wallboard recycling national recycling presentation
TRANSCRIPT
The Sustainable Materials Management Webinar Series
Gypsum Wallboard Recycling Tuesday October 20, 2015/1:30 – 2:45PM EDT
Presenter: Terry L. Weaver, President, USA Gypsum
Gypsum WallBoard Recycling Evolves
Gypsum History As Fire Proofing StructuresGypsum mortar, (plaster of Paris), was used in the Egyptian pyramids
Earliest Fire Code 1667 French King Louis XIV
ordered all wooden building’s plastered with Gypsum to prevent similar fire
???? Lathe, Horse hair & plaster
1894 Sackett board gypsum with felt backing replacing lathe & plaster
1910 Gypsum wallboard similar to todays product developed
London Fire of 1666
Gypsum Powder Is The Only Natural Substance That Can Be Restored To Its Original Rock-Like State With The Addition Of Water Alone, Formed Into Shape And Hardened.
We All Use Gypsum! Tooth Paste Tofu Beer Vitamins
Gypsum Wallboard Recycling
1985 New West Gypsum Canada
1996-2000 Multiple U.S. start ups
2000 EU “plasterboard” Recycling begins
30 Years!
USA Gypsum 1998 – 4,000 Sq. Ft. 2,000 Tons per Year
Gypsum Wallboard Recycling 2000 -2010
USA Gypsum plant 2000-2015 Tons grow from 2,000 to 25,000
Most U.S. Start Ups Fail
Survivors Develop Agricultural Markets
Canada & EU Grow Policy & Regulation High Disposal “Tip”
Fees = Closed Loop Recycling
Why EU Growth?2002 Landfill
Regulations2013 Recycling
Protocol 14 Companies
& 24? PlantsMost Closed
Loop 2020 Recovery
Goal 70%
Why Recycle? Gypsum Is Problematic In The Waste Stream
Land Fill H2S Odors H2S Contamination
Of Recovered Methane
Sulfate Contaminates Leachate
Incineration Produces Sulfur Dioxide Gas
U.S Policy Impact Clean Air Act Requires SO2 Reductions
Synthetic Gypsum Floods Market 2005-2012
EPA CCR Regulation Review 2008-2014 Less Coal Burned = Less Gypsum Clean Air = Farmers Purchase Sulfur
Clean Water Act “Pollution Diets” TMDL Gypsum Controls Erosion & Sediment Gypsum Prevents Phosphorous From
Dissolving Into Surface Waters Which Create Algae
Chesapeake Bay & Great Lakes Gulf Of Mexico Dead ZonesGypsum Transport
Economic Factors
LEED Increases Recycling (Auditing?)
Recession Survival Wallboard
Production Cement Volume Landfill
Competition A Few Landfill Bans
(Enforcement?)
EPA CCR Resolved Less Synthetic
Gypsum New Mine
Feasibility
Wallboard Recycling Poised For Growth?
New USA Gypsum Drywall Recycle Plant – 100,000 Ton Capacity
Construction RecoveryAgricultural DemandLand Fill Capacity
Growing Markets For Bulk Gypsum Increased Demand - Reduced Supply
From Waste to Resource ManagementNew Wallboard
Portland Cement
Photo Courtesy Of The United States Gypsum Company (USG)
Proven & Growing Agricultural MarketsSoil Amendment Calcium & Sulfate Fertilizer Reduces Phosphorus Run Off
Animal BeddingSoft Dry Material For Comfortable Animals
Dissolved Phosphorous Is The Leading Cause for Algae Growth In Natural Water Bodies
Construction & Demolition Waste in U.S.476.5 Million Tons Annually (2013) 100 Million Tons Of
Easily Recycled Wood, Metal, Cardboard, Shingles & Drywall
35 Million Tons Recycled
Source: CDRA White Paper By University of Florida
How Much U.S. Wallboard Waste?EPA 13 Million Tons (2013)CDRA 6 Million Tons (2013)USA Gypsum Estimate 4
Million 20% of New Construction Board
Difference? Pre Consumer, Demolition & Methodology
EU Waste 2.35 million tons
Why Is 20% Wasted?
How Much Wallboard is Recycled In U.S.?300,000 Tons* (7%) 10? Entities *Source CDRA White Paper By University Of Florida
Reclaimed Gypsum
Post Consumer Drywall Scraps
Gypsum Wallboard Recovery Challenges Education: Throw Away
Mentality Co Mingling Waste Reduces
Recovery Rate & Quality Single Stream Recovery
Loss Urban Volume vs. Logistics Rural Logistics vs. Volume
Single Stream Requires Manual “Presort”
New England Recycling, Taunton, MA
Pre Sort Is Being Done SuccessfullyNew England Recycling, Taunton, MA
Mechanical Handling Crushes Wallboard
Grapples Pick Up Material
Pre Grind ? Screening
Removes Fines (Dirt & Wallboard)
Fines Mostly Land Filled As Alternative Daily Cover (ADC) 20-30% of volume
Is ADC Recycling? Photo of Broad Run Recycling Courtesy Frasierphoto.com
Small % Wallboard Recovered on Sort Lines
LEED Version 4 Encourages Transparency And Source Separation?
V4 Challenges “Sham” Recycle
No ADC (20-30%) of Legitimate Single Stream Recycling
1 point 50% Recycling Rate 2 points For 75% or
2.5lbs Waste Per Sq. Ft. (Possible Without Wallboard?)
Pilot Program Point: Single Stream Facilities Approved & Audited By A Certified Independent 3rd party
C&D Waste Transferred to Rail Skirts Regulations & Challenges Recyclers
Rural – Space vs. Volume & Distance
Urban Volume vs. Logistics
Source Separation Logistics
Space for Multiple Dumpsters
Source Separating Urban Challenges
Packer Trucks Crush Wallboard To Powder
Source Separating Urban ChallengesStaging Space Freight Elevators
New York City Generates 300,000* ton Year *Source Building Product Ecosystems
Multiple Attempts to Recycle – Limited Success
Policy efforts since 2003 Audit Recycling Rates Durst Initiates Building
Product Ecosystems Evolving Wallboard
Systems Work Group Established
Partnership Between Academia And Industry Stakeholders
One World Trade Center
Source Separated Closed Loop Pilot Project
Initiated by the Durst Group to optimize the health and transparency of construction product ecosystems through material research and innovation, process improvements, policy/code evolution, and accessible education.
Pilot ProjectStakeholders Collaboration
7 Million Sq. Ft. Wallboard Purchased3 Million lbs. (1,500 Ton) Scrap Estimated273 Dumpsters Columbia University VIA 57 West 32 Story
700 residences + Retail Hudson Yards 47 story
mixed use (Coach Inc) 855 6th Ave 42 story
mixed use (Nike) Google 111 8th Ave
Rendering of VIA 57 West
Source Separated - Creative Solutions
Scrap Carts Staged
Elevators To Dumpster
Lend Lease Manages Congestion on 57th St
Creative Solutions
Dumpsters Accumulated & Transferred By Recycling / Processing Facility Clean Wallboard Load
Cardella Pilot Project Group Tour
Wallboard Transferred To Trailers For Efficient Transport To USA Gypsum Processing
Pilot Project Group Tour USA Gypsum
Reclaimed Gypsum Delivered To
Reclaimed Gypsum is Blended With Other Sources
Process Quality is Successful
Closed Loop CompletePilot Project Group Tour of USG
Research Objective: Develop A Standardized Protocol For Gypsum Wallboard Waste
50+ Samples Tested: Chemical Characterization Continues
Median Metals Levels Did Not Exceed Established Limits
EU Has Protocol PAS 109 Chemical and Physical Spec BMP’s For Collection &
Processing
“GYPSUM WALLBOARD CLOSED-LOOP RECYCLING IN AN ERA OF INCREASED CHEMICAL TRANSPARENCY” Will Be Presented At Greenbuild International Conference & Expo, Washington, DC November 18-20
Closed Loop Conclusion Change Is Hard It Can Be Done: Education
Policy & Collaboration Transparency &
Accountability The Challenge:
Price: When Will The Gypsum Market Support Closed Loop?
Volume: Will It Become A Standard Operating Procedure? (SOP)
USG Wallboard WarehousePilot Project Group Tour of
