Implementing a MRF project: some helpful hints

by Jerry Powell Resource Recycling

A now familiar recycling concept - the materials recovery facility - is undergoing substantial refinement. Already many developers are talking about secondand third-generation materials recovery facilities (MRFs). These new facilities, which process commingled recyclables collected from residents, were the topic of a major symposium recently sponsored by the University of Wisconsin Department of Engineering Professional Development. The panelists at this seminar had many pithy prognostications to offer about how these New Age MRFs will operate. Also in this issue, we offer a directory of MRF operators and equipment vendors. covered space per ton of daily processing capacity (two-shift basis), the space requirement varies among different types of MRFs. Those facilities designed to process less than 100 tons per day of commingled recyclables require about 320 square feet per ton of daily capacity (or about 10,000 to 20,000 square feet in total). The big MRFs - with throughputs over 200 tons per day - require only 153 square feet per ton of daily capacity (or 30,000 to 50,000 square feet). Staffing needs. On average, the perworker productivity at a MRF is 6.8 tons per day. The small facilities of under 100 tons per day have low productivity (3.3 tons per worker day), compared to the large plants of over 200 tons per day with productivity of 10.2 tons per worker day. Much of the differences noted for facility cost and staffing are explained by the level of mechanical sorting in a particular MRF. The smaller MRFs tend to rely more on manual sorting techniques, which require more space and have lower productivity. The larger MRFs are more mechanized, requiring less space and thus less capitalization per ton of capacity and resulting in greater productivity. Location. MRFs are predominantly an East Coast phenomenon. Nearly half the operating or planned MRFs are in the Northeast; many new facilities are coming on-line in the Southeast. Relatively few commingled recyclables sorting plants are or will be located in the West. The mini- and mega-MRF. The data indicate that few medium-sized MRFs (100 to 200 tons per day of capacity) are under construction. The market seems to be heading in two directions, with several large cities or counties building mega-MRFs (over 200 tons per day of capacity) and numerous smaller communities constructing small facilities (under 100 tons per day capacity).

A variety of experts offer recommendations on designing and operating the next generation of materials recovery facilities.

Some numbers
Before we summarize the experience of MRF development in recent years, we will review current data on MRF operations, which reveal many interesting findings. Resource Recycling maintains a database on over 70 commingled recyclables sorting plants. These facilities, located- in 20 states and one Canadian province, are either operating or under construction. Nine of the plants are owned and operated by the sponsoring government, while the others are operated by 26 different private firms. From these data, we can summarize MRF implementation trends in the following manner: Facility cost. A typical MRF is built and equipped at a cost of approximately $22,100 per ton of daily processing capacity, with capacity being figured on a two-shift-per-day basis. Smaller MRFs - under 100 tons per day of capacity cost more than $30,000 per ton. MRFs are also becoming more expensive; the data indicate that the average per-ton cost to bring a MRF on-line is rising. Facility size. Although the typical MRF requires about 177 square feet of

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With aluminum cans representirig 25 percent of aluminum sheet shipments, used cans dominate the available scrap supply.

process is expected to improve the recovery of metal from dross without the need for environmentally troublesome fluxes. It is also speculated that this process can be extended into the melting of UBC and other scrap. If this proves to be the case, this process then has the potential to circumvent the delacquering process and improve metal recovery. Utilize a variable ratio air/oxygen/fuel burner system to increase the melt rate of well-type melters used for the melting of delacquered UBC shreds. RR
For more information, contact Harry Phipps at (919) 597-2370, or fax (919) 597-8633.

The big operators get bigger. With the typical MRF being bid, built and tested in less than 18 months at a cost exceeding $4 million, small private firms find it difficult to compete against bigger MRF operators. At present, six firms operate nearly half of the nations MRFs. These firms are Browning-Ferris Industries, CRlnc., Laidlaw Waste Systems, Resource Recovery Systems, Resource Recycling Technologies and Waste Management. Of these, only RRS has privately held stock. Governmental Advisory Associates has collected more extensive data on MRFs and waste sorting plants. This New York City firm recently issued its second guidebook (see the Information Sources department in this issue). We will be presenting additional MRF data and findings from this report in our May issue. Some rules of thumb
Enough MRFs have now been built or are under construction that some general rules can be identified. The experts offer this advice.

Build it and they will come. Hal McGaughey of CRlnc., one of the leading MRF system vendors, notes that new MRFs tend to hit design capacity very soon after opening. Citizens will participate, he concludes.

Consider both volume and weight.

Kevin Murray is a top consultant with Camp Dresser & McKee. He feels a clear understanding of the volume of materials is needed when designing a MRFs tipping floor and storage area.

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Resource Recycling March 1992

McGaughey concurs: The lack of a sufficiently sized tip floor is the biggest problem Ive seen [in this industry], he says. Murray recommends at least two days storage capacity on the tip floor.

Focus on container lines. Murray believes paper sorting lines will remain fairly typical, while the design of sorting lines for commingled containers will vary more from MRF to MRF, due to differ-

ences in the container mix among communities. Store thy processed materials. With tighter markets and weaker prices for recyclables in recent years, some experts

Strong views of the future

A number of the analysts offer additional comments about the future development and operation of MRFs. Here is a sample. Automatic glass sorting. Automated glass sorting [by color] is just too slow, says Hal McGaughey of CRfnc. Such a system wont be introduced in the U.S. at least until 1993, he predicts. ture MRFs as a way to reduce labor requirements. Lack of uniformity. Rather than moving toward a similarity of facilities, the MRF industry of the mid-90s will incorporate numerous different technologies and ideas, says McGaughey. This isnt a cookie cutter concept, he says. At the same time, the relationship between equipment manufacturer and buyer is changing. CalRecoverys Savage contends that performance guarantees will become more common for MRF equipment purchases.

Interest by OSHA in MRF operations. Wayne Pferdehirt of the University of Wisconsin sees the federal Occupational Safety and Health Administration becoming more interested in MRF operations. According to Pferdehirt, the types of conterns will focus on worker access to sorting platforms, the length of time an employee is required to sort materials and the use of lock-outs or tiedowns on processing equipment.

Shipping of processed materials.

Kevin Murray of Camp Dresser & McKee sees more MRF operators siting facilities along railroad lines to take advantage of improved rail shipping services and rates. Use of air systems. George Savage of CalRecovery, Inc., the consuiting firm, contends that you will see more air classification systems in fu-

New equipment and equipment standards. With the MRF industry

growing, equipment needs and standards are changing. For instance, several speakers at the symposium noted that reliable plastic bag opening equipment is needed if bagged recyclables collection is to become more common. CRlnc.s McGaughey says, We havent found. a good bag opener yet.

Resource Recycllng March 1992

recommend having additional storage capacity for processed materials. Murray feels up to 30 days capacity for processed recyclables is required. Mcconsidering recommends Gaughey spare trailers to store processed materials, particularly if a MRF has little usable storage space and off-site trailer spotting is available, although he does note that MRFs arent really large enough to be able to play the commodities game. Add those docks. McGaughey feels you can never have enough loading docks. Flip thy paper. The experts all agree that newspaper conveyor lines must mechanically flip over the paper so sorters can remove more contaminants.

INTRODUCING -

Carefully consider the role of the mechanic. Murray suggests that highly
mechanized MRF systems require the operator to carefully select and train its mechanics and equipment repair personnel. Several predictions regarding MRF trends are offered as a sidebar.

The realities of ownership

Several analysts now view MRF ownership more as a political question than an economic issue. CDMs Murray contends that the primary reason a local government may desire public ownership of a MRF is one of control. Ron Sundberg, a financial consultant with R.W. Beck and Associates, concurs. The MRF ownership issue is typically not an economic decision, he notes.

Whats all the Plus about?

Safety, safety, safety

The top analysts are uniform in their thinking about one issue, and they sing from the same choir book. Murray of CDM: Pay attention to the worker safety issue. McGaughey of CRlnc.: Worker safety and comfort is becoming much more an issue. Pam Harris, the director of loss control services for Browning-Ferris Industries, has carefully assessed the workplace issues of MRF operations. From her perspective, attention to workplace concerns is not motivated by a desire to avoid federal Occupational Safety and Health Administration citations, but it is about productivity and morale, she concludes. The concern for injury and accident prevention can generate improved morale, which is important when considering the cost of replacing trained, experienced workers. She separates these workplace issues into four categories:
Circle 22 on RR service card

Resource Recycling March 1992

A materials recovery facility in Orange County, Orlando, Florida shows materials being conveyed from the tipping floor to an above-ground sorting platform (1). Conveyors in a materials recovery facility in Denmark move materials in much the same way (2).

Safety. Safety hazards can occur in many areas of a MRF, including those associated with work surfaces, walking surfaces, equipment and overhead hazards, and potential injuries created by poor lighting, excessive noise and extreme temperatures. Harris feels the key safety concern is that there are always problems with putting people in the air. BFls experi- I ence is to carefully design the overhead walkways used by sorting personnel. Health. The five key sources of health problems among MRF workers are vapors; fumes; exposure to liquids; the effect of dusts, such as from metals, wood, paper, glass, dyes and pigments, and dirt; and from biological sources, including bacterial, viral, endotoxin, pollen, insect, fungal, mildew, mold, spore and animal sources. Hazardous waste. Harris sees a growing problem with the receipt at MRFs of small amounts of hazardous materials from residents and small quantity commercial generators. Ergonomic and biomechanical.
Many MRF vendors are becoming more focused on the effect of sorting tasks on the muscular and skeletal system. Harris research shows that the most common injuries are ergonomic in nature and involve shoulders, back and knees. In particular, she urges the elimination of activities that require twisting motions

and to watch for cumulative trauma. Such advice has been heeded by many MRF operators. For instance, CRlncs standard sorting rate is 30 pieces per minute, but the firm tries to rotate workers every two hours. Harris offers a number of safety hints, which are listed in a sidebar. RR