Gypsum Recycling -The Successful Scandinavian Solution

Henrik Lund-Nielsen, MBAChairman, Gypsum Recycling International A/S

The Successful GypsumScandinavian RecyclingSolution International A/S

No more landfilling!

Instead Gypsum waste should be recycled

Content of Presentation• Why Gypsum in Europe should be recycled ?• The unique recycling system, successfully

implemented in Scandinavia• Lessons from Denmark, from the first full-scale

gypsum recycling programme in Europe• Norwegian and Swedish activities• Consequences for the gypsum industry

The Successful GypsumScandinavian RecyclingSolution International A/S

Why Gypsum in Europe Should be Recycled ?Because • App. 3 mill. tons Gypsum waste are otherwise landfilled in Europe annually. This is neither environmentally nor

politically acceptable • Recycling is the only solution that will preserve natural resources and help prevent shortages of raw materials • Recycling will help the European Gypsum manufacturers to obtain the cheapest raw materials of high quality• Recycling will improve the environmental image of the Gypsum industry• EU Directives 31 and 33 (Apr. 1999 and Dec. 2002) where gypsum waste has been classified as non-inert will

further improve the profitability of recycling gypsum, as the implementation of the directives will lead to higher tipping fees

• Because it can be done, now !

The Successful GypsumScandinavian RecyclingSolution International A/S

The unique recycling system, successfully implemented in Scandinavia

Conclusions:• A recycling unit is not enough • A complete system is needed to be successful:

- Specially developed containers for easy filling and removal - A logistic system capable of assuring an effective collection,

handling and invoicing of the waste owners - A Mobile Recycling Unit to lower transport costs by servicing

more recycling plants, and capable of handling new construction waste as well as demolition waste

- Customers that can benefit directly from the recycled materials

The Successful GypsumScandinavian RecyclingSolution International A/S

The unique recycling system, successfully implemented in Scandinavia1- Containers:• Specially designed by GRI to allow for easy filling and easy removal of the waste/gypsum materials; equipped with lids, the top lid

being hydraulic assisted. Operated from the front or from above • Are sold or leased to the waste owners • The 30 cubic meter containers hold 6-7 tons

The Successful GypsumScandinavian RecyclingSolution International A/S

The unique recycling system, successfully implemented in Scandinavia2- Logistics system: • Containers are at new building, reconstruction and demolition si-tes, at waste transfer stations + municipal waste collection sites etc.• The collected waste/gypsum materials are weighed on the truck, and this information is used to invoice the waste owners; the cost

per ton is a little less than the landfilling cost (tipping fees) • The truck collects and brings the waste to a central warehouse

The Successful GypsumScandinavian RecyclingSolution International A/S

The unique recycling system, successfully implemented in Scandinavia2- Logistic system and the recycling unit: • The recycling unit is mobile and can easily be moved from one warehouse to another, allowing an optimal location of the

warehouses - thus minimising transportation costs. This way one recycling unit can service several warehouses/plants• Dismantling/setting up of the unit can be done in a few hours• The warehouses should be located close to a gypsum board plant

The Successful GypsumScandinavian RecyclingSolution International A/S

The unique recycling system, successfully implemented in Scandinavia3- The recycling unit: • Specially designed and developed by GRI • Based on proprietary technology• Produces recyclable gypsum powder + paper separately. The paper can be

incinerated or used for other purposes• Capacity: almost 100.000 tons p.a. at full capacity utilisation

The Successful GypsumScandinavian RecyclingSolution International A/S

The unique recycling system, successfully implemented in Scandinavia3- The recycling unit - continued: • Driven by own diesel generator• Equipped with two containers at the end, each containing approx. 13 tons • Separates all impurities/foreign objects from the gypsum core• Fully automated with automatic controls and sensors• Dimensions: L*W*H = 24m*3m*4m. Weight 47 tons

The Successful GypsumScandinavian RecyclingSolution International A/S

The unique recycling system, successfully implemented in Scandinavia3- The recycling unit - continued:Capable of handling new construction waste and demolition waste:• Acceptable: - Gypsum waste based on FGD/DSG or natural gypsum raw materials - Virgin gypsum board cut-offs - Gypsum board underlayers/dunnage - Complete boards or broken parts - Gypsum ceilings, floors, walls etc. - The gypsum waste may contain

nails and screws- Wallpaper, glass tissue and other wall coverings on the gypsum boards

• Non-acceptable: - Plastics and foils - Insulation materials (glass wool/stone wool/Rockwool)- Steel rails and bars - Wood - Other impurities

The Successful GypsumScandinavian RecyclingSolution International A/S

The unique recycling system, successfully implemented in Scandinavia4- Customers that can benefit directly from the recycled materials:• The gypsum industry is the best and most natural user of the recycled materials. To deliver

recycled gypsum materials for any other purposethan for making new gypsum products has no sense

• The recycling system guarantees gypsum board manufacturers the recycled gypsum powder at a price/t below the cost of virgin raw materials

• The quality of the supplied powder is guaranteed• No investment required at the gypsum board manufacturing plants to utilise recycled gypsum powder• Up to 25% of raw materials in one batch can be recycled powder

The Successful GypsumScandinavian RecyclingSolution International A/S

Lessons from Denmark, from the first full-scale gypsum recycling programme in Europe• Started in the fall of 2001 with collection activities• 50% of all public waste transfer stations are now covered with GRI

containers and increasing fast• Other main suppliers of gypsum waste include construction and

demolition companies• Presently approx. 30% of all gypsum waste in Denmark is being

recycled by GRI and increasing fast• Danogips (Knauf) and Gyproc (BPB) receive and use the recycled

gypsum powder for production of new virgin boards • Warehouses in Hobro close to Danogips and in Kalundborg close to

Gyproc

The Successful GypsumScandinavian RecyclingSolution International A/S

Proven concept

No impurities

No investments

Professional

Quality

Satisfaction

The Successful GypsumScandinavian RecyclingSolution International A/S

Lessons from Denmark: The customers are very satisfied:

Lessons from Denmark: The volume is increasing fast Collected tons in Denmark: Actual per month Actual/expected per year

feb-

02

may

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Tons permonth

2002 2003e 2004f 2005f

Total tons p.a.

The Successful GypsumScandinavian RecyclingSolution International A/S

Norwegian and Swedish Activities• Based on the principle of multiple plants/ware-houses

serviced by one mobile recycling unit• Warehouses are in the process of being established in

Norway and Sweden• GRI will take the mobile recycling unit to the warehouse

when the collected volume of waste is sufficient• GRI recycle the waste and deliver the recycled gypsum

powder to gypsum board manufacturers • Gyproc/BPB in Scandinavia and Norgips, Norway are

among the customers

The Successful GypsumScandinavian RecyclingSolution International A/S

The unique recycling system, successfully implemented in ScandinaviaSummary: How does the system from GRI differ from what other suppliers can offer?

• It is a complete system with all the necessary elements; containers, logistic system, mobile recycling unit and users that can benefit from the recycled materials

• The recycling unit is very mobile and compact and especially takes up limited space in the height. It hereby supports the concept of multiple small plants to reduce transportation cost

• The recycling unit - is nearly noiseless- leaves virtually no gypsum on the paper

- delivers the paper in a very compact form • The system has proved to work in Europe !

The Successful GypsumScandinavian RecyclingSolution International A/S

The unique recycling system, successfully implemented in ScandinaviaSummary: Consequences for the gypsum industry

• The gypsum industry can leave recycling of gypsum materials to competent people, who are familiar with waste collection and recycling, that has proved as the first industry in Europe that recycling is possible

• There are no costs nor investments required for the industry to have a recycling programme established in their area• The industry will absorb the recycled materials, and by doing so the industry will take advantage of the following:

Improved environmental profile and imageAn additional stable source of high quality materialsRecycled materials at a price below that of virgin materials

• A co-operation with Gypsum Recycling International is a win-win situation for the gypsum industry

The Successful GypsumScandinavian RecyclingSolution International A/S

Gypsum Recycling -The Successful Scandinavian Solution

Thank you for your attention!

Gypsum Recycling International A/S Leopardvej 2 Phone: +45 70 22 17 30 7700 Thisted Fax: +45 97 92 42 62 Denmark www.GipsRecycling.com