2016 Excellence Award entry
Recycling System
2016 SWANA
EXCELLENCE AWARDS
RECYCLING SYSTEM
Southern Nevada Recycling Center
Serving Southern Nevada, including Clark County and
the cities of North Las Vegas, Las Vegas and Henderson
Entrant: Republic Services
Title: Southern Nevada Recycling Center
Contact: Tracy Skenandore, tskenandore@republicservices.com / 702.599.5502
Jurisdiction: Southern Nevada
Population: Approximately Two Million
Budget: $35 Million, fully funded by Republic Services
2016 Excellence Award entry
Recycling System
Executive Summary
Republic
Services’
Southern
Nevada
Recycling Center serves the cities of North
Las Vegas, Las Vegas, Henderson, as well as
Clark County. In addition to processing
recyclables for 550,000 households in these
communities, the state-of-the-art facility
was planned and designed in support of the
recycling programs offered to the 42
million visitors welcomed to Las Vegas
annually.
The 110,000 square foot facility features
advanced recycling technologies capable of
processing
two
million
pounds
of
recyclable material per day, or 70 tons per
hour. Technologies employed at the Center
include five optical sorters, touch screen
control
systems
and
tablet-based
capabilities.
The
Center
was
designed
with
sustainability as a priority, with more than
75 percent of the building made from
recycled or remanufactured steel, and
1,776 rooftop solar panels and automatic
low-flow water fixtures. The facility also
features
an
innovative
and
inviting
Learning Center that and incorporates
sustainability in every facet of the design.
April 26, 2016
Design and Planning of Recycling System | 3
2016 Excellence Award entry
Recycling System
1. Design and Planning of Recycling System
The design and planning of the Southern Nevada Recycling Center was in response to
the ambitious goals of the Southern Nevada community to increase recycling for a
more sustainable future. In addition to providing the infrastructure and processing
capacity necessary to accommodate the conversion of additional Clark County Nevada
households to All-in-One Recycling™, the system was designed to support the
innovative recycling programs that are gaining momentum on the Las Vegas Strip and
throughout the region. Site development was completed in only 12 months, from the
groundbreaking in November 2014 to the grand opening at the end of 2015.
Click
to view a
time-lapse video
of facility
construction
The increased volume generated through the expanded residential All-in-One
Recycling™ program, as well as the recyclables collected from residential and
commercial customers throughout the region, exceeded capacity at the existing
88,000 square foot Recycling Center. Originally, the plan was to expand the existing
recycling system. However, the extended down-time this scope of expansion would
require made this approach impractical, as the material would have to be trucked out
of state to provide interim processing capacity. Republic determined that it would be
in the best interest of the community to continue operations at the existing site and
build a new 70-ton per hour state-of-the-art recycling center adjacent to the existing
facility. This allowed Republic to continue meeting the existing recycling needs of the
community and customers while building the infrastructure required to support the
growing demands for increased capacity.
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Design and Planning of Recycling System | 4
2016 Excellence Award entry
Recycling System
The project site presented several challenges. It is crisscrossed by several storm
channels which complicated the site layout that was required to accommodate them.
In addition, geotechnical investigation revealed poor soil conditions that required
extensive over-excavation to ensure proper building support conditions. Related to
the storm channels, there is also a mapped FEMA flood zone on the site, which limited
where the improvements could be made. These challenges presented obstacles that
were overcome with teamwork and an eye toward the final site functionality.
A facility of the ambition and scope of this project required extensive planning to
ensure it met the region’s current and future needs. The resulting Southern Nevada
Recycling Center, which is a 110,000 square foot facility adjacent to the existing
facility, is known as the “the largest and smartest residential recycling center in North
America.” The Recycling Center features dual 35-ton per hour sorting lines and can use
one or both of the sorting lines at any one time. Operators can bypass certain parts of
the system when running different material types.
Recycling by the Numbers
Scales throughout the system calculate the weight
of incoming material and shaft speeds and screen
The facility processes up to
angles can be modified based on that information.
70 tons per hour.
This operational flexibility allows the system to
2 Million pounds of
adapt as the composition of the recycling stream
materials are processed
continues to evolve and has the capability of
through the facility per day.
processing not only residential, commercial, but
Recyclables can travel up to
even industrial streams.
1 mile in 2.5 minutes.
The facility can process the
contents of a fully loaded
truck in 3 minutes.
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Design and Planning of Recycling System | 5
2016 Excellence Award entry
Recycling System
Learning Center
The facility also
A unique aspect of the planning approach was that the
building was designed as an extension of the processing
equipment. The equipment manufacturer, CP Group,
developed the 70-ton per hour system and Cambridge
Construction designed the building from that template.
The plant features a 42’ tall eave that allowed the
equipment, specifically the screens and optical sorters,
to be placed and oriented for optimum efficiency. In
addition, the bale storage and tipping areas were both
designed to be expanded in the future.
April 26, 2016
features a Learning
Center and observation
deck, which was
planned and designed
to offer visitors a rare,
360- degree view of the
recycling process.
Design and Planning of Recycling System | 6
2016 Excellence Award entry
Recycling System
2. Use of Equipment/Systems and Technologies
The Southern Nevada Recycling Center features equipment capable of sorting 70 tons
per hour. Nearly 550,000 households in Southern Nevada now send their All-in-One
Recycling™ materials to the facility. Commercial customers send materials in either
dual-streams or All-in-One Recycling™ streams, depending on the customer.
The state-of-the-art facility features industry-leading technology, including the CP
Glass Cleanup Trommel, which is equipment that is being introduced for the first time
worldwide. This system, created by the CP Group, uses advanced technologies and
principles of engineering and physics to increase glass recovery. The system passes
materials through a trommel screen, removing glass fines, which are tiny particles, as
well as other small debris.
Glass Clean-Up System
The system uses principles of engineering
and physics to achieve glass recovery.
(L-R) glass product, non-glass contaminants
and <3/8” glass
The materials continue through a rotating drum designed to agitate its contents. At
one end of the drum, a large vacuum extracts any non-glass items. Meanwhile, denser
material – clean glass – exits the drum at the other end, where it flows into a container
and awaits additional processing. Through this first-of-its-kind technology, the system
will allow increased levels of glass recovery, which is significant due to the large
quantities generated by the Southern Nevada region’s hotels and casinos.
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Use of Equipment/Systems and Technologies | 7
2016 Excellence Award entry
Recycling System
In addition, the recycling system
features two OCC screens™, two
scalping
screens,
four
NEWScreens™
and
two
CPScreens™ separating 2D from
3D material. These screens
ensure maximum separation
efficiency and provide other
flexible sorting capabilities for
Republic Services as the ton
evolves.
The system also includes five MSS
CIRRUS® optical sorters that
make
material
separation
decisions
in
milliseconds,
maximizing the recovery of all
containers, including PET, HDPE,
and aseptic containers/cartons.
The first CIRRUS® optical sorter
negatively
separates
any
remaining fiber materials or
particles to maximize recovery of
all grades of plastic, including PET,
HDPE and cartons. The remaining optical sorters recover plastics. With this
equipment, the Recycling Center processes material very quickly. In fact, in less than
30 minutes, the system can process as much recycling as 150 households will generate
in a year.
Another advantage of the system is the
highly automated data acquisition system
control technology. Key features include
five
touch-screen
Human
Machine
Interface (HMI) control panels, as well as
two wireless control panels, Supervisory
Control, Data Acquisition monitoring, and
remote access to continually monitor
operations for optimal performance.
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Use of Equipment/Systems and Technologies | 8
2016 Excellence Award entry
Recycling System
Users are able to monitor production and set screens, adjust sorters and change motor
speeds from a tablet, anywhere in the facility. There are also sets of pre-programmed
equipment settings, or “recipes,” that can be selected based on the material being
processed. The application of this technology makes Southern Nevada Recycling
Center the most intelligent facility in North America.
Recycling System Equipment
Individual components selected for the state-of-the-art processing system are shown
and described below:
April 26, 2016
Drum Feeder: Provides
uniform material flow to the
downstream pre-sort line
Glass Breaker Screen: Breaks
and separates glass and
other small materials
Film Vacuum System:
Collects and transports
plastic film
Glass Clean-Up Trommel:
Separates glass from fines
Screw Compactor: Compacts
all collected film into long
tubes
Scalping Screen: Separates
material by size and shape
OCCScreen™: Removes and
recovers large OCC from
other materials
NEWScreen™: Sorts 2D large
and medium fiber from 3D
containers
CPScreen™: Sorts 2D small
fiber from 3D containers
Cirrus® Optical Sorter: Sorts
and recovers mixed plastics
cartons
Drum Magnet: Separates
and recovers steel from
other materials
Fiber Bunker: Holds sorted
fiber before baling
Eddy Current Separator:
Separates and recovers
aluminum
Live Floor Silo: Holds sorted
containers before bailing
and uses screw augers
Vibratory Feeder: Spreads
out material to “feed” the
optical sorter
Advanced MRF Office
Interface System: Systemwide data acquisition and
control solutions
Use of Equipment/Systems and Technologies | 9
2016 Excellence Award entry
Recycling System
3. Regulatory Compliance
Republic Services is deeply committed to being a good neighbor to the communities it
serves, and part of being a good neighbor means strong regulatory compliance.
Sustainability is a critical componant of Republic Services regulatory compliance
practices.
At the Southern Nevada Recycling
Center, sustainability was a priority
throughout
the
design
and
construction. More than 75 percent
of the 110,000 square foot building
was made from recycled or
remanufactured steel. There are
1,776 rooftop solar energy panels
that are expected to generate
enough renewable energy to fulfill 15
percent of the building’s power
requirements. Inside the building,
automatic low-flow water fixtures
will reduce consumption by more
than 20 percent.
Republic is committed to protecting
and preserving natural resources
and educating current and future
generations
on
environmental
compliance. This commitment to
quality of life and regional prosperity
could not be more evident than at
the Southern Nevada Recycling
Center.
We’re using sunshine to
reduce o u r carbon
footprint.
Sunshine abounds in Southern Nevada. This
building features a photovoltaic rooftop solar
energy system comprised of 1,776 panels (315
watts) to harness the renewable resource. The
system generates 933,162 kilowatts of energy per
year, which constitutes more than 15 percent of
the building’s power consumption.
Over the next 30 years, this building’s solar
energy system will offset greenhouse
gas emissions equal to:


1.8 million gallons of oil used


21 million gallons of water used
38 million miles driven by local
motorists
77,189 pounds of smog released
The Southern Nevada Recycling Center complies with all environmental laws and
regulations. The facility is permitted through the Southern Nevada Health District,
with Permit Number PR0035182. The facility has not received any regulatory citations
or notices of violation.
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Regulatory Compliance | 10
2016 Excellence Award entry
Recycling System
4. Worker Health and Safety
The success of the recycling system is directly correlated to the success of the
employees that make it work. To that end, many approaches were taken to improve
their working environment. Worker health and safety was a major consideration in
the planning and design of the facility. The system was designed to exceed American
and international standards for safety, including OSHA and NFPA compliance.
Whether the system is running at full process or in a reduced capacity, all safety
circuits throughout the facility remain active. The Southern Nevada Recycling Center
employs 160 full-time employees on three shifts, with one shift devoted to
maintenance. Since its opening, and at the time of this application submittal, zero
injuries have occurred at the Southern Nevada Recycling Center.
Building Safety Design Features
Numerous features enhance safety of the facility, including a 10’ band of translucent
panels at the eave and over 40 skylights improve indoor lighting levels. LED high bay
lights supplement the daylighting when skies are overcast or when operating at night.
Elevated lighting levels help improve safety and well-being.
Additional features include:
•
Dual-bag house dust suppression system, including collection hoods at dust
generation points in the system, removes particulates from the air, and
improves the quality of indoor air for employees.
•
Misting system for employee comfort uses finely atomized water droplets that
cause evaporative cooling to lower temperatures. Several 12’ diameter highvolume low-speed fans help circulate air to improve worker comfort.
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Worker Health and Safety | 11
2016 Excellence Award entry
Recycling System
•
Comfortable break room and locker room facilities for the facility staff, and an
elevated walkway that links the employee amenity areas to the equipment,
which prevents employees being on the floor, vulnerable to vehicle impact.
Processing System Safety Design Features
Numerous design elements were included in the system to facilitate and enhance
operational safety. The system uses Miller Temporary Anchorage Connectors, which
wrap around l-beams and other structures for supporting workers. Crossbars above
the rotors are dimensioned to hold one person each and provide valid anchor points
for lanyards. All disc drives on each screen have brake motors with locking hand
release levers. Brakes are activated when the power goes off, locking rotors. Rotors
cannot turn when maintenance personnel are walking or standing on them.
The system design also allows easy access to maintenance areas and includes
safeguards built in to protect workers such as trap key systems, hydraulic platforms,
and lanyard connections. All sorters are on the same platform level for safety and
operator supervision. Additionally, a single emergency stop system provides 100%
equipment control while maintaining maximum uptime. Intelligent controls know
exactly when and where an e-stop is triggered, allowing quick identification and
correction to resume production.
The facility also features trapped key
interlocking, which utilizes locks and
keys for sequential control of equipment
and machinery to ensure safe operation.
Trapped key interlocks are used to
ensure safe access to potentially live
equipment in the plant. A safe sequence
of operations is enabled through
transfer of keys that are either trapped
Keylock System
or released in a predetermined order. For
example, a key is used to isolate a power source (circuit breaker or supply valve), this
key is then released and can then be used to gain access through a gate or door to a
high risk area by inserting it into an access lock. The key will then remain trapped until
the gate or door is closed, ensuring that the gate or door cannot be closed and the
initial key released until this personnel or safety key is returned. Access doors contain
a keylock system. The power is shut off when the access doors are opened. With the
double key system, the machine cannot be started while the doors are unlocked.
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Worker Health and Safety | 12
2016 Excellence Award entry
Recycling System
The area behind the access doors of
the CPScreen and NEWScreen gets
closed by a fold-down service
platform, from where the rotors are
accessible. The floor is moved by
hydraulic cylinders, and can only be
unfolded when the screen is in its
lowest
position.
This
system
Fold-Down Service Platform
eliminates the risk of falling during
maintenance and cleaning, and in so doing, provides built-in fall protection so that
harnesses are not required.
Safety Training
Safety is Republic’s highest priority and therefore, a strict policy of safety protocols
has been created with supporting infrastructure, where employees are trained to
think, choose, and work within a training framework designed for safety. Employees
are trained on the first day of employment on key safety topics, then receive refresher
training on these topics during monthly safety meetings. Employees also participate
in Republic Services’ Focus 6 program which trains employees on the skills to avoid the
six most serious types of losses in the industry.
Safety Training Topics

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





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
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Personal Protective
Equipment
Lock Out Tag Out
Confined Space
Hazardous
Communications
Blood Borne Pathogens
Emergency Evacuation
Hearing Conservation
Fire Extinguishers
Heat Stress
Electrical Safety
Fall Protection
Machine Guarding
Drug & Alcohol
Awareness
Worker Health and Safety | 13
2016 Excellence Award entry
Recycling System
5. Performance, Economics and Cost-Effectiveness
The Southern Nevada Recycling Center dual line processing system has proven
capable of operating at its anticipated production rate of 70 tons per hour. The system
has been performance tested by a third party expert and has met and exceeded the
high Republic Services standards.
The system achieves 98 percent purity requirements on container grades and
newspaper, achieves 95 percent purity requirement for fiber content of mixed paper,
achieves over 92 percent glass content purity on a requirement of 90 percent. The
system has also exceeded expectations in reliability, with an average uptime of 92
percent as compared to an industry average goal of 90 percent.
In addition to the numerous performance capabilities and operational goals achieved
by the system, the versatility of the line and ability to accommodate the expanding
volume of recyclables in the region was a critical deliverable realized as a result of the
planning, construction and operation of the facility.
Additionally, the system has achieved economic milestones:
•
The initial investment in the facility was as planned and construction was
completed within budget.
•
The facility is anticipated to reach profitability sooner than expected.
While these are welcome achievements, the anticipated payoff associated with the
versatility of the processing line will be even stronger. Republic Services is committed
to providing the recycling infrastructure needed to support the growing demand for
April 26, 2016
Performance, Economics and Cost Effectiveness | 14
2016 Excellence Award entry
Recycling System
recycling services among the municipalities in the Southern Nevada area. The time
and resources invested in this project will continue to pay off as the recycling system
is able to cost-effectively adapt to provide residential, commercial and even industrial
processing capabilities. Through this system, Southern Nevada Recycling Center is
poised and ready to offer the surrounding communities, as well as sustainabilityfocused businesses and municipalities including Zappos, MGM International,
McCarran International Airport, CDW, Clark County School District, University of
Nevada Las Vegas, Las Vegas Convention & Visitors Authority, City of North Las Vegas
and the City of Henderson, with the capacity and diversion results they seek.
MGM Resorts
MGM Resorts recycle approximately 56,000 tons
annually, or the weight equivalent to 3,700 yellow
school buses. By partnering with Republic Services, we
have achieved an impressive 47 percent diversion rate.
Las Vegas Convention Center
The Las Vegas Convention Center welcomes more
than 1.2 million people and hosts 50 conventions
and trade shows per year. Working with Republic
Services, we recycle an average of 5,000 tons of
paper, plastic, metals and cardboard each year.
City of Henderson
Our community’s response to recycling has been
remarkable. Working with Republic Services, the
City of Henderson introduced a citywide singlestream recycling program in 2012. Over the next
year, recycling participation in Henderson exceeded
90 percent, and we improved our diversion rate by
500 percent.
April 26, 2016
Performance, Economics and Cost Effectiveness | 15
2016 Excellence Award entry
Recycling System
Public Acceptance, Appearance and Aesthetics
The Southern Nevada Recycling Center was designed to serve the region both by
doubling the processing capacity for recyclables, and by creating an inviting facility to
be used to engage the community in outreach and education. Outside the building,
the natural landscape was preserved, for both an aesthetic and environmental
benefit. The architecture of the building was engineered using recycled and
repurposed materials, and features various elements of sustainability throughout the
facility. More than 75 percent of the 110,000 square foot building was made from
recycled or remanufactured steel.
High solar reflectance index roof
materials were installed to minimize
heat retention in the building. There
are 1,776 solar energy panels on the
roof that are expected to generate
enough renewable energy to fulfill 15
percent of the building’s power
requirements. Inside the building,
automatic low-flow water fixtures
will reduce consumption by more
than 20 percent.
Within the Learning Center, sustainability was incorporated into every facet of the
displays and design. Developing an interactive and inviting site where visitors would
feel
welcome
and
engage
in
meaningful
and
memorable
Click
experiences was a priority throughout
here for a
the facility planning process. The
panoramic view
of the Learning
learning center provides visitors with
Center.
a view of the recycling process from
an observation deck, as well as videos,
displays and information on recycling.
Visitors can learn about what can be
recycled and how materials are
repurposed and remanufactured to
make new products.
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Public Acceptance, Appearance and Aesthetics | 16
2016 Excellence Award entry
Recycling System
The Learning Center is
free and open to the
public for guests of all
ages. It is available for
private
meeting
reservations
for
customers, community
organizations
and
business groups. Field
trip reservations are
available
for
youth
groups, school groups,
scout groups, business
groups, and customers.
Interactive Truck Experience
Visitors enjoy a hands-on experience
inside the cab of an actual recycling truck.
The Learning Center offers visitors a rare, first-hand view of the recycling process and
features a variety of customer recycling stories. These customers are moving the
needle in recycling across Southern Nevada including Zappos, MGM International,
McCarran International Airport, CDW, Clark County School District, University of
Nevada Las Vegas, Las Vegas Convention & Visitors Authority, Las Vegas Convention
Center, City of North Las Vegas and the City of Henderson.
City of North Las Vegas
“The City of North Las Vegas is proud to be the
home of the nation’s largest residential recycling
complex. We take tremendous pride in the
facility and in the contributions it will make to
both the economy and the environment. And we
commend Republic Services for creating a
Learning Center that will inspire many new
recyclers, both young and old.”
-Mayor John J. Lee
April 26, 2016
Public Acceptance, Appearance and Aesthetics | 17