nr 538, wis. adm. code reuse of - fet – federation of...

Chapter NR 538, Wis. Adm. Code Beneficial Reuse of Industrial Byproduct

March 27, 2015 FET Sustainability WebinarRuth O’Donnell, WDNR

NR 538 QUICK OVERVIEW

Established January 1, 1998Goal = encourage beneficial use of industrial byproducts in a nuisance‐free and environmentally sound manner

http://www.we-energies.com/environmental/CoalCombustionProducts_2K11018.pdf

Mill

ion

cubi

c ya

rds

29.5 million yd3

available

19.6 million yd3

used

WISCONSIN INDUSTRIAL BYPRODUCTS 2000 – 2013

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/LTotal Elemental Analysis mg/kg

Potential risk to human health & the environmentCategory 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 ProjectsIndustrial Byproduct

Category

NR 538.10 5 4 3 2 1

(1) Raw Material for Manufacturing a Product x x x x x

(2) Waste Stabilization / Solidification x x x x x(3) Supplemental Fuel Source / Energy Recovery 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)

x x x x

(6) Encapsulated Transportation Facility Embankmentx x x x

(7) Capped Transportation Facility Embankmentx x x

(8) Unconfined Geotechnical Fillx x x

(9) Unbonded Surface Coursex x

(10) Bonded Surface Coursex x

(11) Bonded Surface Course (Federal, state or municipal roadways)x x x

(12) Decorative Stone x x

(13) Cold Weather Abrasive X x

NR 538, Appendix ITable 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 specificationsPlacement restrictions Public participation process for large projects Submittal of notification to DNR requesting project concurrence required with some projects

Property owner notificationEnvironmental 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 SiO2+Al2O3+Fe2O3

Concrete, structural fills, asphalt, soil stabilization

Flue gas desulfurization gypsum ‐ CaSO4 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 landfil ls for fil l 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 notincluded 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

OR2) 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

NR 538.08(7) Case Specific

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 LINEGenerators are ultimately responsible for the management and disposition of all their industrial byproducts which are solid waste Know your process inputs and outputs I f the process changes, new analysis is required to verify industrial byproduct category

Work closely with contractor or entity uti l iz ing 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’[email protected]

FET Sustainability Webinar - Beneficial Reuse and Recycling, March 27, 2015

Building the Green Foundry -Beneficial Reuse of Foundry

Byproducts at Waupaca Foundry

Bryant Esch, CHMMEnvironmental Coordinator

Waupaca Foundry, Inc.


Metalcasting as a Sustainable Industry – Primary Recycling

General Steel Scrap Tin Bales

Compressed Pucks Cast

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%.

Beneficial Reuse


Flowable Fill Embankment Fill

Gravel Pit Reclamation Road Construction

Additional Foundry Byproduct Uses

• Cement Production• Geotechnical Fill• Soil Amendments/Agriculture• Impermeable Layers (Manure Pits/Landfill

Liners)


Transportation/Utility Projects


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


Commercial/Community Projects


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.


Agriculture Projects


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.


Mine Reclamations


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 cost-effective fill material to achieve approximate original contours and facilitate the proper reclamation of a legacy mine site.


Before

After

Foley Pit Mine

Reclamation

Waupaca

County


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.

Sand ReclamationPneumatic/Mechanical Sand

ReclaimerThermal Sand Reclaimer


Mechanical Thermal Mechanical

For additional information, please contact:

• Bryant Esch• [email protected]• www.waupacafoundry.com


Recycle and ReuseJon RaymondEHS Coordinator Kikkoman Foods, Inc262-275-1617

Recycle and Reuse Jon Raymond

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 Wife Jennie – 2 Children 2 Corgis and 2 Cats A house divided

Recycle and Reuse

Cardboard Paper Glass Stretch wrap Plastic bottles Metal bottles Super sacks Plastic pails

Paper ingredient bags Scrap metal Aerosol cans Bad pallets Construction debris Plastic barrels Used oil Oil absorbent pads Waste water

Recycle and Reuse Reuse – 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 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!

For more information on the FET Sustainability Committee, contact:

Rebecca Vanderbeck ‐ [email protected]

Watch for information on the next FET Sustainability Webinar

nr 538, wis. adm. code reuse of - fet – federation of...

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