Industrial Resources Council:Industrial Resources Council: Partners in Sustainable Partners in Sustainable Materials ManagementMaterials Management

NERC Fall MeetingNERC Fall MeetingNorthampton, MANorthampton, MAOctober 27, 2008October 27, 2008

www.www.industrialresourcescouncilindustrialresourcescouncil.org.org

Who is the IRC?Who is the IRC?

The Industrial Resources Council (IRC) is a The Industrial Resources Council (IRC) is a collaborative partnership working to develop collaborative partnership working to develop markets for industrial materialsmarkets for industrial materialsGoals:Goals:–– Create awareness & increase understandingCreate awareness & increase understanding–– Share technical & environmental informationShare technical & environmental information–– Develop codes, standards, and regulatory Develop codes, standards, and regulatory

guidance through organizational partnershipsguidance through organizational partnerships

Who is the IRC?Who is the IRC?

IRC is comprised of nonIRC is comprised of non--profit industry associations profit industry associations who spearhead their industrywho spearhead their industry’’s efforts on material s efforts on material utilizationutilization–– American Coal Ash AssociationAmerican Coal Ash Association–– Construction Materials Recycling AssociationConstruction Materials Recycling Association–– Foundry Industry Recycling Starts TodayFoundry Industry Recycling Starts Today–– National Council for Air & Stream ImprovementNational Council for Air & Stream Improvement–– National Slag Association & Slag Cement AssociationNational Slag Association & Slag Cement Association–– Rubber Manufacturers AssociationRubber Manufacturers Association

Why was the IRC formed?Why was the IRC formed?

Industries were engaging with same Industries were engaging with same people in same forumspeople in same forums–– Similar issues & opportunitiesSimilar issues & opportunities–– Similar marketsSimilar marketsCreate single point of contact for Create single point of contact for national & state partnershipsnational & state partnershipsCoordinate technology transfer & Coordinate technology transfer & market development effortsmarket development efforts

IRC IRC –– Focus on Priority Focus on Priority MaterialsMaterials

U.S. EPAU.S. EPA–– Coal CombustionCoal Combustion

Products (CCPProducts (CCP’’s)s)–– Foundry SandFoundry Sand–– Construction & Construction &

Demolition DebrisDemolition Debris–– Others under Others under

considerationconsideration

Federal Highway Federal Highway AdministrationAdministration–– Recycled AsphaltRecycled Asphalt–– Recycled ConcreteRecycled Concrete–– Coal AshCoal Ash–– Foundry SandFoundry Sand–– Steel SlagSteel Slag–– TiresTires

Why care about Industrial Why care about Industrial Materials?Materials?

Material volumes are largeMaterial volumes are large–– Less fragmented than MSWLess fragmented than MSW

Sources are fewer in numberSources are fewer in numberGenerators have economic incentives Generators have economic incentives to reduce, reuse & recycleto reduce, reuse & recycleTargeted efforts can make a big Targeted efforts can make a big difference!difference!

The RCRA Program Total Quantity of Wastes Generated (million tons)

Industrial Waste (7600)

Hazardous Waste - RCRA Managed

(40)

Municipal Solid Waste (232)

Construction & Demolition (136)

Coal Combustion Ash - Sp W (121)

Special Waste - less CC Ash

(4852)

Hazardous Waste - CWA

Wastewater (450)

How Much Material?How Much Material?

Generation Rate:Generation Rate:–– CCPsCCPs

122 million TPY122 million TPY–– Steel Mill ResidualsSteel Mill Residuals

19.7 million TPY19.7 million TPY–– Foundry Sands & Foundry Sands &

SlagsSlags10 million TPY10 million TPY

–– Paper Mill Residuals, Paper Mill Residuals, Boiler Ash & OthersBoiler Ash & Others

15 million TPY15 million TPY–– Tires (est. in 2005)Tires (est. in 2005)

300 million tires/yr300 million tires/yr–– Recycled ConcreteRecycled Concrete

180 million tons est.180 million tons est.325 million total C&D325 million total C&D

Number of Facilities:Number of Facilities:–– Power Plants: ~500Power Plants: ~500–– Steel Mills: ~130Steel Mills: ~130–– Foundries: 2,800 Foundries: 2,800 –– Pulp & Paper Mills: ~430Pulp & Paper Mills: ~430–– Tires: Municipal, Tires: Municipal,

commercial & industrial commercial & industrial generation points generation points

–– Recycled Concrete: ~2,300Recycled Concrete: ~2,300

Industrial Generators Close Industrial Generators Close the Loop on MSW Recyclingthe Loop on MSW RecyclingSteel Mills/FoundriesSteel Mills/Foundries

Recycle 77 Million tons Recycle 77 Million tons of scrapof scrap–– 14 Million vehicles14 Million vehicles–– 90% of Appliances90% of Appliances–– 60 % cans60 % cans–– 96% construction scrap96% construction scrap–– Recycles 1.5 Million Recycles 1.5 Million

Tons of B ScrapTons of B Scrap–– Recycles 4.6 Million Recycles 4.6 Million

Tons of Flux slagTons of Flux slagUse Tires for Fuel, Iron Use Tires for Fuel, Iron and Carbonand Carbon

Pulp/Paper IndustryPulp/Paper IndustryRecycles 50 Million tons of Recycles 50 Million tons of paper per yearpaper per yearRecovered fiber is use in Recovered fiber is use in making: making: –– Paperboard gradesPaperboard grades–– NewsprintNewsprint–– Tissue & towelingTissue & toweling–– Printing & writing gradesPrinting & writing grades

C&D RecyclersC&D RecyclersRecycle 168 Million tons of Recycle 168 Million tons of Construction and Construction and Demolition materials per Demolition materials per year, including 140 million year, including 140 million of concreteof concrete

““Beyond RCRABeyond RCRA””

A Vision of the Future:A Vision of the Future:–– “…“… Materials that were once considered wastes Materials that were once considered wastes

suitable only for suitable only for landfillinglandfilling are now continually are now continually reused and recycledreused and recycled……

–– …… It is likely that the current distinctions It is likely that the current distinctions between wastes and materials (which in a large between wastes and materials (which in a large part are regulatory in nature) will become less part are regulatory in nature) will become less meaningful.meaningful.””

Source: U.S. Environmental Protection AgencySource: U.S. Environmental Protection Agency

EPAEPA’’s Resource s Resource Conservation ChallengeConservation Challenge

–– RCC is a major cross media RCC is a major cross media environmental stewardship effortenvironmental stewardship effort

–– Gives EPA the opportunity to:Gives EPA the opportunity to:Work on national problemsWork on national problemsLeverage outside partnershipsLeverage outside partnershipsCreate sustainable projectsCreate sustainable projectsProvide measurable Provide measurable environmental outcomesenvironmental outcomes

Industrial Material Industrial Material Recycling is RCC PriorityRecycling is RCC Priority

Move large volumes Move large volumes of low hazard of low hazard materials from materials from disposal to reusedisposal to reuseSave energySave energyConserve resourcesConserve resourceshttp://http://www.epa.gov/ewww.epa.gov/epawaste/conserve/rrr/pawaste/conserve/rrr/imr/index.htmimr/index.htm

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Green Highways PartnershipGreen Highways Partnership

Construction of Construction of transportation systems transportation systems can significantly impact can significantly impact the environment.the environment.

Environmental impact Environmental impact can be reduced through can be reduced through sensitive system design.sensitive system design.

Quality and cost can be Quality and cost can be maintained while maintained while meeting technical meeting technical performance standardsperformance standards

““GreenerGreener”” RoadwaysRoadways

SubSub--base Materialsbase Materials made using fly ash made using fly ash aggregate, bottom ash, recycledaggregate, bottom ash, recycled concrete, recycled asphalt or foundry sandsconcrete, recycled asphalt or foundry sands

PavementsPavements made using concrete or asphalt made using concrete or asphalt containing coal ash, foundry sand, or slagscontaining coal ash, foundry sand, or slags

Embankments and FillsEmbankments and Fills made using CCPs, made using CCPs, slag, tires or foundry sandsslag, tires or foundry sands

Landscaping materialsLandscaping materials using CCPs, compost, using CCPs, compost, foundry sands and other industrial residuesfoundry sands and other industrial residues

The Construction InitiativeThe Construction Initiative

Coordinated through Coordinated through OSWOSW’’ss Industrial Industrial Materials Recycling (IMR) ProgramMaterials Recycling (IMR) Program–– Effort to increase use of IMR materials in Effort to increase use of IMR materials in

public & private construction projectspublic & private construction projects–– Outreach to APWA, NACO/NACE & othersOutreach to APWA, NACO/NACE & others

Terminology has changed from Terminology has changed from ““wastewaste”” to to ““byproductbyproduct”” to to ““materialmaterial””

Availability of Coal Combustion Products and Uses in NERC Area

CCP BasicsOnly coal-fueled power plants produce CCPs (fly ash, bottom ash, boiler slag, air emission residues and fluidized combustion bed ash)Plants located in MA, NH, NY, NJ, PA and DE are main producersNot all plants produce CCPs suitable for beneficial useMarketers manage and distribute CCPs on behalf of most utilities

Production and use numbers are submitted Production and use numbers are submitted voluntarilyvoluntarily2007 data includes 170 plants, nationwide out 2007 data includes 170 plants, nationwide out of nearly 500 of nearly 500 Unreported data is extrapolated to achieve Unreported data is extrapolated to achieve national averagesnational averagesApproximately 10 plants reported in NERC Approximately 10 plants reported in NERC area; none from NY, DE or MA.area; none from NY, DE or MA.

Imprecise or Incomplete Data

Fly ash in concrete Fly ash in concrete Fly Ash and Bottom Ash used in the production Fly Ash and Bottom Ash used in the production of of portlandportland cement and in cement and in flowableflowable fillsfillsFA, BA and boiler slag in embankments and FA, BA and boiler slag in embankments and structural fillsstructural fillsSlag in roofing granulesSlag in roofing granulesAll can be used in mining applicationsAll can be used in mining applicationsA few plants report miscellaneous (undefined) A few plants report miscellaneous (undefined) usesusesProbably more than 50% is disposedProbably more than 50% is disposed

Typical Uses in NERC Area

Difficult to account for all Difficult to account for all CCPsCCPs produced as no produced as no obligation for a company to reply to the obligation for a company to reply to the voluntary surveyvoluntary survey

Uses vary by plant according to type of CCPUses vary by plant according to type of CCP

Quality issues limit total amount of Quality issues limit total amount of CCPsCCPs usedused

Most states support beneficial use; many on a Most states support beneficial use; many on a case by case basiscase by case basis

Traditional construction uses most commonTraditional construction uses most common

Conclusions

CCP use directly supports and contributes CCP use directly supports and contributes to a more sustainable environmentto a more sustainable environment

Sound technical, environmental and Sound technical, environmental and operational procedures can address operational procedures can address perceptions and potential objectionsperceptions and potential objections

Properly managed applications will achieve Properly managed applications will achieve desired physical, environmental, economic desired physical, environmental, economic and social resultsand social results

Conclusions – cont.

Foundry Sand & Foundry Sand & SlagsSlags

AsphaltStructural Fills & Embankments

Flowable Fill

Manufactured Soils Road & Building Bases

NERC Profile NERC Profile -- Foundry Foundry Sand GeneratorsSand Generators

CT CT -- 1616DE DE -- 00ME ME -- 1616MA MA -- 4747NH NH -- 2121

NJ NJ -- 2828NY NY -- 5656PA PA -- 137137RI RI -- 1414VT VT -- 11

Source: www.metalcastingvirtuallibrary.com

Foundry Sand Challenges Foundry Sand Challenges & Opportunities& Opportunities

No regNo regional market surveyional market survey–– NEWMOA database would provide BUD NEWMOA database would provide BUD

overviewoverviewFoundry sand is an EPA priority Foundry sand is an EPA priority materialmaterialUS EPA/US Dept. of Agriculture US EPA/US Dept. of Agriculture preparing joint risk assessment & preparing joint risk assessment & usage guidelinesusage guidelines

Foundry sand markets in Foundry sand markets in northeastnortheast

Many NERC states do not have regulatory Many NERC states do not have regulatory framework for foundry sandsframework for foundry sands–– Used in landfill caps & closures, ADCUsed in landfill caps & closures, ADC–– Not highest value use for this materialNot highest value use for this material

Most states allow bound applicationsMost states allow bound applications–– Cement, concrete, asphalt, Cement, concrete, asphalt, flowableflowable fillfill–– Regional cement kilns source some foundry sand but most Regional cement kilns source some foundry sand but most

NE foundries too small for this application to be practicalNE foundries too small for this application to be practical–– Transportation distances to cement kilns also deal breakerTransportation distances to cement kilns also deal breaker

Some examples in NERC states of approvals for Some examples in NERC states of approvals for structural fill & road base, but not commonstructural fill & road base, but not common

Foundry sand marketsFoundry sand markets

Highest value uses for foundry sands are in road Highest value uses for foundry sands are in road base, structural fill & soil manufacture where clay base, structural fill & soil manufacture where clay additives to sand add valueadditives to sand add valuePA new general permit allows use in soil PA new general permit allows use in soil manufacturingmanufacturing–– PA Recycling Markets Center matching foundries with PA Recycling Markets Center matching foundries with

landscaping companieslandscaping companies

Project needed to match foundries with LOCAL Project needed to match foundries with LOCAL construction opportunities, especially municipalities construction opportunities, especially municipalities & towns& towns–– Which is where recycling programs are!Which is where recycling programs are!

Regional market development approach for smaller Regional market development approach for smaller generators is neededgenerators is needed

Foundry Sand Risk Foundry Sand Risk AssessmentAssessment

In April 2007, US EPA issued a In April 2007, US EPA issued a ““Foundry Foundry Sand StatementSand Statement””–– Supports the use of ferrous and aluminum foundry sands Supports the use of ferrous and aluminum foundry sands

in many applicationsin many applications

US EPA/US Dept. of Agriculture will release US EPA/US Dept. of Agriculture will release joint risk assessment/guideline document joint risk assessment/guideline document this fallthis fallUS EPAUS EPA’’s conclusion: Properly managed s conclusion: Properly managed ferrous and aluminum foundry sands are ferrous and aluminum foundry sands are comparable to native soils and safe for comparable to native soils and safe for residential useresidential use

Steel SlagSteel Slag

AGGREGATEAGGREGATEBituminous Concrete Bituminous Concrete (Asphalt)(Asphalt)Construction AggregateConstruction AggregateCement Kiln Raw FeedCement Kiln Raw Feed

NERC Profile NERC Profile -- Steel SlagSteel Slag

Steel slag is generated in the Steel slag is generated in the Northeast by mills in PA, NJ, NY & MDNortheast by mills in PA, NJ, NY & MDSlag is marketed through commercial Slag is marketed through commercial broker/processorsbroker/processorsSlag cement (ground granulated blast Slag cement (ground granulated blast furnace slag) sold throughout the furnace slag) sold throughout the region for use in concreteregion for use in concrete

Steel slag typesSteel slag types

Blast furnace slagBlast furnace slagSteel furnace slagSteel furnace slagSlag cement (ground granulated blast Slag cement (ground granulated blast furnace slag)furnace slag)

Each type has different properties and Each type has different properties and different applicationsdifferent applications–– Steel slag can be expansiveSteel slag can be expansive

Markets for Steel SlagMarkets for Steel Slag

Cement kiln feedstockCement kiln feedstockPortland cement concrete productionPortland cement concrete productionCoarse aggregateCoarse aggregate–– AsphaltAsphalt–– Road baseRoad base–– Drainage systemsDrainage systems–– Construction aggregate (blast furnace slag)Construction aggregate (blast furnace slag)

Issues & ChallengesIssues & Challenges

Differing beneficial use regulations from state to Differing beneficial use regulations from state to statestateDiffering DOT specifications from state to stateDiffering DOT specifications from state to stateLack of knowledge of part of end usersLack of knowledge of part of end users–– For example, steel slag is a superior aggregate to hot mix For example, steel slag is a superior aggregate to hot mix

asphalt because provides better friction properties than asphalt because provides better friction properties than most virgin most virgin aggregtesaggregtes (granite and high quality gravel)(granite and high quality gravel)

Paper Industry ByPaper Industry By-- ProductsProductsThe paper industry produces a number The paper industry produces a number

of byof by--product types. Two major product types. Two major ones areones are……

Wastewater treatment residualsWastewater treatment residuals

5.5 million dry tons/year5.5 million dry tons/year

Power boiler ashPower boiler ash≈≈

4.0 million dry tons/year4.0 million dry tons/year

NERC Profile NERC Profile -- Pulp & Pulp & Paper ResidualsPaper Residuals

Number of mills:Number of mills:Total paper Total paper production:production:WWTP residual WWTP residual production:production:Boiler ash:Boiler ash:

1001008 million TPY8 million TPY

460,000 dry tons/yr.460,000 dry tons/yr.

330,000 dry tons/yr.330,000 dry tons/yr.

WWTP Residuals WWTP Residuals ManagementManagement

Land applied:Land applied:Other beneficial Other beneficial use:use:Burned:Burned:

Landfilled:Landfilled:

9%9%5%5%

31% (mostly on31% (mostly on--site, site, some energy recovery)some energy recovery)55%55%

Other Beneficial Uses for WWTP Other Beneficial Uses for WWTP Residuals in NERC statesResiduals in NERC states

Soil ManufactureSoil ManufactureCompostingCompostingMine reclamationMine reclamationAnimal beddingAnimal beddingIndustrial/commercial absorbentIndustrial/commercial absorbentLandfill cap (hydraulic barrier layer)Landfill cap (hydraulic barrier layer)Daily landfill coverDaily landfill cover

Boiler Ash ManagementBoiler Ash Management

Land applied:Land applied:Other beneficial Other beneficial use:use:Landfilled:Landfilled:

35%35%26%26%

39%39%

Other beneficial uses for Other beneficial uses for boiler ash in NERC statesboiler ash in NERC states

Cement manufactureCement manufactureEarthen construction/soil Earthen construction/soil stablizationstablizationWaste stabilizationWaste stabilizationRoad traction agentRoad traction agent

Scrap Tire Management in Scrap Tire Management in NERC statesNERC states

Separate handout from Rubber Separate handout from Rubber Manufacturers Association provides Manufacturers Association provides state by state information (30 slides)state by state information (30 slides)

Scrap Tire ConclusionsScrap Tire Conclusions

TDF the predominant market TDF the predominant market Asphalt rubber used in 2 statesAsphalt rubber used in 2 states–– Limited market impactLimited market impact

Civil engineering used in 2 statesCivil engineering used in 2 states–– Limited market impactLimited market impact

Tires flow to major marketsTires flow to major marketsWell established infrastructureWell established infrastructure

Scrap Tire ConclusionsScrap Tire Conclusions

1 state considering scrap tire legislation1 state considering scrap tire legislationNo other legislation likely (nearNo other legislation likely (near--term)term)Scrap tires seem to be a concern; not a Scrap tires seem to be a concern; not a problemproblemLoss of any/all current markets would Loss of any/all current markets would create new problems for the regioncreate new problems for the region

Scrap Tire ConclusionsScrap Tire Conclusions

Additional markets are neededAdditional markets are neededPotential for new TDF marketsPotential for new TDF marketsPotential for new CE projectsPotential for new CE projectsPotential for new/expanded products Potential for new/expanded products AR will be longAR will be long--term projectterm projectRegional cooperation exists: should be Regional cooperation exists: should be used to develop markets used to develop markets

Industrial Material IssuesIndustrial Material Issues

Requires same type of coordinated Market Requires same type of coordinated Market Development strategies developed for postDevelopment strategies developed for post--consumer recyclingconsumer recyclingPostPost--industrial materials differ in scaleindustrial materials differ in scale–– Smaller number of higher volume generatorsSmaller number of higher volume generators

Regulatory agencies play a larger roleRegulatory agencies play a larger roleGoal: Create demand for alternative materialsGoal: Create demand for alternative materialsGoal: Match supply and demandGoal: Match supply and demand

IRC Educational ToolsIRC Educational Tools

ToolkitToolkit–– General IMR brochureGeneral IMR brochure–– Material to application matrixMaterial to application matrix–– Individual material & application profilesIndividual material & application profiles

Website Website –– www.industrialresourcescouncil.orgwww.industrialresourcescouncil.org–– Resource for multiple stakeholdersResource for multiple stakeholders–– Inc. links to association websitesInc. links to association websites

Regional and state construction workshopsRegional and state construction workshops

Industrial Resources Industrial Resources CouncilCouncil

Industrial Resources Industrial Resources Council is a resource for Council is a resource for information about how to information about how to use industrial materials in use industrial materials in various applicationsvarious applicationsOutreach through IRC to Outreach through IRC to APWA, NACE, and othersAPWA, NACE, and othershttp://www.industrialresouhttp://www.industrialresourcescouncil.orgrcescouncil.orgInformation on specific Information on specific materials used in specific materials used in specific applicationsapplications

IRC & NERCIRC & NERC

Beneficial use rules & specifications differ from state to Beneficial use rules & specifications differ from state to statestate–– Raises costs for industries trying to do the right thingRaises costs for industries trying to do the right thing

Different rules for different materials in same situation Different rules for different materials in same situation –– EPA, USDA, RMRC use different environmental evaluation EPA, USDA, RMRC use different environmental evaluation

methodologiesmethodologies–– EPA developing Risk CompendiumEPA developing Risk Compendium

NEWMOA BUD study a good beginningNEWMOA BUD study a good beginningMid Atlantic Green Highways Partnership has a project Mid Atlantic Green Highways Partnership has a project to try to harmonize BUD rules and specs in EPA R3 to try to harmonize BUD rules and specs in EPA R3 We would like to work with NERC and other partners!We would like to work with NERC and other partners!–– IRC members have a presence in all 50 statesIRC members have a presence in all 50 states–– IRC conducts regional and state workshops in partnership with IRC conducts regional and state workshops in partnership with

EPA, FHWA and other stakeholdersEPA, FHWA and other stakeholders

For More InformationFor More Information

American Coal Ash AssociationAmerican Coal Ash Associationwww.acaawww.acaa--usa.orgusa.org

Construction Materials Recycling Construction Materials Recycling AssociationAssociation

www.cdrecycling.orgwww.cdrecycling.orgwww.concreterecycling.orgwww.concreterecycling.org

Foundry Industry Recycling Foundry Industry Recycling Starts TodayStarts Today

www.foundryrecycling.orgwww.foundryrecycling.org

For More InformationFor More Information

National Council for Air & Stream National Council for Air & Stream ImprovementImprovement

www.NCASI.orgwww.NCASI.org

National Slag Association & National Slag Association & Slag Cement AssociationSlag Cement Association

www.nationalslag.orgwww.nationalslag.orgwww.slagcement.orgwww.slagcement.org

Rubber Manufacturers AssociationRubber Manufacturers Associationwww.rma.orgwww.rma.org

ncasincasi