Analysis of material recovery facilities for use in life-cycle assessment

- Life-cycle assessment of solid waste management relies on accurate process models.
- Material recovery facility (MRF) processes were modeled with new primary data.
- Single stream, dual stream, pre-sorted, and mixed waste MRFs were considered.
- MRF electricity consumption ranges from 4.7 to 7.8 kW h per Mg input.
- Total cost ranges from $19.8 to $24.9 per Mg input.

Insights derived from life-cycle assessment of solid waste management strategies depend critically on assumptions, data, and modeling at the unit process level. Based on new primary data, a process model was developed to estimate the cost and energy use associated with material recovery facilities (MRFs), which are responsible for sorting recyclables into saleable streams and as such represent a key piece of recycling infrastructure. The model includes four modules, each with a different process flow, for separation of single-stream, dual-stream, pre-sorted recyclables, and mixed-waste. Each MRF type has a distinct combination of equipment and default input waste composition. Model results for total amortized costs from each MRF type ranged from $19.8 to $24.9 per Mg (1 Mg = 1 metric ton) of waste input. Electricity use ranged from 4.7 to 7.8 kW h per Mg of waste input. In a single-stream MRF, equipment required for glass separation consumes 28% of total facility electricity consumption, while all other pieces of material recovery equipment consume less than 10% of total electricity. The dual-stream and mixed-waste MRFs have similar electricity consumption to a single-stream MRF. Glass separation contributes a much larger fraction of electricity consumption in a pre-sorted MRF, due to lower overall facility electricity consumption. Parametric analysis revealed that reducing separation efficiency for each piece of equipment by 25% altered total facility electricity consumption by less than 4% in each case. When model results were compared with actual data for an existing single-stream MRF, the model estimated the facility's electricity consumption within 2%. The results from this study can be integrated into LCAs of solid waste management with system boundaries that extend from the curb through final disposal.