FACT SHEET
Market summary – shredder floc
In 2013-14 Sustainability Victoria commissioned market analysis into four
waste materials identified as priorities for market development and four which
are emerging materials of interest. This fact sheet summarises the findings for
shredder floc.
Terminology
Shredder floc is a by-product of metal reprocessing, primarily from the recovery of end-of-life
vehicles (ELVs) and white goods, including refrigeration and air conditioning equipment.
ELV reprocessing in Australia has a recovery rate of approximately 65-75 per cent1 and
involves removing pollutants, dismantling, shredding and metal separation. The material
remaining after the separation of metals is called shredder floc.
Composition
Shredder floc typically consists of a combination of plastics, rubber, textiles, metals and inert materials
such as dirt and glass (see table), and is generally contaminated with heavy metals, mineral oils and
hydrocarbons. The composition of shredder floc does not differ greatly between ELVs and white goods,
although older white goods can contain polychlorinated biphenyls (PCBs), which ELVs do not, as well
as higher levels of copper.
Table 1: Average shredder floc composition
Material type
Average composition range (% weight) 2
Plastics
35 – 55%
Rubber
10 – 20%
Metals
6 – 13%
Textiles
7 – 15%
Fines (paint, glass, sand) 10 – 20%
Shredder floc is composed of two distinct fractions based on size.
1.
A finer ‘heavy’ fraction (particle size less than 25 mm), which is predominantly inert material
with minor organic content. Anecdotal estimates indicate that the fine fraction accounts for
approximately 30 per cent of the total shredder floc produced.
“Environmental Impact of End-of-Life Vehicles: An Information Paper”, last modified 2002,
http://www.environment.gov.au/archive/settlements/publications/waste/elv/impact2002/index.html.
1
2
Ciacci, Luca, et al. "A comparison among different automotive shredder residue treatment
processes." The International Journal of Life Cycle Assessment 15.9 (2010): 896-906.
2.
A coarser ‘light’ fraction (particle size varies, generally in excess of 50 mm), which is
predominantly plastic, rubber and textiles. Anecdotal estimates indicate around 30 per cent of
total shredder floc produced is around 50 mm in size, and 40 per cent exceeds 50 mm.
Volumes
There is no specific information available on volumes however anecdotal industry estimates
indicate there is between 150,000 and 200,000 tonnes of shredder floc produced per annum
in Victoria.
Table 2: Estimate of potential shredder floc volumes in Victoria
Year
Total shredder floc
generation
Assumed shredder floc composition
Fine ‘heavy’ fraction (25 mm
or less, mostly inert)
(lower
(higher
(lower
estimate) estimate) estimate)
Coarse ‘fluffy’ fraction (over 25 mm,
mostly plastic, rubber and textiles)
(higher estimate)
(lower estimate)
(higher
estimate)
2013 140,000
200,000
42,000
60,000
98,000
140,000
2014 142,460
203,500
42,700
61,000
99,700
142,460
2015 145,000
207,100
43,500
62,000
101,500
145,000
2016 147,600
210,900
44,300
63,300
103,300
147,600
Products and applications
In Australia, shredder floc is sent to landfill for disposal, although the industry commonly uses
it as a daily cover on landfills. Internationally, some recovery of shredder floc does occur. In
Europe, this is mostly driven by the European Commission Directive 2000/53/EC, which aims
to reduce the hazardous componentry of vehicles and achieve a target of 85 per cent for
reuse and recycling (excluding energy recovery), and 95 per cent for reuse and recovery
(including energy recovery), by 2015.
Two main types of technologies exist for the treatment of shredder floc; those based on
mechanical separation, and those based on thermal treatment.
Mechanical separation allows for the shredder floc to be sorted into different sized fractions
which can then be recycled. Textile fibres are then used as a de-watering agent or a coal
substitute in coke production. The mineral fraction is used as landfill cover, for slope filling
and in road construction. (Note: there is only one landfill in Victoria that is currently licensed to
accept shredder floc and use it as daily cover).
In contrast, thermal treatment usually involves initial separation of metals, and then
combustion of the residual material via technologies such as gasification. The gas can be
combusted to create energy, or used in the manufacture of various chemical products. The
ash from the gasification process can be used as an inert construction material.
A combination of these two technologies can also be used.
Market overview
Shredder floc is currently landfilled in Victoria as there is no established market. Industry
consultation suggests that generators of shredder floc face disposal costs of $70–$100 per
tonne, or between $15 - $20 million in total. Industry therefore has a strong desire to identify
an alternative use. Potential markets, and barriers, are shown below.
Table 3: Potential market opportunities and barriers for shredder floc in Victoria
Potential market
Barriers
Use in a non-load bearing
cement material, such as a
fascia product.
The shredder floc would require a significant amount of preprocessing to improve particle consistency and product
quality.
Use of the finer inert
shredder floc fraction in road
base or asphalt production,
as a substitute for virgin
sand.
The shredder floc is potentially contaminated with volatile
hydrocarbons. Vapours and fumes would likely be produced
during asphalt production.
Use of the coarser fraction
(composed mainly of plastic,
rubber and textiles) in an
energy from waste
application.
Given the variable composition of the shredder floc, the type
of technology capable of accepting it for this use may be
limited.
The material is likely to require treatment prior to use in
asphalt. The cost is likely to be prohibitive given the relative
cheap price of substitute material (virgin sand or recycled
glass sand).
Ability to secure shredder floc feedstock long term.
Market barriers
The key market barriers for use of shredder floc are cost and contamination. Residual oil is
the primary contaminant persisting in shredder floc and it is therefore treated as a prescribed
industrial waste. There are processes and technologies available that would allow oil to be
easily extracted from ELVs. However, this would require additional cost in a market already
experiencing pressures from the downward trend on scrap prices.
Industry consultation suggests that the only viable end market for shredder floc is as a fuel,
either co-fired or more likely as an input to a bespoke Energy from Waste (EfW) facility but
that the barriers are currently unsurmountable.
The uncertainty regarding contaminant levels and high processing costs, at present,
precludes shredder floc from being used in other products such as fascia or road base.
Market risks
There are three key market risks for the use of shredder floc.
Environmental: The impact of contamination indicates that environmental risks are significant.
While recent studies suggest that polychlorinated biphenyl (PCB) contaminants are largely
locked up in plastic componentry, the risk of oil contamination remains very high.
Regulatory: Shredder floc is currently not a classified industrial waste and this impacts on the
ability of the material to be used in other applications. Uncertainty means long-term
investment is unlikely.
Social: Social concerns are likely to be high in the event that EfW infrastructure is installed to
process shredder floc, and pose risks for planning applications.
Market opportunities
There is little market opportunity for shredder floc under current conditions. The material is
not currently a prescribed industrial waste, however should this change, it could potentially
make a number of processing options financially viable. However, risks associated with
contamination would need managing. They could also limit available market options and
impact on processing of end-of-life vehicles and other feedstock in Victoria given high
disposal costs and the low value of scrap metal.
Further Information
For more information contact Jane Street on:
T: (03) 8656 6709
E: jane.street@sustainability.vic.gov.au
or visit www.sustainability.vic.gov.au/marketanalysis
Sustainability Victoria
Level 28, Urban Workshop,
50 Lonsdale Street, Melbourne VIC 3000
Phone (03) 8626 8700
sustainability.vic.gov.au
Published by Sustainability Victoria.
Market summary – shredder floc
© Sustainability Victoria, September 2014 IWM030