Reliable classification of moving waste materials with LIBS in concrete recycling.

Effective discrimination between different waste materials is of paramount importance for inline quality inspection of recycle concrete aggregates from demolished buildings. The moving targeted materials in the concrete waste stream are wood, PVC, gypsum block, glass, brick, steel rebar, aggregate and cement paste. For each material, up to three different types were considered, while thirty particles of each material were selected. Proposed is a reliable classification methodology based on integration of the LIBS spectral emissions in a fixed time window, starting from the deployment of the laser shot. PLS-DA (multi class) and the hybrid combination PCA-Adaboost (binary class) were investigated as efficient classifiers. In addition, mean centre and auto scaling approaches were compared for both classifiers. Using 72 training spectra and 18 test spectra per material, each averaged by ten shots, only PLS-DA achieved full discrimination, and the mean centre approach made it slightly more robust. Continuing with PLS-DA, the relation between data averaging and convergence to 0.3% average error was investigated using 9-fold cross-validations. Single-shot PLS-DA presented the highest challenge and most desirable methodology, which converged with 59 PC. The degree of success in practical testing will depend on the quality of the training set and the implications of the possibly remaining false positives.

Sensor-based control in eddy current separation of incinerator bottom ash.

A sensor unit was placed online in the particle stream produced by an eddy current separator (ECS) to investigate its functionality in non-ferrous metals recovery. The targeted feed was the 1-6mm size fraction bottom ash from a municipal waste incinerator. The sensor unit was attached to the ECS splitter, where it counted in real-time metal and mineral particles and accurately measured the grade of the stream in the metals product. Influence of segregation (e.g. due to particle size or density) on the metals concentrate were detected and studied using the sensor data collected at different splitter distances. Tests were performed in the laboratory and in a bottom ash processing plant with two different types of ECS and two sources of bottom ash with different moisture content. The measured metal grades matched the manual analyses with errors 0%, 1.5% and 3.1% for moist, dry and very wet feed, respectively. For very wet feed the ECS metals recovery dropped, which was observed from the strongly reduced particle counts and the large changes in cumulative particle properties. The measured sample proved representative for the whole metals concentrate if it is collected at a representative position within the metals particle trajectory fan produced by the ECS. ECS-performance proved sensitively dependent on splitter distance, since a 10mm shift may result in 10% change in metal recovery and 18% change in grade. The main functionalities of the sensor unit are determined as online quality control and facilitation of automatic control over the ECS splitter distance. These functionalities translate in significant improvements in ECS metals recovery which in turn is linked to economic benefits, increased recycling rate of scrap metals and a further reduction of the ecological drawbacks of incinerator bottom ash.

Hybrid sensor for metal grade measurement of a falling stream of solid waste particles.

A hybrid sensor system for accurate detection of the metal grade of a stream of falling solid waste particles is investigated and experimentally verified. The system holds an infrared and an electromagnetic unit around a central tube and counts all the particles and only the metal particles, respectively. The count ratio together with the measured average particle mass ratio (k) of non-metal and metal particles is sufficient for calculation of grade. The performance of the system is accurately verified using synthetic mixtures of sand and metal particles. Towards an application a case study is performed using municipal solid waste incineration bottom ash in size fractions 1-6mm, which presents a major challenge for nonferrous metal recovery. The particle count ratio was inherently accurate for particle feed rates up to 13 per second. The average value and spread of k for bottom ash was determined as 0.49 ± 0.07 and used to calculate grade within 2.4% from the manually analysed grade. At higher feed rates the sensors start missing particles which fall simultaneously through the central tube, but the hybrid system still counted highly repeatable. This allowed for implementation of a count correction ratio to eliminate the stationary error. In combination with averaging in measurement intervals for suppression of stochastic variations the hybrid system regained its accuracy for particle feed rates up to 143 per second. This performance and its special design, intended to render it insensitive to external interference and noise when applied in an eddy current separator, make the hybrid sensor suitable for applications such as quality control and sensor controlled separation.

Ultrasound imaging techniques in density separation of polyolefin waste.

Ultrasound imaging techniques are investigated using a multi-element sensor array for purposes of monitoring and measurement ofpolyolefin waste particles inside the black ferrous liquid ofa magnetic density separator (MDS). A medical ultrasound imaging system with real-time capability was adapted first to assess the potential of imaging technology inside the MDS. An image processing routine was developed to determine the depth distribution of the detected particles as they are carried by the flow in the MDS channel. This real-time information is vital for optimizing the splitter position, which directly influences quality and recovery of the MDS polyolefin products. Despite successes in the laboratory, the medical technology proved unsatisfactory for continuous high-quality image forming in the industrial set-up as it requires regular operator intervention. Therefore, research has been initiated into alternative imaging methods, which are also being investigated in other fields such as non-destructive testing and geophysics. The influence of different ultrasound datasets and related image-forming techniques were investigated, for which dedicated algorithms were implemented in Matlab. The main advantages and disadvantages of the different techniques are addressed. It is concluded that the alternative imaging methods may be more robust and deliver higher image quality compared to the commercial medical imager. In particular, sizing of polyolefin particles may improve significantly if the method takes into account the correct ultrasound velocities of both the ferrous liquid and the immersed polyolefin particles.

Recovery and distribution of incinerated aluminum packaging waste.

A study was performed into relations between physical properties of aluminum packaging waste and the corresponding aluminum scraps in bottom ash from three typical incineration processes. First, Dutch municipal solid waste incineration (MSWI) bottom ash was analyzed for the identifiable beverage can alloy scraps in the +2mm size ranges using chemical detection and X-ray fluorescence. Second, laboratory-scale pot furnace tests were conducted to investigate the relations between aluminum packaging in base household waste and the corresponding metal recovery rates. The representative packaging wastes include beverage cans, foil containers and thin foils. Third, small samples of aluminum packaging waste were incinerated in a high-temperature oven to determine leading factors influencing metal recovery rates. Packaging properties, combustion conditions, presence of magnesium and some specific contaminants commonly found in household waste were investigated independently in the high-temperature oven. In 2007, the bottom ash (+2mm fraction) from the AEB MSWI plant was estimated to be enriched by 0.1 wt.% of aluminum beverage cans scrap. Extrapolating from this number, the recovery potential of all eleven MSWI plants in the Netherlands is estimated at 720 ton of aluminum cans scrap. More than 85 wt.% of this estimate would end up in +6mm size fractions and were amenable for efficient recycling. The pot furnace tests showed that the average recovery rate of metallic aluminum typically decreases from beverage cans (93 wt.%) to foil containers (85 wt.%) to thin foils (77 wt.%). The oven tests showed that in order of decreasing impact the main factors promoting metallic aluminum losses are the packaging type, combustion temperature, residence time and salt contamination. To a lesser degree magnesium as alloying element, smaller packaging size and basic contaminations may also promote losses.