Chapter NR 538, Wis. Adm. Code Beneficial Reuse of Industrial Byproduct
March 27, 2015 FET Sustainability Webinar
Ruth O’Donnell, WDNR NR 538 QUICK OVERVIEW
 Established January 1, 1998
 Goal = encourage beneficial use of industrial byproducts in a nuisance‐free and environmentally sound manner
http://www.we-energies.com/environmental/CoalCombustionProducts_2K11018.pdf
Million cubic yards
WISCONSIN INDUSTRIAL BYPRODUCTS 2000 – 2013
29.5 million yd3
available
19.6 million yd3
used
 NR 538.03(4) Specific high‐volume industrial byproducts: paper mill sludge, coal ash, flue gas desulfurization material, foundry sand & slag, lime kiln dust, Other non‐hazardous solid waste with similar characteristics  Creates 5 categories of industrial byproducts
 Specific uses are allowed for each category
Industrial Byproducts
 RCRA non‐hazardous  Category (1‐5) assigned based on lab analysis ASTM Water Leach Test mg/L
Total Elemental Analysis mg/kg
 Potential risk to human health & the environment
Category 1 = few restrictions on use Category 5 = most restrictions on use & placement  Category standards based on:
NR 140 (drinking water)
NR 105 (surface water quality) NR 720 (soil cleanup) Beneficial Uses Projects
NR 538.10
Industrial Byproduct
Category
5
4
3
2
1
x
x
x
x
x
(1)
(2)
Raw Material for Manufacturing a Product
Waste Stabilization / Solidification
(3)
Supplemental Fuel Source / Energy Recovery
x
x
x
x
x
x
x
x
x
x
(4)
Landfill Daily Cover / Internal Structures at landfills having a leachate
collection system
x
x
x
x
x
(5)
Confined Geotechnical Fill
(a) commercial, industrial or institutional building subbase
(b) paved lot base, subbase & subgrade fill
(c ) paved roadway base, subbase & subgrade fill
(d) utility trench backfill
(e) bridge abutment backfill
(f) tank, vault or tunnel abandonment
(g) slabjacking material
(h) soil and pavement base stabilization for structural improvements listed
in (5)(a) - (c)
(i) controlled low strength material (flowable) fill for structural
improvements listed in (5)(a), (d), (e) and (f)
(6)
Encapsulated Transportation Facility Embankment
(7)
Capped Transportation Facility Embankment
(8)
Unconfined Geotechnical Fill
(9)
Unbonded Surface Course
(10)
Bonded Surface Course
(11)
Bonded Surface Course (Federal, state or municipal roadways)
(12)
Decorative Stone
(13)
Cold Weather Abrasive
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
X
x
x
NR 538, Appendix I
Table 4 *Byproducts and uses need to meet structural and physical specifications and generally accepted engineering practices for the use. Obligated to meet all other Federal, State & Local permits, zoning and regulatory requirements that may apply. Regulatory Requirement Overview*  Initial & annual reporting  Industrial byproduct testing  Storage & transportation requirements  Project‐specific specifications
 Placement restrictions  Public participation process for large projects
 Submittal of notification to DNR requesting project concurrence required with some projects
 Property owner notification
 Environmental monitoring – large volume DOT embankment projects
* see code for all requirements
Coal Combustion Residuals
 Bottom Ash – coarse to fine‐grain, sand‐like  Structural fills, road bases and sub-bases,
aggregate for concrete, asphalt and masonry,
 Fly Ash – fine powder, silt, cementitious
 SiO 2 +Al 2 O 3 +Fe 2 O 3
 Concrete, structural fills, asphalt, soil stabilization
 Flue gas desulfurization gypsum ‐ CaSO 4
 Agricultural soil amendment*, source of plant
nutrients Ca & S, wallboard, cement manufacturing
and concrete production
*as allowed by NR 538.08(7)
Foundry Byproducts
 Spent sand from mold process  Geotechnical & structural fills, paved roadway base, sub-base,
embankments
 Slag
 Cement manufacturing, aggregate replacement
Category 2
Paper Mill Byproduct  Pulping sludge
used as raw material to make “soil”*
*as allowed by NR 538.08(7)  Used in mine reclamation, on landfills for fill purposes or to establish rooting zone for final grass cover NR 538.08(7) Case Specific • Allows the DNR to:
1) assign a category to a high volume solid waste not
included in the definition of industrial byproduct Examples – Foundry baghouse dust containing high % of foundry sand from molding & unmolding process
– Non‐ferrous foundry spent sand or slag NR 538.08(7) Case Specific OR
2) Conditionally approve a use not specified in rule at NR 538.10 for an industrial byproduct Examples – Beneficial use of material captured in flue gas desulfurization systems and paper mill sludge used for agricultural soil amendment
Low‐Hazard Waste Exemption • What if….
– Material is not an industrial byproduct and
– Proposed use is not specified in NR 538
• Then….
Investigate a low‐hazard exemption as allowed in sub. 289.43(8), Stats. DNR publication WA‐1645 Exempting Low‐Hazard Wastes from Solid Waste Regulations
 ch. NR 538.05 Solid waste rules exemption  Persons who generate, use, transport or store industrial byproducts that are characterized and beneficially used are exempt from licensing under s. 289.31, Stats, and the regulatory requirements in chs. NR 500 to 538. HOWEVER
 If industrial byproducts are improperly handled and environmental problems result, the DNR will assess the cause and address the situation using administrative code and statutory authority
BOTTOM LINE
 Generators are ultimately responsible for the management and disposition of all their industrial byproducts which are solid waste  Know your process inputs and outputs  If the process changes, new analysis is required to verify industrial byproduct category
 Work closely with contractor or entity utilizing the byproduct Resources • WDNR Beneficial Use of Industrial Byproducts
– http://dnr.wi.gov/topic/Waste/Beneficial.html
– http://prodoasext.dnr.wi.gov/inter1/pk_wm_doc_public$.startup (publications)
• EPA Industrial Materials Recycling
– http://www.epa.gov/osw/conserve/imr/index.htm
• American Foundry Society – FIRST – http://www.afsinc.org/government/AFSFirst.cfm?ItemNumber=7887&navItemN
umber=528
• American Coal Ash Association
– http://www.acaa‐usa.org/
• Coal Combustion Product Utilization Handbook
– http://www.we‐energies.com/environmental/recycle_coalash.htm
Ruth O’Donnell
[email protected]
Building the Green Foundry Beneficial Reuse of Foundry
Byproducts at Waupaca Foundry
Bryant Esch, CHMM
Environmental Coordinator
Waupaca Foundry, Inc.
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Metalcasting as a Sustainable
Industry – Primary Recycling
General Steel Scrap
Compressed Pucks
Tin Bales
Cast
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Waupaca Foundry’s 10-year
Environmental Sustainability Vision
•
•
•
•
Goals (2020):
Reduce energy use intensity by 25%.
Promote alternative processes and maintain state of
the art pollution control technologies.
Reduce spent foundry sand generation by 30% while
promoting offsite reuse/recycling opportunities of the
remaining spent foundry materials to achieve zero
landfill disposal.
Reduce water use consumption by 80%.
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Beneficial Reuse
Flowable Fill
Gravel Pit Reclamation
Embankment Fill
Road Construction
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Additional Foundry
Byproduct Uses
• Cement Production
• Geotechnical Fill
• Soil Amendments/Agriculture
• Impermeable Layers (Manure Pits/Landfill
Liners)
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Transportation/Utility
Projects
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Foundry Sand Use in Transportation
Projects (USH 10 Roadway Relocation)
Wisconsin Department of Transportation - North Central
Region
•
USH 10 Corridor, Portage County (2006)
– Sand, slag, dust used as subbase fill to relocate USH 10
to the north over an adjacent historical sand mine
– 160,000 tons
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Commercial/Community
Projects
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Swan Park -Sledding Hill and Recreation Area
SWAN PARK (2014)
Waupaca, Wisconsin
Project Description:
Structural fill for a sledding/recreational hill,
amphitheatre, parking lot expansion and
construction of an ice skating rink. Project
designed to the city of Waupaca’s engineer, parks
and recreation department and mayor ‘s
specifications.
Project Scope:
275,000 tons of foundry sand and slag generated
from the Waupaca Foundry of Waupaca,
Wisconsin. The beneficial reuse material is being
used to provide a park expansion in a previously
unusable portion of the municipal park property.
Project Benefit:
$2,000,000 in avoided construction and materials
costs and recovery of previously undevelopable
city property.
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Agriculture Projects
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Farm Project-Barn Expansion
EDGEWOOD DAIRY FARM PROJECT (2012)
Custer, Wisconsin
Project Description:
Structural fill for foundation for barn expansion.
Project Scope:
15,000 tons of foundry sand generated from the
Waupaca Foundry of Waupaca, Wisconsin.
Project Benefit:
$50,000 in avoided construction and materials costs
and expansion of farming operations.
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Mine Reclamations
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Foley Pit Mine Reclamation
MINE RECLAMATION (2005)
Waupaca, Wisconsin
Project Description:
Foundry sand was used as an unconfined
geotechnical fill material in the reclamation of the
Foley Sand/Gravel Pit. The foundry sand was
placed at 3:1 horizontal to vertical slope and then
covered with 18 inches of native soil and 6 inches of
topsoil extending to the top of the pit sidewalls.
Project Scope:
90,000 yd3 of foundry sand and slag generated
from the Waupaca Foundry of Waupaca,
Wisconsin.
Project Benefit:
The foundry sand proved to be a safe and costeffective fill material to achieve approximate
original contours and facilitate the proper
reclamation of a legacy mine site.
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Before
Foley Pit Mine
Reclamation
Waupaca
County
After
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Foundry Sand as an Impermeable
Construction Material
•
•
•
•
Select foundry sand exceeds
the environmental barrier
requirements for landfill
construction projects.
Select foundry sands may
contain up to 15 percent clay
Can be used as a sustainable
alternative to native clays in
construction projects requiring
impermeability barriers.
Referenced in USDA-NRCS
313 guideline for manure pit
construction sub-base fill.
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Sand Reclamation
Pneumatic/Mechanical Sand
Reclaimer
Thermal Sand Reclaimer
Mechanical  Thermal  Mechanical
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
For additional information, please
contact:
• Bryant Esch
• [email protected]
• www.waupacafoundry.com
FET Sustainability Webinar - Beneficial Reuse and Recycling,
March 27, 2015
Recycle and
Reuse
Jon Raymond
EHS Coordinator
Kikkoman Foods, Inc
262-275-1617
Recycle and Reuse
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Jon Raymond
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Graduate of Carthage College -1986
 Created my own Environmental Degree (Triple Major in
Conservation, Geography and Natural Science)
Seven Years with Environmental Monitoring and Technologies
 Environmental Consultant
Fourteen Years with Sta-Rite Industries(Pentair)
 Environmental Engineer
Currently over 8 years with Kikkoman Foods Inc
 Environmental Health and Safety Coordinator – In charge of
Directing, Implementing and Maintaining EHS policies and
programs
Live in Edgerton, Wisconsin
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Wife Jennie – 2 Children 2 Corgis and 2 Cats
A house divided
Recycle and Reuse
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Cardboard
Paper
Glass
Stretch wrap
Plastic bottles
Metal bottles
Super sacks
Plastic pails
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Paper ingredient bags
Scrap metal
Aerosol cans
Bad pallets
Construction debris
Plastic barrels
Used oil
Oil absorbent pads
Waste water
Recycle and Reuse
 Reuse
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– no processing step – viable as is.
Soy cake
Soy oil
Celite – diatomaceous earth
CO Water
Card board boxes
Fiber glass tanks
Recycle and Reuse
 Lessons
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Learned
Make it easy
Think outside of the box
Always talk to the person next to you on an
airplane
WDNR can help – Conditional exemptions,
Small business office, Green Tier
Represent material as waste – end user
determines acceptable for application
Thank you!
Watch for information on the next FET Sustainability Webinar
For more information on the FET Sustainability Committee, contact:
Rebecca Vanderbeck ‐ [email protected]