases  and 
other  values  from  existing  landfills.   Rapid  conversion  of  organic  materials 
to  fuel  products  should  be  pushed  with  greater  vigor.   It  might  well  be  that 
this  approach  will  be  the  most  efficient  and  direct  method  for  capturing 
energy  from  the  sun. 

New  extensive  studies  should  also  be  made  on  other  disposal  systems  such 
as  subsurface  disposal  of  slurried,  zero-value  wastes  by  high-pressure 
hydraulic  techniques . 

Finally,  one  of  the  most  promising  and  important  areas  for  future  research 
is  in  the  utilization  of  products  reclaimed  from  urban  wastes.   This  should 


21 


center  on  possible  new  uses  for  large  amounts  of  glass,  paper,  metals,  and 
putrescibles  in  urban  refuse.   It  is  logical  to  assume  that  a  wide  range  of 
new  uses  will  be  found  as  soon  as  a  continuous  and  significant  supply  of 
recycled  raw  materials  is  assured. 

THE  FUTURE  OF  RECYCLING 

The  most  accurate  predictions  of  the  future  are  most  often  derived  from 
a  thorough  analysis  of  related  matters  of  the  past  and  present.   Putting  this 
approach  to  use,  we  readily  observe  that  recycling  certainly  is  not  new.   It 
appears,  in  fact,  to  be  one  of  the  most  obvious  laws  of  nature,  much  like  the 
seasons,  the  tides,  and  the  life  and  death  processes.   It  is  not  surprising, 
therefore,  that  the  greatest  motivating  force  behind  present  recycling  efforts 
is  the  worldwide  concern  for  the  deteriorating  natural  environment.   Histori- 
cally, there  has  been  no  concern  about  resources  until  they  were  found  to  be 
in  short  supply,  nor  has  there  been  any  alarm  about  the  environment  until  it 
became  disturbingly  bad. 

Recycling  mineral  resources  first  began  during  the  stone  age  when  flint 
arrowheads  were  retrieved  from  slain  animals.   The  recycling  of  more  materials 
continued  as  civilization  progressed.   Now  there  exists  the  greatest  oppor- 
tunity ever  available  to  recycle  needed  resources  and  concurrently  improve  the 
deteriorating  environment. 

Mining  natural  ores  of  iron,  copper,  aluminum,  and  all  of  the  other  metal 
commodities  is  commonplace,  as  are  the  extraction  of  materials  for  making 
glass  and  plastics  and  the  growing  and  harvesting  of  papermaking  raw  materials, 
In  striking  contrast,  urban  ore  need  not  be  mined,  and  the  contained  values 
are  already  in  a  refined  state,  ready  for  immediate  recycling  after  they  have 
been  separated.   The  technology  for  making  such  separations  has  been  developed 
for  prompt  extensive  application,  and  some  applications  are  in  fact  accom- 
plished or  underway.   Furthermore,  considerable  decisionmaking  information  is 
beginning  to  emerge,  and  the  results  are  generally  favorable.   Considering  the 
high  cost  of  conventional  waste  disposal  in  terms  of  dollars  and  the  potential 
value  of  an  improvement  of  the  environment,  there  is  no  sound  reason  to 
delay  the  exploitation  of  waste  resources  wherever  the  opportunity  exists. 

There  is  no  question  that  disposal  costs  must  enter  the  economic  aspects 
of  recycling  the  constituents  of  urban  ore.   However,  it  will  also  be  noted 
that  the  potential  improvement  of  the  environment  has  seldom  been  given  the 
full  value  it  deserves  in  the  economic  considerations.   What  is  the  dollar 
value  of  a  clean  lake  or  a  river?   How  much  does  the  value  drop  when  the  land, 
air,  and  water  environments  become  polluted?   It  appears  that  society  has 
considered  these  questions  and  concluded  that  the  environment  is  valuable. 
The  cost  of  any  recycling  needed  to  maintain  the  quality  of  the  environment 
must  be  balanced  against  the  value  of  that  environment. 

The  annual  gross  value  of  the  constituents  of  municipal  wastes  alone  is 
estimated  at  nearly  $2  billion.   If  these  wastes  are  processed  for  recycling, 
there  could  also  be  an  annual  savings  of  $3  billion  or  more  in  disposal  costs, 
and  a  large  undetermined  amount  of  energy  could  be  saved.   Accordingly,  the 


22 


practice  of  recycling  will  continue  to  increase  steadily  as  the  demand  for 
improved  environmental  quality  persists  and  the  demand  for  more  resource 
materials  continues  to  rise.   These  trends  will  occur  at  a  much  higher  rate, 
at  least  during  the  next  decade.   By  then,  industries,  municipalities,  and 
governments  will  have  overcome  the  major  obstacles  and  will  have  established 
integrated  systems  and  coordinated  operations  in  all  of  the  industrialized 
countries.   Fortunately,  it  is  expected  that  the  developing  nations  will  have 
ready  access  to  all  advanced  recycling  technology  as  it  develops  and  they,  too, 
will  adopt  recycling  more  extensively  as  they  achieve  higher  standards  of 
living. 


23 


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sec.  A,  p.  1,  sec.  D,  p.  20. 

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Story.   History,  Operation,  Economics.   1973,  10  pp. 

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13.  Johnson,  P.  W. ,  and  J.  A.  Barclay.   Economic  Studies  of  Uses  of  the  Glass 

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14.  Kenahan,  C.  B.   Solid  Waste --Resources  Out  of  Place.   Environ.  Sci .  and 

Technol.,  v.  5,  No.  7,  July  1971,  pp.  594-600. 

4Title  enclosed  in  parentheses  is  a  translation  from  the  language  in  which  the 
item  was  originally  published. 


24 


15.  Kenahan,  C.  B.,  R.  S.  Kaplan,  J.  T.  Dunham,  and  D.  G.  Linnehan.   Bureau 

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16.  Landsberg,  H.  H.   Low  Cost  Abundant  Energy:   Paradise  Lost?   Science, 

v.  184,  No.  4134,  Apr.  19,  1974,  pp.  247-253. 

17.  Makar,  H.  V.,  and  P.  M.  Sullivan.   Resource  Recovery  From  Urban  Refuse. 

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Status  Report.   Washington,  D.C.,  December  1975,  2  pp. 

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D.C.,  June  1973,  pp.  4D-6-4D-9'. 

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(Utilization  of  Urban  Refuse  in  the  U.S.A.).   UMSCHAU  in  Wissenshaft 
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24.   .   A  Profile  of  the  Nonferrous  Secondary  Metals  Industry.   Proc. 

2d  Mineral  Waste  Utilization  Symposium,  cosponsored  by  Bureau  of  Mines 
and  IIT  Research  Institute,  Chicago,  111.,  Mar.  18-19,  1970,  pp.  87-105. 

25.  Stanczyk,  M.  H. ,  and  R.  S.  DeCesare.   Recycling  Materials  in  Urban  Refuse, 

A  Progress  Report --Incinerator  Residues  and  Raw  Refuse.   Proc.  3d 
Mineral  Waste  Utilization  Symposium,  cosponsored  by  Bureau  of  Mines 
and  IIT  Research  Institute,  Chicago,  111.,  Mar.  14-16,  1972, 
pp.  287-294. 

26.  Sullivan,  P.  M. ,  M.  H.  Stanczyk,  and  M.  J.  Spendlove.   Resource  Recovery 

From  Raw  Refuse.   BuMines  RI  7760,  1973,  28  pp. 

27.  U.S.  Bureau  of  Mines.   Bureau  of  Mines  Research  1973.   A  Summary  of 

Significant  Results  in  Mining,  Metallurgy,  and  Energy.   1974,  107  pp. 

28.  U.S.  Congress.   Solid  Waste  Disposal  Act.   Public  Law  89-272,  Oct.  20, 

1965,  Stat.  306,  10  pp. 


25 


29'   "196^2™  °f  ^  Interi°r-   SUrfaCe  Mining  and  0ur  Environment. 

30.  U.S.  Office  of  Science  and  Technology,  Executive  Office  of  the  President 

Washington,  D.C.,  May  1969,  111  pp.  president 

31.  U.S.  Office  of  Solid  Waste  Management,  Environmental  Protection  Agencv 

Resource  Recovery  and  Source  Protection.   No.  SW-122,  1974^12  pp 


*U.S.  GOVERNMENT  PRiNTING  0FF,CE:  1976-603-755/Z0O 


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