As the world's largest carpet manufacturer, Shaw is continually seeking opportunities to maximize the potential reuse of reclaimed materials. It is the key to our closing the loop β of turning our vertical integration into circular integration. Re2E, our second major investment in alternative energy, is the first energy plant in the world completely fueled by carpet materials. The facility has a patent pending for its unique process β a true example of Sustainability through Innovation.
Fueled by 84 million pounds of carpet per year from a combination of carpet manufacturing waste and post-consumer carpet from residential and commercial sites, Re2E is capable of producing 50,000 pounds of steam energy per hour. This steam is sent to carpet manufacturing plants adjacent to the Re2E site β offsetting the use of traditional and fossil fuel-based energy. Re2E will save enough fossil fuel to power the equivalent of approximately 7,500 homes annually β eventually co-generating enough electrical energy to help sustain its own operations.
At Re2E, the old carpet goes through multiple shredders to eliminate post-consumer urban debris that might have inadvertently been included and to separate fines that are used for other purposes. Then a series of rollers separate any remaining calcium carbonate from the fiber, which has the most energy value. Once heated, the remaining fuel transitions from a solid state to a gas. The heat rises and crosses over to a fire-tube section, which heats a series of water tubes, creating the steam that is then superheated to more than 400 degrees Fahrenheit before it goes through a turbine to create electricity.
Learn more about how the Re2E process works.