ENGR 7028 Proposal
ENGR 7028 Proposal
Nishan Kharel
22032944
Automotive Shredder Residue (ASR) is a complex mixture of waste materials generated during
the recycling process of End-of-life vehicles (ELVs) which typically comprises of hazardous
substance that can degrade the environment as well as impact human health in the occurrence
of improper management. This thesis is primarily based on the scenario of Australia since it
does not have its own standard for ASR management and the physical characterization of ASR
in Australia can help to overcome the environmental impacts and health issues that may occur
due to ASR dumped into the landfill. In this project, the Italian standard has been taken as a
reference to characterize ASR in the context of Australia. Similarly, the ASR sample from an
Australian metal recycler will be taken to undergo the physical characterization in an
environmental lab in Kingswood Campus, Western Sydney University. The lab results will
help to analyse the physical composition of ASR in Australia and identify the most efficient
method for recycling and disposal. Furthermore, this will give the waste management
practitioner an overview of the condition of ASR in Australia and assist in enhancement of the
recycling process and management of the waste.
TABLE OF CONTENTS
1. INTRODUCTION ............................................................................................................... 1
3.2 Aims............................................................................................................................... 14
4. METHODOLOGY ............................................................................................................ 15
6. REFERENCES .................................................................................................................. 20
7. APPENDICES .................................................................................................................... 23
1. INTRODUCTION
The automotive industry is a significant contributor to the global economy, providing mobility
and employment opportunities to millions of people worldwide. However, the production, use,
and disposal of automobiles generate a substantial amount of waste, including end-of-life
vehicles (ELVs) that are no longer suitable for road use. ELVs are typically shredded to recover
valuable materials such as metals, plastics, and rubber, leaving behind a complex waste stream
known as automotive shredder residue (ASR) (ASTM International 2018). ASR is a
heterogeneous mixture of materials, including plastics, rubbers, foams, textiles, fibers, metals,
glass, and other inorganic and organic contaminants (Quaghebeur et al. 2016).
ASR presents significant challenges for waste management due to its high volume and
complexity, as well as its potential environmental and health risks. ASR has been shown to
contain hazardous substances, such as heavy metals, persistent organic pollutants (POPs), and
flame retardants, which can leach into the environment and pose risks to human health and
ecosystems (Kuo et al. 2018). Therefore, understanding the composition and properties of ASR
is crucial for developing effective strategies for its management, including recycling, disposal,
and resource recovery.
One of the main environmental impacts of ASR is soil and water contamination. When ASR is
not properly disposed of, it can leach toxic chemicals such as lead, mercury, and cadmium into
the soil and water (Vogl et al. 2015). This can lead to soil and water contamination, which can
have long-term effects on the ecosystem. ASR can also contribute to air pollution. When ASR
is burned or decomposed in landfills, it can release harmful air pollutants such as dioxins and
furans, which can contribute to respiratory problems and other health issues (Gentil et al. 2015).
Improper disposal of ASR can also lead to habitat destruction. When ASR is dumped in natural
areas, it can harm wildlife and disrupt the ecosystem (Vogl et al. 2015). Finally, ASR takes up
valuable space in landfills. Since it is difficult to recycle, it can remain in landfills for many
years, taking up space that could be used for other waste (Chen et al. 2017).
To mitigate these effects, it is important to properly manage ASR. This can include separating
and recycling as much of the materials as possible, using alternative waste-to-energy
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technologies that can capture the energy content of the ASR, and developing more sustainable
products that can be easily recycled or repurposed (Gentil et al. 2015).
Australia, like many other countries, generates a substantial amount of ASR due to its
significant automotive industry and high rate of vehicle ownership. However, research on the
material characterization of ASR in Australia is limited, and there is a need to investigate its
composition and properties to inform sustainable waste management practices.
2. LITERATURE REVIEW
For recycling and recovery of automotive waste, the End-of-Life Vehicles (ELVs) are typically
shredded in a shredding facility which gives rise to various compositions of waste. ELVs are
considered one of the most significant contributors to environmental pollution since they contain
hazardous waste which are complicated to recycle and most of them end up in the landfill. The
main purpose of recycling ELV waste is to minimize the waste that goes to the landfill.
In this process of recycling, firstly, ELVs are gathered, disassembled, and the wreck is shredded
once the batteries, tyres, fluids, and other pieces that can be reused have been removed. Physical
techniques are used to separate the metallic components, which are then collected as ferrous
and nonferrous metals for recycling. The Automobile Shredder Residue (ASR), which makes
up the remaining 25%, is primarily made of plastics but may also contain metallic pieces and
other pieces that couldn't be separated (Inglezakis V.J & Zorpas A.A 2009). Overall, the three
fundamental streams that are produced during shredding are:
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• Ferrous Metal: It generally contains iron and steel and comprises 65-70% of the total
waste by weight. It is separated using magnetic separation method which divides
ferrous and non-ferrous metals.
• Automotive Shredder Residue (ASR): The remaining materials also known as ‘fluff’
contains materials such as plastics, glass, rubber, foam, textiles, carpeting, etc. which
comprises 20-25% of the total waste by weight.
Figure 1 shows the flowchart of the process of shredding and separating various waste of ELVs.
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Figure 1 Typical flowchart showing the process of ELV shredding.
The ASR can be divided into two categories based on their density as follows:
• Light ASR ‘Fluff’: It comprises of more than 80% of the total ASR. Light ASR refers
to the lighter fraction of the Auto Shredder Residue (ASR) that remains after the ELV
is shredded and the metals are separated. It consists mainly of plastics, rubber, foam,
and other lightweight materials. Light ASR is typically the fraction of the ASR that is
sent to landfill, as it has low calorific value and limited recycling potential. Its disposal
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represents a significant environmental challenge due to the presence of hazardous
substances and the potential for long-term pollution. The management of light ASR is
an ongoing area of research, with efforts focused on finding sustainable solutions for
its treatment and disposal.
• Heavy ASR ‘Fluff’: Heavy ASR refers to the heavier fraction of the Auto Shredder
Residue (ASR) generated during the shredding of End-of-Life Vehicles (ELVs). This
fraction is typically composed of materials such as glass, metals, stones, and other
heavy objects that could not be separated during the shredding process. Heavy ASR is
generally less voluminous but more complex and heterogeneous than light ASR, as it
contains a diverse range of materials with varying properties and characteristics.
According to Davis et al. 2020 and Brown et al. 2019, the composition of Automotive Shredder
Residue (ASR) can vary depending on several factors, including the type of vehicles shredded,
the recycling processes used, and the source of ASR since it is a complex waste stream
consisting of a heterogeneous mixture of materials. Some of the major components of ASR
includes:
• Plastics: Plastics are a significant component of ASR and can comprise a wide variety
of polymer types, such as polypropylene (PP), polyethylene (PE), polyvinyl chloride
(PVC), and acrylonitrile-butadiene-styrene (ABS) that are commonly used in various
automotive parts, such as bumpers, interior trim, and dashboard components, and can
account for a significant portion of ASR.
• Rubbers: Rubbers, including both natural rubber and synthetic rubber, are often present
in ASR from the shredding of tires, which is a common automotive waste material, can
be used in tire treads, sidewalls, and other tire components, and can be a major
component of ASR due to the large volume of tires generated as waste in Australia.
• Foams: Foams, such as polyurethane (PU) foam and expanded polystyrene (EPS) foam,
are commonly used in automotive seats, cushions, and other interior components, and
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can be present in ASR that can contribute to the bulk and weight of ASR and can have
specific properties, such as thermal insulation and cushioning, that can impact its
material properties.
• Textiles: Textiles, such as fabrics, carpets, and upholstery materials, can also be found
in ASR from shredded vehicles that can be made of various fibers, including natural
fibers (e.g., cotton, wool) and synthetic fibers (e.g., polyester, nylon), and can be used
in different automotive parts, such as seats, carpets, and headliners.
• Metals: Metals, including ferrous and non-ferrous metals, are commonly present in
ASR due to the metallic components of vehicles, such as body frames, engine parts,
and fasteners that can include steel, aluminum, copper, brass, and other metals, and
their composition and concentration in ASR can vary depending on the source of ASR.
• Glass: Glass is another component that can be found in ASR, primarily from the
windows, windshields, and mirrors of shredded vehicles that can be a minor component
of ASR compared to plastics, rubbers, and metals, but it can still contribute to the
overall composition of ASR.
• Other inorganic and organic contaminants: ASR may also contain other inorganic
and organic contaminants, such as paint, adhesives, sealants, fluids, and other
miscellaneous materials that can arise from various automotive components, coatings,
and fluids used in vehicles and can add to the complexity and variability of ASR
composition.
A typical composition of ASR as described by Inglezakis V.J & Zorpas A.A 2009 is tabulated
below:
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Table 1: ASR composition
As per the Italian standards (Morselli L et al. 2010), the material characterization of
• Sample collection: The first step is to collect a representative sample of the ASR
material which should be collected in a manner that minimizes contamination and
ensures that the sample is representative of the entire lot of material.
• Chemical analysis: To determine the chemical makeup of the ASR material. In this
step, the concentrations of various elements in the sample are determined using methods
like X-ray fluorescence (XRF), atomic absorption spectroscopy (AAS), and inductively
coupled plasma mass spectrometry (ICP-MS).
• Organic analysis: The ASR material should have its organic composition examined.
In this step, the organic chemicals present in the substance are identified and measured
using methods like Fourier-transform infrared spectroscopy (FTIR) and gas
chromatography mass spectrometry (GC-MS).
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• Toxicity analysis: The toxicity of the ASR material needs to be investigated. In this
step, the leaching potential of the substance is assessed using methods like the synthetic
precipitation leaching process (SPLP) and the toxicity characteristic leaching procedure
(TCLP).
• Residue disposal: Finally, the ASR material needs to be disposed of in a way that is
both safe and kind to the environment. This phase entails following all applicable laws
and making sure the substance won't endanger the environment or human health.
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As defined by Morselli L et al. 2010, ASR has complex and heterogeneous properties, which can
vary depending on the composition of the materials that are shredded. The properties of ASR can
also change over time due to weathering, aging, and exposure to the environment.
Studies have shown that the properties of ASR can change over time, particularly regarding its
chemical composition and stability. One study published in the Journal of Hazardous Materials
in 2015 found that the chemical composition of ASR can change due to weathering and
leaching, which can cause the release of potentially harmful substances into the environment
(Yang L et al. 2015). Another 2016 article in the journal Waste Management looked at how
microbial activity affected the characteristics of ASR. According to the study's findings
(Aleluia J et al. 2016), bacteria can degrade the organic components of ASR, changing both its
physical and chemical properties.
In addition, the properties of ASR can also change depending on how it is managed and treated.
For example, a study published in the Journal of Material Cycles and Waste Management in
2018 found that the properties of ASR can be improved through a process known as
"mechanical-biological treatment," which involves the use of mechanical and biological
processes to reduce the amount of organic matter in the waste. Overall, the properties of ASR
can change over time and depending on various factors. Further research is needed to fully
understand these changes and to develop effective strategies for managing and treating ASR to
minimize its impact on the environment.
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concentrations of metals including iron, aluminium, and copper as well as organic compounds
like plastic and rubber. It also found that Australian ASR had lower levels of dangerous
substances like lead than ASR produced in other nations. The authors concluded that the
composition of Australian solid waste (ASR) makes it a potentially useful resource for
recycling, but they also underlined the difficulties in sorting and recovering the various
components in ASR.
The potential environmental effects of ASR in Australia were the subject of a different study done
in 2018 by Yu et al. The life cycle assessment (LCA) method was employed in the study to assess
the environmental effects of ASR at every stage of its life cycle, from manufacture through disposal.
The study suggest that if ASR is not adequately handled, it could release dangerous contaminants
like heavy metals and organic chemicals into the environment. It also discovered that recycling
ASR, as opposed to landfilling or incineration, could greatly lessen its environmental impact. The
authors advocated for the creation of an all-encompassing ASR management approach that
incorporates steps to lessen ASR production, boost recycling rates, and lessen the environmental
effects of ASR disposal.
Harris et al.'s 2016 study, which was another one, looked at the possibility of employing pyrolysis
to turn ASR into valuable products like fuels and chemicals. The ideal conditions for turning ASR
into liquid, gas, and solid products were found using laboratory-scale pyrolysis studies. While the
study concluded that pyrolysis might be a beneficial process for transforming ASR into useful
products, it also made notice of the fact that the quality and quantity of the products varied
depending on the ASR feedstock and the pyrolysis settings.
To summarize, previous studies on ASR in Australia have highlighted the complexity of this
waste stream, as well as the potential environmental impacts associated with its disposal. These
studies have also identified opportunities for recycling and recovering valuable materials from
ASR, as well as for converting ASR into useful products through pyrolysis or other methods.
However, significant challenges remain in terms of managing and disposing of ASR in a
sustainable and environmentally responsible manner. As such, further research and policy
development are needed to address these challenges and ensure the long-term sustainability of
Australia's automotive industry.
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2.5 Physical characterization of Automotive Shredder Residue (ASR)
The physical characterization of Automotive Shredder Residue (ASR) will typically include
following steps (Xiao et al., 2019):
• Sample Collection: ASR samples can be collected from automotive shredding facilities
or recycling centres in Australia that should be collected using appropriate sampling
protocols and stored in clean, labelled containers to avoid cross-contamination.
• Particle Size Analysis: Particle size analysis is an essential parameter for ASR
characterization that can be done using techniques such as sieving or laser diffraction
to determine the particle size distribution of ASR particles. This information can
provide insights into the physical properties of ASR, such as its bulk density, porosity,
and flow characteristics.
• Density Measurement: The density of ASR can be determined using methods such as
gas pycnometer or liquid displacement that can provide information on the compaction
characteristics of ASR, which can be important for waste management and resource
recovery strategies.
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• Microscopic Analysis: Microscopic analysis techniques, such as optical microscopy or
scanning electron microscopy (SEM), can be used to characterize the morphology and
microstructure of ASR particles. This can provide insights into the composition and
physical properties of ASR, including the presence of different materials, particle shape,
and surface characteristics.
• Data Analysis: Data obtained from the physical characterization tests should be
analysed using appropriate statistical techniques to interpret the results and draw
conclusions.
Although this process will give us more efficient result on the physical characterization of
materials, this thesis will only cover simpler form of physical characterization which involves
visual inspection of the sample following the analysis of a case study in Italy.
As per Inglezakis V.J & Zorpas A.A 2009, two types of waste were collected in the shredding
facility in Bologna (Northern Italy) which are listed below:
• Scrap waste from central collection site such as electrical appliances: 29.5%
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The total capacity of the plant was 250000 tons per year which produced 180000 tons of ferrous
materials while 6000 tons of non-ferrous materials were produced. Similarly, a total of 64000
tons of light and heavy fluff (known as ASR) were produced. Among this waste, 69.51% were
able to be recovered which comprised of ferrous and nonferrous materials while 0.44% of
recovered materials contained materials such as tyres, bumpers and tanks. Lastly, remaining
waste (ASR) comprising of 30.05% was sent to landfill.
For the characterization of ASR, 125kg of sample from the shredding facility was repeatedly
collected in a storage tank and compacted till a final weight reached 650 kg and covered so that
it wasn’t exposed to air and water. Finally, according to Italian norm UNI 10802:2004,
quartering process was performed up to four times to obtain a resulting sample of 16-18 kg.
Further the sample was categorized into 4 parts based on their size as: 0 < Φ< 20 mm; 20 < Φ
< 50 mm; 50 < Φ < 100 mm; Φ > 100 mm. The coarser fraction underwent through the material
analysis as described before in 2.3 according to Italian Environmental Protection Agency
(ANPA, 2002; APAT, 2008).
Materials below 20mm were considered as fines since it was not possible to characterize each
minute pieces, hence, it couldn’t be considered for recycling. However, the remaining three
categories composition is explained by Table 2 as below:
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Quartering procedure of ASR
The quartering procedure is a commonly used method for sampling automotive shredder
residue (ASR) in the recycling industry (Ahmed et al. 2017). This procedure involves dividing
the ASR sample into four equal parts, discarding one part, and combining and mixing the
remaining three parts thoroughly. This process is repeated until the desired sample size is
obtained, with each new sample being generated from a subset of the previous one (ASTM
2016).
The quartering procedure is crucial in the analysis of ASR, as it ensures that the sample is
representative of the entire material. By eliminating localized variations or clumping in the
ASR material through repeated quartering and remixing, the resulting sample provides a more
accurate representation of the entire material (Ahmed et al.
2017).
The main questions developed during the research are listed below:
• Since there is no Australian standard for characterization of ASR, in what ways can the
physical characterization of Automotive Shredder Residue take place in Australia?
• What might be the difficulties faced during the visual inspection of the ASR sample in
the lab?
• Can all the materials be distinguished solely by visual inspection?
3.2 Aims
This project aims to physically characterize ASR supplied by one of the Australian metal
suppliers which will be an initiative in the field of ASR waste management since there are no
Australian standard introduced for the management.
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The goal of the material characterization of Automotive shredder residue (ASR) in Australia is
to better understand the composition and properties of this waste material generated from end-
of-life vehicles (ELVs). ASR is a complex mixture of various materials, including plastics,
rubber, glass, metal, and other contaminants, which makes its disposal and recycling a
challenging task.
By characterizing the ASR, researchers and policymakers can develop effective strategies for
the management and disposal of this waste material, including identifying potential recycling
options and determining the best disposal methods. Additionally, material characterization can
help in assessing the environmental impact of ASR and identifying any potential risks
associated with its disposal.
Furthermore, the information obtained from material characterization can also be used to develop
innovative and sustainable solutions for the recovery and reuse of valuable materials from ASR,
which can help reduce the environmental impact of ELVs and promote a circular economy.
3.3 Objectives
4. METHODOLOGY
Since there are no Australian standard for the characterization of ASR, the Italian standard will
be followed as a guideline in this thesis in the material characterization process. Also, since
ASR is a complicated waste and has altering behaviour, a detailed material characterization as
explained above in literature review (2.3 & 2.5) will not be carried out. Rather, only physical
characterization of a sample from a shredding facility in Sydney, NSW will be done in a lab
using visual inspection.
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Likewise, a case study in Bologna (Northern Italy) as explained in 2.6 will be taken as a
reference to carry out the lab work which will take place in an environmental lab in Western
Sydney, Kingswood. This work will be done under the supervision of the subject coordinator
and an industry partner which is yet to be decided.
To simplify, the process that will undergo for the physical characterization of ASR can be
described as below:
1. ASR sample: The ASR generated from a shredding plant in Sydney, NSW will be sent
through multiple quarterly procedures until the desired amount of ASR sample is
generated for the lab work.
2. Visual inspection: The sample will be taken to an environmental lab in Western Sydney
University, Kingwood where visual inspection will take place under the supervision of
subject coordinator and an industry partner.
3. Sorting procedure: During the visual inspection, the materials will be categorized based
on their types such as plastic, foam, rubber, metal, textiles, cellulosic, dirt and other
materials. After that, the materials can be sorted based on their size as well as discussed
in the case study of Italy in 2.6.
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4.1 Resource Requirements
The equipment required for the lab work are listed below:
• Lab Bench
• Lab Balance
• Beaker
Similarly, the resource required to accomplish this project can be listed as below:
• Time: A timeframe of 14 weeks is allocated to complete the first progress report of the
project starting from the 1st week of March and ending on the 2nd week of June.
• Research materials: Various journals and articles were accessed online to gain more
insights on the topic ‘Material characterization of Automotive Shredder Residue (ASR)
in the context of Australia’.
• Advisor/Mentor: Feedback on various aspects such as literature review and
methodology were possible with the guidance of the supervisor.
• Institutional support: The materials from Western Sydney University online library
were accessed to gain more knowledge on the project. Similarly, the guidelines to
writing a proposal and project were followed thoroughly with the help of provided files.
• Lab Work: As discussed with the supervisor, an industry partner will be allocated to
help in the lab work in this project. The lab work will take place in an environmental
lab in Western Sydney University, Kingswood Campus and a sample of ASR will be
provided via an Australian metal recycler for the physical characterization.
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5. PROPOSED TIMELINE
11 Lab work, Analysing results and Final Thesis July November 14 weeks
report (ENGR 7028 (PG) Engineering Project
2)
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Figure 4 Gantt chart illustrating the proposed timeline of the thesis.
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6. REFERENCES
Ahmed, M. J., Ali, M., Zahed, M. A., & Islam, M. R. 2017, ‘A review on automated sorting of
source-separated municipal solid waste for recycling’, Waste Management, vol. 60, pp. 56-74.
<https://doi.org/10.1016/j.wasman.2016.11.023>
ASTM 2016, ‘ASTM D2013-16 Standard Practice for Preparing Coal Samples for Analysis’,
Retrieved from <https://www.astm.org/Standards/D2013.htm>
ASTM International 2018, ‘ASTM D7058-18: Standard Test Method for Determination of
Shreddability of End-of-Life Vehicles by the Random Sampling and Sequencing
Technique. ASTM International’
Brown, S., Saeed, K., & Rasul, M. 2019, ‘Material characterization of automotive shredder
residue (ASR) for resource recovery: A review. Resources’, Conservation and Recycling, vol.
147, pp. 32-45.
Chen, M., Li, X., Zhang, C., Gao, Y., & Liu, J. 2017, ‘Automotive shredder residue (ASR):
Reviewing its production, characteristics, and recycling potentials, ‘Resources,
Conservation and Recycling’, vol. 124, pp. 182-193.
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Davis, M., Santos, R., & Lopes Silva, D. 2020, ‘Automotive Shredder Residue (ASR): A
review on its composition, characteristics, and management’, Waste Management, vol. 102,
pp. 913-932.
Gentil, E., Andreasi Bassi, S., Costa, S., & Rossetti, G. 2015, ‘Analysis of the environmental
impacts of automotive shredder residue in Italy’, Journal of Cleaner
Production, vol. 104, pp. 392-398.
Harris, A., Bartle, J., & Ahamed, R. 2016, ‘Pyrolysis of automotive shredder residue: influence
of feedstock and pyrolysis conditions on product yields and quality’, Waste
Management, vol. 56, pp. 289-300.
Ho, K. L., Zhu, M., & Tay, T. L. 2019, ‘Composition of automotive shredder residue
Kuo, Y. L., Wibowo, C., Hall, P. J., & Cheeseman, C. R. (2018), ‘A review of the recycling of
non-metallic fractions of printed circuit boards. Resources’, Conservation and Recycling, vol.
134, pp. 308-318.
Morselli L., Santini A., & Passarini F. 2010, ‘Automotive Shredder Residue (ASR)
characterization for a valuable management’, Waste management, University of Bologna, Dept,
Industrial Chemistry and Materials, Viale Risorgimento 4, I-40136
Bologna, Italy
Quaghebeur, M., Cappuyns, V., & Geysen, D. 2016, ‘Automotive shredder residue (ASR):
Reviewing its production from end-of-life vehicles (ELVs) and its recycling, energy or
chemicals’ valorisation’, Journal of Environmental Management, vol. 181, pp. 89-104.
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Quaghebeur, M., Laenen, B., & Geysen, D. 2016, ‘Automotive shredder residue (ASR):
Reviewing its production from end-of-life vehicles (ELVs) and its recycling, energy or
chemicals' valorisation’, Journal of Cleaner Production, vol. 114, pp. 18-40.
Vogl, A. P., Johnson, J. A., & Hansen, B. G. 2015, ‘Environmental impacts of automotive
shredder residue (ASR): A critical review’, Journal of Environmental
Management, vol. 149, pp. 153-166.
Xiao, Y., Qiao, Y., Zhang, J., Li, G., Wang, Y., & Zhang, X. (2019), ‘Comprehensive
characterization of automotive shredder residue generated in China’, Waste
Management, vol. 88, pp. 208-217. <https://doi.org/10.1016/j.wasman.2019.03.036>
Yang L., Li X., Li X., Su Z., Zhang C., Xu M., & Zhang H. 2015, ‘Improved stability and
enhanced efficiency to degrade chlorimuron-ethyl by the entrapment of esterase SulE in cross-
linked poly (γ-glutamic acid)/gelatin hydrogel’, Journal of Hazardous
Materials, vol. 287, pp. 287-295 <https://doi.org/10.1016/j.jhazmat.2015.01.056>.
Yu, J., Yin, X., Shen, L., Wang, J., & Xie, F. 2018, ‘Environmental assessment of automotive
shredder residue (ASR) management in Australia’
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7. APPENDICES
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Appendix 2: A typical picture of ASR after shredding (extracted from engineeredrecyclingsystems.com)
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