PROJECT DESCRIPTION
BACKGROUND
Glassmakers generally have to demolish and rebuild their kilns every five to eight years. This activity alone produces more than a quarter of the 250 000 tonnes of refractory waste created every year in Europe. Apart from some of this, which contains chromium, the refractory waste in itself does not pose a threat to the environment. The problem arises when it is contaminated with certain heavy metals, such as lead, which are used in the manufacture of special glasses, or by deposits left behind by the fuels used. Valoref's LIFE project aims to double the waste recycling rate by developing a specialised and comprehensive procedure incorporating the rationalisation of sorting methods of and better characterisation of the sorting residues.
OBJECTIVES
The project set up a complete, specialised process for the management and recycling of scrap refractories produced during the demolition of glass furnaces. The installations facilitated the comprehensive treatment of 20.000 tons/year of refractory waste and permitted a doubling of the recycling capacity. The project provides an economically viable, technologically reliable and ecologically sound solution to the treatment of refractory waste. The project includes the industrial validation of special processes and know-how on site at VALOREF, in the industrial area of La Croisière and the start of a specialised installations on the river port of Bollène. The pilot plant's capacity at the river plant is 20.000 tons/year. The treatment comprises the following stages: selective demolition of the furnace, transportation of the waste material by river boats or railway wagons, check in and analyses of waste material, sorting by category and destination, crushing and grinding, cleaning of some refractories, control and packing of secondary raw materials for recycling, and treatment and management of non recyclable materials before evacuation. The project guarantees the comprehensive treatment of refractory waste: 50% will be recycled as secondary raw materials, 40% as gravels and 10% will be eliminated on special disposal areas.
RESULTS
The equipment produced at the new site at Bollène river port permits optimised management of the waste. Fifty per cent of the waste treated is recovered in the form of secondary raw materials and 40% as granulate. Only 10% goes to a final storage centre. Certain waste (siliceous refractories, waste containing chromium, electro-cast refractories of the AZS type, etc..) will from now on be completely recycled. The average cost of treatment is FRF 325 per tonne, treated ex waste production site. Taking into account the development of European and French legislation, this treatment cost, coupled with efforts to recover recycled materials, makes it possible to achieve a reasonable level of profitability for products which on the face of it have low intrinsic value. The closeness of the industrial site, and the existance of the river link, favours the transport of the waste by barge, which is less polluting (62.50% of the waste is being brought by this means). The mobile sorting line will reduce the amount of waste transported because a large proportion of it (mainly granulates) can be treated and recovered in the kiln demolition zones. The project has made it possible to create around 10 new jobs and considerably improve working conditions. The methods and techniques employed have already allowed Valoref to apply this methodology to other industrial sectors using kilns, such as steelmaking and metallurgy, and in other geographical areas. A follow-up ex-post evaluation, carried out by the LIFE external monitoring team in August 2004, showed the following results: By the end of 1999, the beneficiary was treating 18,000 tonnes of waste, which was slightly below the initial target. However, by the end of 2003, 20,500 tonnes were being successfully treated. This means the initial target was successfully achieved within three years of the close of the project. The beneficiary also reported a recovery rate of 65%, depending on the type of waste. The equipment produced at the new site at Bollène river port permits optimised management of the waste. Fifty per cent of the waste treated is recovered in the form of secondary raw materials and 40% as granulate. Only 10% goes to a final storage centre. Certain waste (siliceous refractories, waste containing chromium, electro-cast refractories of the AZS type, etc..) will from now on be completely recycled. The average cost of treatment is FRF 325 per tonne, treated ex waste production site. Taking into account the development of European and French legislation, this treatment cost, coupled with efforts to recover recycled materials, makes it possible to achieve a reasonable level of profitability for products which on the face of it have low intrinsic value. The closeness of the industrial site, and the existance of the river link, favours the transport of the waste by barge, which is less polluting (62.50% of the waste is being brought by this means). The mobile sorting line will reduce the amount of waste transported because a large proportion of it (mainly granulates) can be treated and recovered in the kiln demolition zones. The project has made it possible to create around 10 new jobs and considerably improve working conditions. The methods and techniques employed have already allowed Valoref to apply this methodology to other industrial sectors using kilns, such as steelmaking and metallurgy, and in other geographical areas. A follow-up ex-post evaluation, carried out by the LIFE external monitoring team in August 2004, showed the following results: By the end of 1999, the beneficiary was treating 18,000 tonnes of waste, which was slightly below the initial target. However, by the end of 2003, 20,500 tonnes were being successfully treated. This means the initial target was successfully achieved within three years of the close of the project. The beneficiary also reported a recovery rate of 65%, depending on the type of waste.
