asogravas_panorama_de_los_agregados_reciclados_en_la_union_europea.pdf

AGREGADOS RECICLADOS

MITOS Y REALIDADES

UNION EUROPÉENNE DES PRODUCTEURS DE GRANULATS

EUROPÄISCHER GESTEINSVERBAND

EUROPEAN AGGREGATES ASSOCIATION

The European Aggregates Association

Recycling of C&D Materials = European Perspectives

Jim O’Brien, President UEPG

Bogotá DC, Colombia, July 27, 2011

Presentation Overview

1.Introduction to UEPG

2. EU Aggregates Production & Recycling Data

3. EU Driving Forces on Recycling

4. Examples of Recycling in Ireland, Finland, Switzerland (CRH) and Netherlands (FIR/BRBS)

5. Economic, Technical and Other Aspects

6. Some Conclusions & Open Discussion

Introduction to UEPG

UEPG created in 1987

Brussels Office since 2003

Now 31 Member Countries

Represents Industry with:

Sales of ~€20 billion

Over 3 billion tonnes of

aggregates per year

24,000 quarries & pits

16,000 companies

300,000 employed (including contractors)

UEPG Vision, Mission

Our Vision: A Sustainable Industry for a Sustainable Europe

Our Mission: To be the Industry Champion and a Trusted Partner

Our Objective: To be Economically Competitive, Socially & Environmentally Responsible

Our Values: To be Open, Transparent and Honest

Secretary General: Antony Fell Public Affairs

Manager: Dirk Fincke

Public Affairs Officer: Sandrine Devos

Public Affairs Officer: Miette Dechelle

Very dynamic, active

& effective Team!

UEPG Secretariat

UEPG Lobbying Activity

• Frequent informal & formal meetings with officials • They listen to us - industry viewpoint is respected • We prepare briefing notes to inform our Members

• EU Commission High-Level Conferences

• Parliamentary Dinner Debates (involving MEPs)

• Partnership with Environmental NGOs

• Site visits with EU key decision makers


1. Introduction to UEPG

2.EU Aggregates Production & Recycling Data



5. Economic and Other Aspects


EU Geology

Geology varies widely across EU

Determines quality & aggregate types

Some countries well endowed with hard rock sources (eg Norway, Finland)

Others with scarcity even of sand & gravel (eg Poland, Hungary)

Aggregates Production 2009

Total EU 2009 production was 3.25 billion tonnes Overall 51% crushed stone, 39% S&G, 2% marine,

6% recycled and 2% manufactured aggregates

Aggregates Tonnes/Capita

EU average was (only) 5.4t/c in 2009, Colombia ~3t/c European output fell -11% in 2009, ~-10% in 2010

Tonnes/capita 2009

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

Cyp

rus

Norw

ay

Finla

nd

Austri

a

Sweden

Irela

nd

Den

mark

Bel

gium

Net

herla

nds

Germ

any

Gre

ece

Cro

atia

Cze

ch Rep

Switz

erla

nd

France

Italy

Hungar

y

Slova

kia

Poland

Spain

Portugal

Turkey

Bulg

aria U

K

Serbia

Rom

ania EU

U

SO

Z NZ

Trend in Tonnages 2010 v 2009

There are a few “green shoots”, but overall further economic and tonnage declines in 2010

Has the EU now reached the bottom of the cycle?

Tonnage Predictions 2010 v 2009

-50%

-40%

-30%

-20%

-10%

0%

10%

20%

Norway

Swed

en

Switz

erland UK

Belgiu

m

Finla

nd

Poland

Turkey

France

Ger

man

y

Cyprus

Nether

lands

Serbia

Austria

Czech

Rep

Denmar

kIta

ly

Slovak

ia

Hungary

Spain

Gre

ece

Portugal

Bulgar

ia

Irela

nd

Roman

ia

Croatia

Tonnes/Capita v €GDP/capita

Aggregates usage continues to grow as the economy grows

Growth needs aggregates!

Tonnes/Capita v GDP/capita 2009

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

0 20 40 60 80

€000 GDP/capita

To

nn

es

/ca

pit

a

Colombia

Definition of Recycled Aggregates

Recycled Aggregates are those produced on-site or off-site through crushing, screening, sorting, etc of construction and demolition materials

(Asphalt recycling considered separately)

Does not include: Excavated materials By-products of

natural stone, slate processes (both are “natural aggregates”)

Aggregates produced from other industrial processes, like slag, etc (“manufactured aggregates”)

Global C&D Materials Recycled

Global data on recycling is often based on best estimates

The recent EU’s Bio-Intelligence Report did little better

C&D materials = ~0.9-1.0t/capita Better called “materials” not “waste”!

Amount of

waste (Mt)

Europe US Japan

Construction

and Demolition

Waste (C&DW)

510 317 77

Municipal

Waste

241 228 53

% EU C&D Materials Recycled

These are best estimates, difficulties both in varying definitions and probable under-reporting

Total EU C&D materials available est’d at ~535mt

Overall EU just on 200mt of recycled = 37% recycled

C&D Materials % Recycled (Est)

0%

20%

40%

60%

80%

100%

UK

Belgiu

m

Nether

lands

Germany

Poland

Switzerla

nd

France

Austria

Roman

ia

Norway

Finla

nd

Slovakia

Sweden

EU Recycled Aggregates %

Best performers are UK, Belgium & Netherlands Even in those cases, recycled is only 20-25% market Overall EU, only 6% of demand is recycled material If all countries recycled 100% = ~15% total demand

Recycled Aggs as % National Demand

0%

5%

10%

15%

20%

25%

UK

Belgiu

m

Nether

lands

Germany

Poland

Switzerla

nd

France

Austria

Roman

ia

Norway

Finla

nd

Slovakia

Sweden




3.EU Driving Forces on Recycling




The EU Legislative Drivers

• EC Raw Materials Initiative, launched by Commission VP Günter Verheugen in 2008

• Raw Materials and Resource Efficiency Strategies, launched by Commission VP Antonio Tajani in early 2011

• Waste Framework Directive, which sets target of recycling 70% of all available C&D materials by 2020

• In some cases, even more ambitious national legislations

The EU Legislative Obstacles

• Definition of “Waste” as any material not immediately used on site

• Ensuing very complex permitting procedures

• Need to establish “End-of-Waste” Criteria

• REACH requirements, avoided by acceptance of Recycled Aggregates as “Articles”

The Practical Drivers

• Lack of landfill space, particularly around major urban areas (leading to the associated landfill taxes)

• Lack of availability or high cost of natural aggregates in some countries/regions, particularly near urban areas

• Environmental benefits, Green Procurement, etc

• Recycling is an exciting business opportunity!

UEPG Action on Recycling

• UEPG now has the promotion of Recycling as one of its top priorities

• It cooperates with FIR (International Federation of Recycling)

• Both work together with others in EPRA (European Platform for Recycled Aggregates)

• Currently seeking EC support as an Innovation Union Project

www.fir-recycling.com

www.uepg.eu





4.Examples of Recycling in Ireland, Finland, Switzerland (CRH) and Netherlands (FIR/BRBS)



Irish Case Study

Company had major quarries near Dublin

Experienced in handling its own quarry waste

Saw Recycling as a complementary activity to natural aggregates - a business opportunity!

Had existing quarry infrastructure and plant

All recycling processing was to be contracted out

Irish Recycling Activity

Got “waste” permits in 2002 – a significant challenge Used existing quarry area, mobile crushers, loaders Focused on clean concrete “waste”, rigorous QC Built up to 350kt/y by 2007, ~€5m sales, profitable! Closed down end 2008 due to “Celtic Tiger” collapse!

Recycling success depends on state of the economy!

Irish Technical Aspects

Focused on producing road base material (0-40mm)

Specification had to be agreed with and tested for local authorities

QC of incoming and outgoing materials was very crucial, including on-site blending

Strong relationships with suppliers and customers

Experiences learnt: Need jaw/impact crusher Hammer for items >0.6m Strong mobile plant tyres Strong conveyor belts

Finnish Case Study

Built activity over 8 years In 2011, up to 0.5mt/y Prices & profitability up Had to lobby long and

hard on landfill laws

Started in 1992, grew steadily to 23 locations

60-70% of all demolition materials are recycled

Very selective demolition Tight incoming controls Pre-cutting with scissors

and hammer to <1m Used 3 mobile impact

crushers with screens Made 0-45mm product

with good grading curve

Approved by authorities

Finnish Applications

Better than natural

aggregates as re-

hardening adds 1-2MPa

bearing capacity, so layer

thickness can be reduced!

Focused on utilisation in road construction base & sub-base layers

Design & utlisation guidelines published by road authorities

Quality management system published as national standard

Environmental quality tested by leaching (Cd, Cr, Cu, Pb, SO4)

Other Finnish Experiences

Permitting is difficult Some illegal dumping Must achieve standards

higher than competitors Advantage to combine with

other quarry/pit activities Can be done a contract &

campaign basis QC must cover grading,

compressive strength, frost resistance, water content, impurities & leaching


Can recycle in all seasons (down to -30oC)!


RA not used in sensitive groundwater areas

Swiss Case Study

Started 10 years ago: strong Government pressure to increase use of recycled materials

Some operate small mobile crushing units, but now trend is towards fixed larger recycling plants

Access to

natural

aggregates

is very

limited, also

promotes

recycling

Swiss Experiences

Big focus on selective demolition....

Swiss Experiences

Followed by careful sorting of waste streams....

Swiss Experiences

Removal of steel, metals, plastics, etc....

Swiss Experiences

Often with grading and blending on site....

Swiss Recycling Plants

Then processed at fixed recycling installations....

Swiss Recycling Plants

Including weighbridge, test laboratory, etc....

Swiss Market Demands

Most projects now demand 25-30% of RA in concrete (also actually incentivised)

New major public projects must have up to 60% RA in concrete!

Major challenges on mix design and pumpability!

Accepted to be more expensive, also maybe not optimum environmentally

Must also match C&D market supply & demand!

Swiss Recycled Products

Requires significant expertise to produce various fractions (4-8mm, 8-16mm, 16-32mm)

More profitable, but entails higher operating costs

Minimise 0-4mm dust as it is most easily contaminated, not good for concrete

Rigorous sampling, testing and reporting protocols, must be independently verified

Margins typically ~20-30%

The Dutch Experience

Probably the longest experience in recycling

Driven by lack of natural resources, high degree of urbanisation and strong Government pressures

Landfilling of C&D materials banned or very costly

Favourable permitting regime

High public awareness and acceptance & embedded in public procurement

Dutch Experiences

Starts with selective demolition, separating out and selling the separate streams....

Several of these streams may be quite valuable (cables, plastics, steel)!

Dutch Experiences

Must remove all hazardous and contaminating materials (like asbestos, halons, gypsum, etc....)

Dutch Experiences

By-Products (mainly from demolition site) may also include: Wood Plastics Metals Glass Plasterboard (gypsum)

These also other sources of income!

Dutch Recycling Technology

May have large mobile installations.....


Or large fixed installations.....


Flowsheet for Van Bentum Recycling Centrale

Dutch Applications

May be used as Road-Base Material (then to EN 13242), as Coarse Sub-Base (roads,

airports, etc) Unbound top layers

(paths, paving layer)

Such uses typically

necessary for Dutch ground conditions

50

Dutch Applications

Also for drains, dykes, riverbanks, fillers, banks, lightweight foundations

Dutch Applications

Products also are aggregates for concrete, mortars

Must then comply with harmonised standard EN 12620

Includes testing for Geometric Properties Mechanical & Physical

Properties Thermal & Weathering

Properties Chemical Properties

Dutch Applications

In concrete, may have up to 100% replacement of primary materials, including fines! Up to 50% RA without

redesign of mixture Up to 20% of RA without

notification Up to C35/45 (EN206-1)

strengths to 65 N/mm2

Accepted in market as

premium products!


1.Introduction to UEPG




5.Economic, Technical and Other Aspects


Useful References - 1

Some very useful publications are free downloads...

www.wbcsdcement.org/recycling www.sustainableconcrete.org.uk

www.concretecentre.com

Useful References - 2

Important technical guide now being finalised by New Zealand Cement & Concrete Association

Compares technical aspects across many countries (UK, US, OZ, Germany, Portugal, HK)

Therefore will be a very useful technical reference for the recycling industry

www.ccanz.org.nz

Technical Report No. 14

Best Practice Guide

on the

Use of Recycled Materials in

Concrete

CCANZ/BRANZ/AQA

Recovered Aggregates

Recovered aggregates (1-3% of demand) from truck wash-out can perform as well as natural aggregates

However re-use left-over sludge and wash-water may require testing for alkalis, sulphates and chlorides

NZ summary of Restrictions on RA

Draft UK “End-of-Waste” Criteria

Important UK document in process of finalisation

Other similar approaches being developed by Belgium and Netherlands

Industry is taking the lead in getting these adopted at an EU level

Purpose is to reduce legislative burden and uncertainty of “waste” designation

QUALITY PROTOCOL

End of waste criteria for the

production of aggregates from

inert waste

Contents

Section1: Introduction

Section 2: Producing aggregates

from inert waste

Section 3: Providing evidence of

compliance with the Quality

Protocol

Section 4: Application and use of

recycled aggregates

Appendix A - Definitions

Appendix B - Product standard, specification and

related testing procedures to which this Quality

Protocol applies

Appendix C - Wastes considered to be inert waste for

the purposes of this document

Appendix D - Good practice applicable to the

transport, storage and handling of recycled aggregates

Recycling Truths & Rationales

Truth Rationale

Cement cannot be recycled True, but concrete can

Demolition concrete is inert Generally true, but may require some

leaching tests to confirm inertness

Recycled aggregate can be better than

natural aggregates in some

applications

True, as in road base applications for

example it achieves better compaction;

also can have some cementitious value

Using recycled aggregate reduces

land-use impact

True, less landfilling of waste and less

natural aggregates used

Recycling all C&D materials will not

avoid need for new natural aggregates

True, even recycling of all C&D

materials meets only about 20% of

demand

Figures are not complete for recycling

rates

True, but reporting is improving

Recycling Myths and Realities

Myth Reality

Concrete cannot be recycled Yes it can!

Recycled concrete aggregate may not

be used for structural concrete

Yes it can!

Although some concrete can be

recycled, it is not possible to achieve

high rates

Yes it is!

Concrete can be 100% made by

recycling old concrete

Yes, it is possible, but may not be

economically or environmentally viable

Recycling will reduce greenhouse gases

and the Carbon footprint

Maybe, maybe not (see next slide)

Recycling into low-grade aggregate is

environmentally the best solution

That’s still an open debate

Recycled aggregate is more expensive That depends on recycling location

(slide to follow)

Carbon Balance

The UK MPA has done a detailed study on the Carbon footprint of RA versus natural aggregates

It concluded that if the transport distance for RA is >15km, there will be a negative Carbon impact

Recarbonation through Recycling

Nordic study (2005) has shown that between 25% and 50% of the CO2 emitted during the cement manufacture can be re-absorbed by concrete crushed during recycling!

Confirmed by 2010 New Zealand study

An unexpected environmental benefit!

Relative Economics of Recycling

Euro/tonne %

Waste reception fees 10

Product sales 3

Total income 13 100

Reception & storage costs -1

Processing costs -5

Total production costs -6 46

Fixed costs -1 8

Operating profit (PBIT) 6 46

Illustrative Recycling Cost Structure






5. Economic and Other Aspects

6.Some Conclusions & Open Discussion

Green Building Initiatives

Use of RA gains strong recognition in several Green Building Inititiatives, such as:

UK BREEAM (www.breeam.org)

US LEED (www.usgbc.org)

Japanese CASBEE (http://www.ibec.or.jp/CASBEE/english/

overviewE.htm)

NZ Greenstar (www.nzbgc.org.nz)

Austalian Green Star (www.gbca.org.au)

http://www.ibec.or.jp/CASBEE/english/overviewE.htm

http://www.ibec.or.jp/CASBEE/english/overviewE.htm

http://www.nzgbc.org.nz/main/

http://www.gbca.org.au/

Final Comments - 1

C&D recycling is a good business opportunity! The technology is basically fairly simple However the bigger challenges are in:

Finding the suitable market niches for the products Finding reliable high-quality sources of C&D materials Meeting all relevant technical standards Finding the way through permitting hoops Finding the way through unhelpful legislative obstacles

Plan for the “long-haul” in entering the business Aim for highest quality and best market position

Regard it RA as complementary business to natural

aggregates, not a competitor

Final Comments -2

Government promotion can stimulate recycling It can set precedence for a certain % of recycled

materials in public projects through adopting a “points scheme” that will favour project bidders

Landfill tax creates a financial incentive for recyclers Authorities, industry and standard-makers need to

develop and agree standards for recycled materials, and these standards need to be enforced

Need a fair/easy permitting regime for recyclers Public needs to be educated that recycling is good

Otherwise good luck to recycling in Colombia!

UNION EUROPÉENNE DES PRODUCTEURS DE GRANULATS

EUROPÄISCHER GESTEINSVERBAND

EUROPEAN AGGREGATES ASSOCIATION

The European Aggregates Association

Thanks for your Attention!

Jim O’Brien, President UEPG

Bogotá DC, Colombia, July 27, 2011

asogravas_panorama_de_los_agregados_reciclados_en_la_union_europea.pdf

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