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Recycling Gypsum Wallboard
- 1. Evolving Wallboard Recycling Closed Loop Pilot Project Presented by: Amanda Kaminsky, Founding Partner, Building Product Ecosystems Terry L. Weaver, President, USA Gypsum
- 2. Gypsum Wallboard Recycling 1996 U.S. start ups Close loop Fail. “upcycling”required 20 Years! USA Gypsum 1998 – 4,000 Sq. Ft. 2,000 Tons per Year
- 3. U.S Policy Impact Clean Air Act Requires SO2 Reductions Synthetic Gypsum Floods Market 2005-2012 Recession Shrinks Demand Cheap Natural Gas More Air Regulations Less Coal Burned = Less Gypsum Clean Air = Farmers Purchase Sulfur Gypsum Transport
- 4. Photo Courtesy Of The United States Gypsum Company (USG) 0 2,000,000 4,000,000 6,000,000 8,000,000 10,000,000 12,000,000 14,000,000 16,000,000 18,000,000 20,000,000 Scraps Agriculture Cement Wallboard Increased Demand - Reduced Supply From A Waste to Resource
- 5. Single Stream Requires Manual “Presort” New England Recycling, Taunton, MA
- 6. Pre Sort Is Being Done Successfully New England Recycling, Taunton, MA
- 7. Gypsum Market Owner Driven Changes Educating construction industry Changes in Waste Management Recycling Growth Barriers? Mining A Resource From Construction Waste New USA Gypsum Drywall Recycle Plant – 100,000 Ton Capacity
- 8. New York City Generates 165,000* ton Year *Source NYS DEC, 2010 Multiple Attempts to Recycle – Limited Success Policy efforts since 2003 Audit Recycling Rates Durst Initiates Building Product Ecosystems Evolving Wallboard Systems Work Group Established One World Trade Center One Bryant Park
- 10. Driver: Transparent Lifecycle + Content Accountability
- 11. Driver: Drywall Numbers in the U.S. ~9 million tons drywall waste generated/year ~400,000 tons recycled/year Millions of tons being landfilled each year
- 12. Driver: Availability of Synthetic Gypsum/Coal Byproduct
- 13. Driver: Comingled Packer Truck Loads = Mixed Fines
- 14. NYC BPE Evolving Wallboard Systems Closed Loop Recycling Pilot Project Participants
- 16. Durst Jobsite Source Separation
- 17. Lend Lease Jobsite Solutions
- 18. Hauler + Recycler, NJ
- 19. Received by Trailer @ USA Gypsum for Processing
- 20. Manufactures with Post-Consumer Gypsum
- 21. Gypsum Category No. of Samples Avg. Conc. (ppm) Max Conc. (ppm) < Detection Limit (0.001 ppm) Renovation board: Demolition 30 0.05 0.3 40% New trim scrap: Natural- mined 6 0.04 0.1 50% Synthetic 6 0.07 0.2 17% Research Objective: Understand Content to Inform Reuse
- 22. Research Objective: Understand Content to Inform Reuse Gypsum Source Natural-Mined Synthetic Study This Study (2015) Yost (2007) Sanderson (2008) This Study (2015) Yost (2007) Sanderso n (2008) EPA* (2009) Sample Size 6 - 10 6 - 12 20 Average Mercury (ppm) 0.04 0.024 - 0.07 0.38 - - Maximum Mercury (ppm) 0.1 - 0.03 0.2 - 0.95 3.1 *Gypsum tested is pre-wallboard production. Other studies use post-wallboard production gypsum.
- 24. QUESTIONS? Or Contact Presenters Amanda Kaminsky: (917) 816-6246, Amanda@BuildingProductEcosystems.org Terry L Weaver: 717-335-0379, terry@usagypsum.com
Editor's Notes
- NWG leader today operating in Canada & Europe
- Clean air, water & gypsum Scrubbers installed to meet clean air act Total Maximum Daily Load (TMDL) Countless research over 20 years supports E&S and P control
- Why are we revisiting “failed close Loop” chart explains why: The questions is when?
- Many of you know the challenges of wallboard in single stream systems
- But 2 dozen are doing it
- Barriers. Pilot is a solution that proves it can work
- Tried One World Trade & didn’t work out
- Packer Trucks crush wallboard to powder
- 7 Million Sq. Ft. Wallboard Purchased 3 Million lbs. (1,500 Ton) Scrap Estimated 273 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
- Reclaimed Gypsum is Blended With FGD/Synthetic Gypsum Process Quality is Successful Closed Loop Complete
- Mercury is a concern in synthetic gypsum because of the production process. One of the goals of this study was to see if there is a large difference between natural and synthetic gypsum. We’ve found that synthetic gypsum does have slightly higher mercury levels. In the last column you can see that natural-mined has the highest percentage below detection limit. Since the gypsum source of the demo board is unknown, we also wanted to compare that to new trim. The maximum is higher than new trim but the average is in the same range. In the end, all samples in this pilot are below allowable standard thresholds.
- Recent literature also shows higher levels for synthetic gypsum than for natural-mined. In these studies, the maximum is less than 1 ppm. An interesting idea is gypsum may lose mercury during wallboard production. In the EPA study, they found the mercury concentration of unprocessed gypsum to be 3.1 ppm, more than 3 times that of the processed gypsum in the Sanderson study. This idea is inconclusive though, due to the variety in the synthetic gypsum feedstock and the manufacturing processes.
- in order for wallboard recycling to go mainstream we need wallboard manufacturers to use some of the 4 million tons. “Until costs and legislation associated with the disposal of scrap gypsum in landfills becomes more restrictive, recycling will likely continue to remain a low priority within the industry”. ( Source USGS) 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)