Transforming non-recyclable Fibreboard waste in high-value activated carbon and renewable energy

Abstract

Every year in Europe, around 10 million tonnes fibreboard waste is generated without any recycling solution at hand, resulting in an environmental issue and high disposal costs for producers and endusers. On the other hand, the world’s activated carbon consumption is forecasted to rise by 5.3% per year to 2.6 million tonnes in 2025. From which around 23% is made from fresh wood resources or around 8 million trees (52cm diameter 12 m stem) that are cut every year. The high demand for wood is leading to a supply deficit in the next years. Furthermore, these trees lock-up 29 million tonnes of CO2. A solution is needed! Aligned with Act&Sorb’s business strategy, a dedicated energy producing process has been developed allowing to make use of the specific components in the fibreboard-waste - nitrogen from the glue and the wood itself– to produce, a high quality “wood-board waste” activated carbon (+ 1000 mg/g I2-number) enriched with nitrogen and renewable energy. In this way Act&Sorb replaces the need for fresh wood reducing the amount of trees cut every year. The patented 2 step carbonisation/gasification process, enables the encapsulation of high amounts of nitrogen within the activated carbon matrix while co-currently enhanced calorific syngas is produced covering the internal electricity and heat requirements over the other part of the syngas is used for renewable electricity and heat production. The overall process therefore is referred to as a self-sustaining energy producing upcycling process for fibreboard waste. Act&Sorb plans to commission its first commercial recycling facility by 2021. This world’s first industrial fibreboard recycling set-up will process around 50 000 tonnes fibreboard waste per year and produce 2MWe electricity.