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Journal of Air and Waste Management Association (in press)
RECYCLING IN A MEGACITY
Nickolas J. Themelis and Claire E. Todd
Earth Engineering Center, Columbia University
New York, NY 10027
(Corresponding author: [email protected])
ABSTRACT
In the aftermath of the 9/11 disaster, Mayor Bloomberg of New York City
unveiled an aggressive budget plan that included the temporary suspension of glass and
plastics recycling. This was considered by many to be anti-environmental but the results
of this study show that for lack of markets, even at zero or negative prices, nearly 90% of
the plastic and glass set aside by thoughtful New Yorkers, was transported to Materials
Recovery Facilities (MRF) and from there to landfills. Sending bales of plastics to
landfills is not limited to New York City. It is an environmental paradox that the U.S. is
digging up new oil fields in pristine areas and, at the same time, keeps converting
greenfields to brownfields by burying nearly 20 million tons of plastic fuel annually. The
study also determined that at the present rate of source separation, estimated to be less
that 30% of the available recyclables in 1999, building large, modern MRFs may increase
substantially the rate of NYC recycling and also allow single-stream collection of
commingled recyclables, as is done in Phoenix, Arizona. Single-stream collection
simplifies separation at the source by citizens and increases the amount of collected
recyclables. Also, since collection represents a large fraction of the costs of waste
management, it may have a significant economic advantage.
Implications of paper for law makers and policy makers There is much pressure on lawmakers to impose prescribed rates of recycling. This study showed that after sorting of the “recyclables” set aside by New Yorkers in Materials
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Recovery Facilities (MRF), most of the paper and metals were recycled, while most of the glass and plastics were landfilled, for lack of markets. Recycling would be increased somewhat by improved collection (e.g., less glass breakage) and modern MRFs but the main factors are greater citizen participation and, for glass and plastics, markets for the sorted materials. For example, less that 10% of the 25 million tons of plastic wastes generated in the U.S are recycled into plastics.
INTRODUCTION
Until the summer of 2002, New York City’s Department of Sanitation (NYC
DOS) collected three types of wastes from NYC residents: Paper, metal-glass-plastic
(MGP), and mixed putrescible wastes (“black bag”). The first two streams went either to
sorting Materials Recovery Facilities (MRFs) that separated the waste into different
materials or to paper recyclers, like Visy Paper on Staten Island. The “black bag” stream
went to transfer stations and from there was shipped in 20-ton trucks, mostly to landfills
in other states. The disposition of the MSW collected by NYC-DOS is shown in Figure 1.
A 2001 study by the Earth Engineering Center of Columbia University (Todd
2002) examined in detail the fate of NYC MSW after it reached the MRFs. The objective
was to determine the effectiveness and cost of these operations and examine whether the
implementation of automated, state-of-the-art MRFs, such as have been built in cities like
Chicago and Phoenix, might help in increasing the rate of recycling. All tonnages in this
report are in short tons (1.1 short ton = 1 metric ton).
16.6%
12.4%
71.0%
RecyclingWaste-to-energyLandfilling
Figure 1. Disposition of the MSW collected by NYC-DOS in 2000
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THE NEW YORK RECYCLING PROGRAM
New York and many other cities in the late 1980’s responded to decreasing local
landfill capacity and to public opinion by launching municipal recycling programs. As
part of this effort, some municipalities established publicly-owned materials recovery
facilities (MRFs) to sort the recyclable materials that citizens put aside from the rest of
the municipal solid waste (MSW). While some material recovery technology such as
magnetic separation is common to all of these facilities, MRFs range all the way from
manual sorting to highly automated facilities. In 1999, NYC-DOS collected 394,000 tons
of paper (“paper stream”, Todd 2002) and 278,000 tons of commingled metal-glass-
plastic materials (“MGP stream”, Todd 2002). In addition, NYS-DOS diverted from
landfills another 838,000 tons of “other” wastes, such as construction and demolition
materials. In addition to the nearly 5.4 million tons of materials managed by NYC-DOS,
hundreds of private carters took care of nearly ten million tons of “commercial” wastes
of businesses and institutions (NYC Comprehensive Commercial Waste Study-
Preliminary Report, June 2002). This paper addresses only “paper” and the “MGP”
streams collected by NYC-DOS.
Paper Recycling
Although the NYC formal recycling program began in the 1990s, the paper
recycling industry has been established in the City for over three decades. Despite
currently depressed markets, New York City’s paper recyclers maintain very steady and
saleable recoveries, relying on international and domestic paper markets to absorb the
recovered material. In 1999, the city had contracted five recycling facilities to process
municipal paper recyclables. Four of these companies sorted and baled the paper stream
to marketable grades. The fifth company, Visy Paper, is a paper mill with an on-site
pulper and paper machine that processes about 350,000 tons per year of used corrugated
cardboard (OCC) and mixed paper to cardboard-grade paper; 160,000 tons of the Visy
Paper feedstock is provided by NYC-DOS and the rest by “commercial” sources.
Newspaper grades range from #6 to #8, with higher numbers indicating a greater
percentage of newspaper content. In January 2002, the Official Board Markets were
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reporting the following prices in the New York region: $20-25/ton of mixed paper, $35-
40/ton of OCC, and $25-30/ton and $40-45/ton of #6 and #8 news, respectively. When
the recycled paper is pulped, there is a residue, containing mostly plastic films, that
ranges from 10-20% of the feed material. News and cardboard represent most of the
material recovered and sold by New York City paper recyclers. The average recovery at
the NYC paper stream MRFs is estimated at 10%. Accordingly, the tonnage of recovered
paper in 1999 is estimated at 394,000*.90 = 354,600 tons.
The Metal-Glass-Plastic (MGP) Stream
At the beginning of 2002, the city was paying a fee ranging from $45-65 per ton
of MPG to the processing MRFs. They were responsible for selling the products and
disposing their residues to landfills. Of the four recycling facilities processing the DOS-
collected MGP, three provided on-site tours and interviews during the EEC study.
Together, they represented 69% of the MGP stream of NYC.Most of the glass fraction of
the DOS-collected stream was mixed broken glass mixed up with a small amount of dirt
and small pieces of metal and plastic. However, a simple wash at the laboratory produced
a nearly pure mixture of broken glass of different colors. Our study showed that most of
the mixed broken glass is sent to landfills to be used as “daily cover” (at a tipping fee of
about $10/ton less than landfilled MSW); some is pulverized for use either as aggregate
substitute (e.g., road fill) or as landfill cover.
MGP Material Recovery Facilities
The operation of Plant A is similar to all three MRFs visited. It is located in the
Bronx and was built in 1988. Labor needs fluctuate seasonally since waste flow generally
increases during the summer, requiring a larger staff to process the material. Plant A
operates around the clock five days a week and twenty hours on Saturdays. Shifts are
eight hours long and employ about 40 workers. The plant receives 1100-1300 tons per
week of DOS-collected MGP. It also bales 200 tons per week of used cardboard from
commercial carters.
The processing of DOS commingled material consists of
1) Tipping: After weighing in, trucks deposit waste on the tipping floor.
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2) Pre-processing: 5-7 workers open the blue bags that contain MGP and screen the waste
for non-recyclable, bulky items.
3) An inclined conveyor belt lifts the waste to a horizontal sorting belt.
4) 7 workers remove additional blue bags, plastic bags, and all other non-recyclable
items. These materials are dropped down a chute for baling..
5) Glass separation: 2 workers positively sort green glass, dropping glass down a chute
into a bin.
6) 2 workers positively sort clear glass into a chute for collection.
7) 2 workers positively sort amber and brown glass into a chute for collection.
8) Screening of fines: Waste is conveyed over a vibrating screen and then through a
rotating trommel screen that separates small particles, mostly broken glass.
9) Separation of ferrous metals: Material is passed under a magnetic separator which
removes metal, primarily steel cans, into a bin for baling.
10) Separation of plastics: What remains of the stream, plastics and backend residue, is
conveyed to a third conveyor belt.
11) 2 workers positively sort colored high density polyethylene (HDPE1) into a bin.
12) 2 workers positively sort natural-colored or clear high density polyethylene
(HDPE2) into a bin.
13) 2 workers positively sort polyethylene terephthalate (PET) into a bin.When markets
are strong, workers also sort out PVC and polypropylene items into smaller bins.
14) The remaining residue (mostly plastic bags and other non-recyclable plastics) is
deposited in a bin for baling. Bales are approximately 3 feet x 5 feet x 6 feet and
weigh about 1400 lbs. each.
The plant residue consists of mixed broken glass and dirt particles separated by
the trommel, bales of non-recyclable plastic film, and large plastic and wood objects. The
residues are transported by 20-ton trucks to landfills in Ohio, Pennsylvania, and West
Virginia. Metal goods are hauled to local scrap metal recyclers. The marketable plastic
materials are baled and transported to plastic recycling plants, where the plastic is melted
down and pelletized for use in production of clothing, plastic containers and other goods.
The operation of Plant B is very similar to that of Plant A.
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Plant C is operated by a nationwide waste management company and serves as a
transfer station for both DOS and commercial waste and also processes DOS-collected
MGP. The plant is in operation six days a week and the total work force consists of forty
five people working ten-hour shifts. It uses similar equipment to Plant A but is equipped
with an eddy current separator for separating aluminum from steel objects. A hammer
mill is used to pulverize the mixed broken glass stream so it can be used either as an
alternate grading material or daily cover in landfills (in place of soil).
The distribution of the products and by-products of the three plants visited are
shown in Table 1 and are summed up in Table 2. Collectively, these plants processed
nearly two thirds of the total MGP stream of NYC (278,000 tons per year).
Table 1. Products and residues of MRFs A-C that process the NYC MGP stream
Plant A Plant B Plant C
Material Tons/year % of input Tons/year % of feed Tons/year % of feed
Clear HDPE 920 1.60% 299 1.62% 1960 1.69%
Colored HDPE 920 1.60% 325 1.76% 1610 1.39%
PET 920 1.60% 292 1.58% 2130 1.84%
Other plastics 1,900 3.30% 7 0.04% 0.00%
Aluminum 580 1.01% 177 0.96% 1370 1.18%
Steel cans 3,800 6.59% 1440 7.80% 10940 9.44%
Steel misc. 14,400 24.99% 3290 17.81% 16130 13.91%
Color-sorted glass 4,780 8.30% 720 3.90% 0.00%
Total recycled 28,220 48.98% 6,550 35.46% 34,140 29.45%
Mixed broken glass 14,400 24.99% 9580 51.87% 45620 39.35%
Plastic film and other
residue
15,000 26.03% 2340 12.67% 36170 31.20%
Total landfilled 29,400 51.02% 11,920 64.54% 81,790 70.55%
Total processed 57620 100.00% 18470 100.00% 115930 100.00%
Fraction of total NYC
MGP stream (278,000
tons/y)
20.6%
6.6%
41.4%
Table 2. Summary of materials recovered in Plants A, B,C
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Material Tons/year % of total
Clear HDPE 3179 1.7%
Colored HDPE 2855 1.5%
PET 3342 1.7%
Other plastics 1907 0.99%
All plastics: 11,283 5.9%
Aluminum 2127 1.1%
Steel cans 16,180 8.4%
Iron and steel objects 33,820 17.6%
All iron and steel 50,000 26.0%
Color-sorted glass 5500 2.9%
Total recycled materials 68,911 35.9%
Mixed broken glass residue 69,600 36.3%
Plastic film and bulky items residue 53,510 27.9%
Total residues 123,110 64.1%
Total processed 192,020 100.0%
On the basis of published information on the constitution of the NYC MSW (Life
Fresh Kills 2002) and the recycling data of Table 2, it is possible to make a rough
estimate of the percent recovery of each recyclable material in the three MRFs examined.
Table 3 shows that the highest recovery was for ferrous metals (84.5%) followed by
aluminum (23.0%), plastics (12.3%), and glass (10.7%).
Table 3. Estimated % recovery of MGP recyclables at MRFs A+B+C of NYC
Component Distribution
in MSW*
Corresponding
Distribution
in MGP**
Tons MGP
delivered to
MRFs**
Tons actually
recycled
by MRFs
% recovery of
recyclables
Plastics 8.9% 47.6% 91,389 11,283 12.3%
Ferrous metals 3.9% 20.9% 40,047 33,820 84.5%
Aluminum 0.9% 4.8% 9242 2127 23.0%
Glass 5.0% 26.7% 51,342 5500 10.7%
Total 18.7% 100.0% 192,020 52,730 27.5%
*“After Fresh Kills” Report to NYC DOS ; ** assuming that MGP delivered to
Plants A-C has same distribution as NYC MSW
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Applying the 27.5% overall recovery rate of plants A,B, C to the entire tonnage of
MGP stream collected by NYC-DOS results in 278,000*.275= 76,450 tons of actually
recycled materials. Thus, the total of MGP and papermaterials recovered in 1999 is
estimated to 431,050 tons.
CURRENT RECYCLING IN NEW YORK CITY
In the aftermath of the 9/11 disaster, Mayor Michael Bloomberg unveiled an
aggressive budget plan designed to close a near-future budget gap estimated at billions of
dollars. The temporary suspension of part of the MGP recycling program (glass and
plastics) was one of the proposed cost-cutting measures. In February 2002, the Mayor
stated that of the two recycling streams, paper “worked” and MGP did not. The data
presented in this paper document the reasons: Only 12% of the plastics and 11% of the
glass collected by the City at considerable cost (including the use of non-renewable fuel),
were actually recycled. Most of the plastic residue was baled and sent to landfills so both
its material and energy values were effectively wasted. The glass residue consisting of
broken mixed glass had no market value or it would not end up in landfills. Yet the
temporary suspension of glass and plastic collection was derided as “anti-environmental”.
Since its inception, the curbside recycling efforts of the Department of
Sanitation’s have been the subject of intense scrutiny. Although the size and density of
New York represent an enormous waste management challenge, DOS has developed a
collection infrastructure and awareness of recycling in all of its residential communities
through innovative public education efforts and some research initiatives (e.g.
composting). However, the success of any recycling system depends on public response
(to actually set apart recyclable materials) and markets for recyclable products that are
beyond the jurisdiction of municipalities, no matter how large they may be. For example,
the estimated (Life After Fresh Kills 2002, Table B-5) total of potentially recyclable paper
in the DOS-collected MSW (4.5 million tons total) is about 1.5 million tons. Yet, the
amount of paper that was set aside by New Yorkers for collection by DOS amounted to
only 0.39 million tons, i.e. 26% of the maximum available in the MSW. Also, as shown
in Table 3, for lack of markets, only 27.5% of the materials in the MGP collected by the
city were actually recycled. Obviously, there is a long way to attaining the 100%
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recycling rates expected by some, even for recyclable materials, let alone the fact that
some materials like disposable diapers are not recyclable by any stretch of imagination.
POSSIBILITIES FOR INCREASING RECYCLING RATES
Sending bales of plastics to landfills is not limited to New York City. EPA reports
that only 5.4% of the plastics generated in the U.S. were recycled in 2000 (Municipal
Solid Waste in the U.S.: 2000 Facts and Figures (www.epa.gov). It is an environmental
paradox that the U.S. is digging up new oil fields and coal mines in pristine areas and, at
the same time, converts greenfields to brownfields also greenfields by burying nearly 20
million tons of fuel in the form of plastics. It is regrettable that the environmental
organizations that rightly oppose opening oil exploration in Alaska are not taking any
interest in the vast new deposits of combustible and putrescible materials spreading over
the land.
With respect to glass, an obvious response to the low NYC recovery is to avoid
breakage on route between kitchens and MRFs. This will require modifying the present
collection system so that bottles are not crushed during handling of the “blue” bags or by
compaction of the waste in the DOS trucks. By itself, this will increase the cost of
collection since it depends on the volume of material collected. However, the collection
cost may be decreased by changing from the NYC two-stream of recyclables (“paper”
and “MGP”) to a single combined stream of all recyclables. This single stream would
then be sent to new, automated MRFs that separate marketable materials from non-
recyclable residues.
Such a system is partially used by the City of Phoenix, Arizona. It consists of
collecting two streams, the “black bag” waste that, unfortunately, in Arizona goes to
landfills and a “recyclable” stream (equivalent to the NYC combined paper and MGP
streams) that goes to two modern MRFs. Single-stream MRFs have been in use since the
late 1980’s, with facilities currently also operating in Los Angeles, Seattle, and Palm
Beach, amongst other cities (Todd 2002). The simplicity and lower cost of collecting one
stream of recyclables appeals both to citizens and municipalities, for different reasons.
The 27th Avenue MRF of Phoenix, AZ
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Figure 1 shows the flowsheet of one of the two single-stream MRFs of Phoenix,
AZ. This facility was designed by the McGuire Group in collaboration with Resource
Recovery Technologies (RRT) of Melville, New York. The total capital cost was eight
million dollars in 1999 (Phoenix Public Works Department). It has a capacity of 100,000
tons per day and is based on recovery technology common to other modern single-stream
MRFs in the U.S. (Biddle 1998). The capital cost of this MRF amounted to about $80 per
annual ton capacity ($30,000 tons per daily ton capacity). A third facility is scheduled for
completion in 2005.
Figure 2. Schematic of single-stream materials recovery facility in Phoenix
As shown in Figure 2, the sorting of waste starts on the tipping floor where
bulky, non-recyclable items and scrap metal are removed. The remainder of the stream is
then loaded onto an inclined conveyor belt by means of grapples and front-loaders.
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Workers then further screen the conveyed material for bulky items unsuitable for the
automated separation equipment. The first automated device is the primary screening
machine which sifts out small particles such as dirt and broken glass using vibrating
horizontal screens.
The oversize material passes over the screens and is deposited at the top of an
inclined sorting “table”. The table surface consists of a number of conveyor belts that
move in a horizontal direction. As the materials move down the inclined table, the paper
materials tend to “stick” on the conveyor belts, are conveyed across the incline, and are
discharged off to one side of the table and onto conveyor belts below it. Metal, glass, and
plastic containers, and other objects tend to roll down the surface of the inclined “table”,
and fall onto a conveyor belt disposed underneath the base of the sorting table. This
stream is first conveyed past a magnetic separator that collects the ferrous objects. The
remaining objects are conveyed through an inclined conveyor belt where the heavy glass
containers roll through a rotating curtain of heavy chain while the lighter plastic and
aluminum containers continue to move on the conveyor belt. The glass containers are
then separated manually to sort the glass stream into flint, amber, and green glass. The
plastics-aluminum stream is sent through an eddy current separator to recover aluminum
and then the plastic containers are sorted manually.
The paper stream resulting from the inclined sorting table is also subjected to
magnetic separation to recover any ferrous materials. Workers then manually sort the
remaining material into newspaper, telephone books, cardboard, mixed paper, and high-
grade paper streams. Using this technology described above, the city of Phoenix diverted
82,236, i.e. 76.9% of the collected recyclables. This material represented 14.3% of the
573,834 tons of MSW collected by Phoenix in 2001. Table 4 shows the tonnages of
“theoretically available” recyclables in the total MSW stream of Phoenix, the combined
tonnage of source-separated recyclables, the tonnages actually recycled at the MRFs and
the capture rate of each material.
Table 4. Performance of Phoenix MRFs
Materials Estimated
tons in MSW
As % of total
MSW
Total
collected
recyclables,
Actually
recycled,
tons
Actually
recycled as
% of total
Recycled
material as %
of collected
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tons collected recyclables
Paper 218,631 38.10% 70,906 66.29% 86.22%
Metal 44,759 7.80% 3407 3.19% 4.14%
Glass 31,561 5.50% 3198 2.99% 3.89%
Plastic 60,253 10.50% 4725 4.42% 5.75%
Targeted
materials
355,204
61.90%
106,970
82,236
76.88%
100.00%
All other
materials
218,630 38.10%
Total MSW 573,834 100%
Landfilled: 491,598 85.7%
Table 5 compares the performance of the NYC and Phoenix recycling programs.
It can be seen that the current collection efficiency of NYC is 16.6% vs 18.6% for
Phoenix. However, assuming that collection of recyclables in Phoenix can increase by
50%, when the third MRF is started in 2005 the Phoenix overall recycling efficiency will
increase to 27%. The NYC MRF recovery efficiency (2000) was 69.8% vs 76.9% for
Phoenix. The tons of recycled materials were nearly the same at about 0.06 tons per
person. The one advantage of NYC is that it sends 550,000 tons of MSW per year to
waste-to-energy plants that generate electricity. This resulted in 77.9% of the NYC MSW
being landfilled vs 85.7% of the Phoenix MSW.
Table 5. Comparison of Phoenix (2001) and NYC (1999) MRFs
NYC Phoenix
Population (2000) 8,008,000 1,321,000
Collected residential MSW, tons 4,525,000 573.834
Collected Paper + MGP, tons 672,000 106,970
Collected Paper+MGP, as % of total MSW 14.9% 18.6%
Actually recycled Paper+MGP, tons 431,050 82,236
Actually recycled Paper+MGP, as % of total MSW 9.5% 14.3%
Actually recycled Paper+MGP, as % of Paper+MGP to MRFs 64.1% 76.9%
Tons of MSW to Waste-to-Energy 550,000 0
Recyclables recovered, tons per capita 0.05 0.06
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MSW to Waste-to-Energy, tons per capita 0.12 0
Conclusions
The results of the Todd study (1) showed that despite an apparent all-out effort by
DOS to collect paper and MPG, less than one third of the generated materials were
actually source-separated by the citizens; the rest never reached the MRFs or recycling
plants. Also, for lack of markets, even at zero or negative prices, nearly 90% of the
plastic and glass that was collected by DOS in the MGP stream, at a considerable cost to
the City, ended up in landfills.
Another interesting finding was that building large, modern MRFs such as the
ones in Phoenix, may increase the 1999 rate of NYC recycling by as much as 50%.
Commingled collection of recyclable materials, as is done in Phoenix, AZ, will reduce
the present number of recyclable collections from two to one and, properly implemented,
will reduce glass breakage. Since collection represents the largest fraction of recycling
costs, this should have a significant impact on overall program costs. Single-source
collection of recyclables also simplifies separation at the source, thus increasing the
amount of collected recyclables. Also, investing in a few well-designed MRFs will
provide better jobs and will improve the neighborhoods where small and antiquated
MRFs are located.
New York’s Department of Sanitation explored the possibility of building city-
owned Materials Recovery Facilities (MRFs) in the early 1990s (Dubanowitz 2000) but
the plans were halted by opposition from private recyclers as well as by lack of political
support. The overwhelmingly negative reaction to Mayor Bloomberg’s suspension of
glass and plastic recycling suggests that perhaps now there is sufficient motivation and
public support to address and improve the NYC recycling program.
References: TO EDITOR, REFERENCES BELOW WILL BE COMPLEMENTED
WITH REFERENCES NOTED THROUGHOUT THE TEXT
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Questionnaire (Carl Smith of the City of Phoenix Dept. of Public Works), 2001.
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City Office of Management and Budget: Feb.13, 2002.
http://nyc.gov/html/om/html/2002a/budget_2003.html
City of Chicago Department of Environment, Blue Bag Recycling Program Results,
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http://www.nyc.gov/html/dos/html/bw_what/index.html.
Recyclers World. RecycleNet Waste Paper Index – Online Market Prices, May 15,
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