Clear Solutions Engineering - Glass Recycling Project Overview
Clear Solutions Engineering is working on a project to recycle glass for the City of Fredericton. The project aims to determine the economic feasibility and environmental soundness of recycling glass. Various aspects such as market review, recommended system, collection methods, processing stages, and economic considerations are covered in the project. The recommended system involves collecting 430 tonnes of glass per year, with an estimated output of 390 tonnes per year after processing. The system includes steps like coarse crushing, initial sorting, cleaning, storing, contaminant separation, and fine grinding. The project also evaluates product selection criteria, shipping options, and potential applications of recycled glass products.
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Clear Solutions Engineering Recycling Glass for the City of Fredericton James Carvell Mohd Zuki Jonah Tremblay ENGG 4025 Multidisciplinary Design Project Client: Mr. Mark Hymers, City of Fredericton Academic Co-Mentors : Dr. Michel Couturier, Mr. Andrew Steeves Industrial Co-Mentor: Mr. Kevin Scott
Clear Solutions Engineering Outline Objective of the project Market review Collection Review Recommended system Description of system Economics Conclusions and recommendations Question period 2
Clear Solutions Engineering Objective Recycle glass Determine economic feasibility Environmentally sound 3
Clear Solutions Engineering Market Review Product Selection Criteria 1. Environmental impact 2. Product value 3. Estimated costs 4. Public acceptance 4
Clear Solutions Engineering Market Review Shipping containers to glass processor near Montreal Aggregate Glassphalt Concrete Glass/recycled concrete mix Abrasive Blasting Grit Abrasive Blasting Beads Reflective Glass Beads $0/tonne $10/tonne $270/tonne $500/tonne $650/tonne 5
Clear Solutions Engineering Recommended System 13,000 tonnes waste per year in Fredericton 4% glass 75% of glass estimated recoverable 10% contaminants 430 tonnes per year collected 240 operating days per year + 10 (stat. holidays) + 10 (shutdown maintenance) 6
Clear Solutions Engineering Recommended System Estimated Input: 430 tonnes per year Product Output: 390 tonnes per year Coarse Crushing Collection Initial Sorting Cleaning Storing & Selling to Market Contaminant Separation Fine Grinding 7
Clear Solutions Engineering System Description 8
Clear Solutions Engineering Part 1: Collection Picked up by the skid steer 9
Clear Solutions Engineering Collection Review 4 potential collection systems: 1) Make use of four recycling depots in Fredericton 2) Install large recycling bins for each neighbourhood 3) Recyclable glass drop-off at FRSWC 4) Add glass to existing box Design a new box just for the glass Rearrange the current curbside box collection program 10
Clear Solutions Engineering Collection Review Chosen method: Designate a new bin for glass (for curbside bin program) Benefits: Better quality control Recover more recyclables Increased citizen participation 11
Clear Solutions Engineering Part 2: Initial Sorting and Coarse Crushing From the tipping floor To the washer To the landfill 12
Clear Solutions Engineering Part 3: Cleaning and Screening From the hammer mill To the magnetic separator To the landfill 13
Clear Solutions Engineering Part 4: Metal Separating, Fine-sizing and Fine-screening From the Trommel screen To the landfill To be stored and bagged 14
Clear Solutions Engineering Part 5: Coarse Crushing, Cleaning, Contaminant Separation From the vibratory screen 15
Clear Solutions Engineering Potential Issues Collection, Processing & Product Health & Safety Sharp edges Respiratory hazard Environmental Inert Social Citizen desire Processing noise/smells Failure mode and effect analysis (FMEA) 16
Clear Solutions Engineering Economics Capital Costs Operating Costs Annual Revenue Sensitivity Analysis Return on Investment Optimization 17
Clear Solutions Engineering Capital Cost - Equipment Equipment Capacity (tph) 0.2 20 0.2 0.2 10 20 0.2 20 0.2 to 7 Various Total Equipment Cost $232,000 Cost $2,200 $7,900 $9,400 $1,500 $100,000 $5,000 $7,500 $31,000 $11,500 $1,200 1 Hammer mill 2 Ball mill 3 Trommel screen 4 Vibratory screen 5 Eddy current separator 6 Magnetic separator 7 Washer 8 Dryer 9 Conveyors 10 Bins 18
Clear Solutions Engineering Capital Cost - Equipment Total Equipment Cost: Delivery Cost: Total Purchased Equipment Cost $232,000 $41,000 $272,000 19
Clear Solutions Engineering Fixed Capital Cost Estimate Total Cost $230,000 Major equipment, total purchase cost (less skid steer and bins) (PCE) Skid steer loader and bins (no factors required) $47,000 Factor 0.50x PCE = 0.20x PC(washer) = 0.10x PCE = 0.10x PCE = 0.18x PCE = 0.05x PCE = 0.00x PCE = 0.00x PCE = Cost Equipment erection Piping (for washer only) Instrumentation Electrical Building Utilities Site development Ancillary buildings Total physical plant cost (PPC) Design and Engineering Contractor's fee Contingency Fixed capital Working Capital Total Fixed Capital $115,000 $3,200 $23,000 $23,000 $40,000 $12,000 $0 $0 $493,000 0.20x PPC = 0.05x PPC = 0.10x PPC = $99,000 $25,000 $49,000 $666,000 $120,000 $786,000 20
Clear Solutions Engineering Operating Costs Utilities & Labour Utilities Electricity ~730 kWh/day Water ~1.3 kilolitres/day Total = $15,000/year $260/year $15,260/year Labour (operators + truck drivers) 10 staff X $15/hour X 2080 hours = $312,000/year 21
Clear Solutions Engineering Operating Costs - Variable Misc. Materials (Diesel, Detergent, etc): $47,000 Utilities: $15,000 $1,700 $63,700 Product Packaging: Variable Cost Total = 22
Clear Solutions Engineering Operating Costs - Fixed $312,000 Fixed Cost Total = Maintenance: $39,000 Operating labour: Supervision: $62,000 $7,800 $16,000 Insurance: Property tax: $436,800 23
Clear Solutions Engineering Operating Costs General - Collection Truck lease Total Annual Production Cost $70,000 $570,000 Cost per 23 kg (50 lb) bag: $30 $1500 $2300 Cost per tonne: Cost per day: 24
Clear Solutions Engineering Annual Revenue Product (390 X $270): $105,000 $29,000 $134,000 ($570,000) ($436,000) Waste tipping fee (390 X $74): Annual Revenue: Annual Operating Costs: Annual Gross Loss 25
Clear Solutions Engineering Return on Investment (ROI) ROI = _____after tax loss_____ = -$436,000 = -56% Total capital investment $776,000 26
Clear Solutions Engineering Sensitivity Analysis Key input change effect on ROI ROI -70% -65% -60% -55% -50% -45% Total Capital Cost Labour Cost Input - 15% Key Input Input + 15% Product Price Fuel Cost Tipping Fee 27
Clear Solutions Engineering Optimization What factor affects the ROI the most? 1. Total capital cost 2. Labour cost How can this factor be changed? 1. Scale up and down 2. Shared collection 28
Clear Solutions Engineering Scale Optimization $8,000,000 40.00% $7,000,000 20.00% 15.00% $6,000,000 0.00% Revenue ($) Operating cost ($) $5,000,000 ROI (%) -20.00% $4,000,000 -40.00% $3,000,000 -60.00% $2,000,000 -80.00% $1,000,000 $0 -100.00% 0 5000 10000 15000 20000 25000 Tonnes per year 29
Clear Solutions Engineering Collection Optimization Shared collection (current blue/grey bin truck) 1. Pro: significant labour savings (+ fuel and lease) 2. Con: cross-contamination risk; custom truck cost Result: 1. ROI: -56% -4% 2. Scale increase to 2000 t/y: ROI 30% 30
Clear Solutions Engineering Conclusion Collection Curbside pickup Processing rate 430 tonnes/year Market Abrasive blasting ($270/tonne, bulk) Economics ROI = -56% 31
Clear Solutions Engineering Recommendations Do not implement this solution Look into reducing the costs of collection Look into increasing the amount of glass collected 32
Clear Solutions Engineering Acknowledgements Mr. Mark Hymers (City of Fredericton) Mr. Brett McCrea and Mr. Andrew McGilligan (FRSWC) Mr. Kevin Scott, Mr. Andrew Steeves, and Dr. Michel Couturier (UNB) Mr. Gilles Boudreau (Gaudreau Environment Inc) Mr. Scott MacDonald (Department of Transportation and Infrastructure) Mr. Mike Walker (City of Fredericton) Dr. Eldo Hildebrand (UNB) Mr. Tony Durling (Martime Case Ltd) Mr. Mitchell Amos (Perfection Paving Ltd) Mr. Darrin Provost (D&L Engineering Sales Ltd) 33
