Energy from Waste

What about the leftovers?

Opportunities for bottom ash recyclingDavid York

MD Ballast Phoenix Ltd

BALLAST PHOENIX Ltd – major shareholder is Feniks Recycling, a Dutch IBA processor since the early 1980s

•Commenced first commercial operations in 1998.•Six facilities currently operating.•Over 3 million tonnes of IBA processed and sold.•Over 35 plant years of experience.•All products are sold NOT land filled.•From early days BPL has continued to develop new markets for IBAA.

Company culture

Key elements are:

• Safe working• Environment protection• Providing a full and professional service to

our customers• A REAL BELIEF IN WHAT WE DO!

A Sustainable Cycle?

AsphaltConcreteUnbound

Residual C&I and MSW Energy

Steam & Electricity

IBA22% of MSW

IBA AggregatesMetalsOrganics

What do we do?

Following the thermal treatment, the main residue is ‘bottom ash’ – a misleading term as much of it has not burnt, metals, glass, porcelain and the like are a large part of

the material. We process this and:• Recover the ferrous metal• Recover the non ferrous metals• Create alternative aggregates for

construction

An Aggregates business• Whilst IBAA processing recovers all these

resources, it is only successful if it produces GOOD QUALITY AGGREGATE.

• This means particle sizes up to 40mm of hard durable inert material such as glass porcelain, brick, stone, with some slag, clinker and ash

• There are many uses for well processed IBA

IBA aggregates

What can IBAA be used for?

Many applications

800 series: A component in Clause 803 Type 1 sub-base 800 series: A component in Clause 803 Type 1 sub-base and can beand can be

used as HBM & CBM aggregateused as HBM & CBM aggregate

900 series: A component in bituminous mixes 900 series: A component in bituminous mixes BS 3797: Lightweight aggregate for masonry BS 3797: Lightweight aggregate for masonry

HIGHWAYS AGENCY -HIGHWAYS AGENCY -Specification for Highway WorksSpecification for Highway Works500 series: Pipe Bedding - Drainage Media500 series: Pipe Bedding - Drainage Media

600 series: Numerous fill specifications including 6F2 600 series: Numerous fill specifications including 6F2 CappingCapping

Examples of usage• M25 Jct 28 - approx 10ktonnes • M6 Toll Road – approx 30ktonnes• Olympics Logistics Park -approx11ktonnes• Docklands Light Rail - approx 15ktonnes• Felixstowe Docks – approx 55000ktonnes• Heathrow T5 – approx 5ktonnes• The above include unbound, cement

bound and asphalt uses

IBAA used for a piling mat

Backfill for a utility trench

CBM Aggregate for a port project

Sub base to an industrial floor

Capping layer for site development

Incinerator Bottom Ash AggregatesIBAA

1. Comply with UK and European Standards

2. Products manufactured to a robust Quality Protocol

3. Low embodied energy demand during production

4. Supporting a sustainable future

IBA has pozzolanic properties and this property is beneficial. A stockpile about 18 months old being ripped to separate particles. The temperature inside the stockpile was 55°c.

A Sustainable Aggregate

<1% non-ferrous

<10% ferrous

<0.5% organic

~90% IBAA

Low Density

-fewer transportmovements.-urban quarry

Negative carbon

footprint

Unbound mixtures, Type 1, pipe bedding

Asphalt <30%

Foamed conc/asphalt

CBGM and HBMs

Lightweight aggs.

IBAAIBA CARBON PRODUCTS

Local Government SustainableProcurement Strategy Nov. 2007

• The residue from MSW and C&I waste, after energy recovery can now be processed for re-use (IBAA)– Sustainable

• IBAA gives local authorities value for money without compromising quality

• Compliant with ‘Procuring the Future’ 2006• BREEAM sustainable construction (BRE)

• SLAM requires 20% recycled for all new build(Single Living Accommodation Modernisation Programme)

Government led initiative

IBAA is part of a sustainable solution for MSW and C&I waste

IBAA will reduce the carbon footprint of any construction project where it is employed

We have plants operating in London, Birmingham, Teesside, Essex, Kent and

Sheffield

Carbon footprint

IBAA has a very low carbon footprint. Carbon costs in production are low and

the benefits high. BPL has consulted Carbon Trust and will seek accreditation.

Energy and Carbon Savingson delivery of 2000 m3 of aggregate

Transport EnergyIBAA 17.2 GjoulesLimestone 39.1 GjoulesCrushed Concrete 36.4 GjoulesGranite 44.7 Gjoules

Transport CO2IBAA 1,024.1 kgCO2Limestone 2,331.4 kgCO2Crushed Concrete 2,164.9 kgCO2Granite 2,664.4 kgCO2

www.ballastphoenix.co.uk

IBAA Carbon Sequestration

• CO2 is absorbed from atmosphere

• Similar to concrete – carbonation

• >8% by weight of CO2 can be absorbed

• IBA Aggregates have a negative footprint

How do we make IBAA from IBA?

Our ‘sister’ company in Holland first started this kind of business in the early 80s. BPL started in the UK in 1998, using the Dutch

process technique, but with UK applications. Since then the process has

been extended such that a target of ZERO LANDFILL can be a reality.

The process - but Safety first!

Fresh IBA

Fresh IBA is matured for weeks

Loading the feed hopper

Indoor process

Elevated control room

Aggregate sizing

Aggregate stream

0-10mm Aggregate

10-40mm Aggregate

Recovered metals

Handpicked oversize

Stockpiled aggregate products

Lagoon to store site drainage

Environmental Management• The impending WRAP Quality Protocol is designed to

give new users confidence in IBAA – BPL has had it’s own scheme for many years. Site Specific Environmental Assessments are available to BPL customers free of charge

• BPL is accredited with BSI to BS EN 14001:2004

• The Environmental Liability Directive (ELD) came into force on 1st March 2009, outlining responsibilities!

• The Water Framework Directive is designed to ensure that groundwater and water courses are not polluted.

‘DUTY OF CARE’Environment Protection Act 1990

• Applies to companies and individuals• Primary and secondary aggregate producers• BPL assess every site prior to supply• IBAA leach test results normally around UK

drinking water quality standard

Example of EA’s Groundwater Protection Zones

Contact: David YorkTel: 01778 423345 or 07860 230006Email: david.york@ballastphoenix.co.ukAddress: Victoria Stables South Rd BOURNE PE10 9JX

Exploding concrete????An unfortunate incident took place in Aug

2009. I believe this is the subject of an ongoing HSE investigation. Gas was

trapped beneath a footbridge, inside a building. Sparks created by work activity

ignited the gas and two workers were unfortunately injured. Our H&S data sheet states that when IBAA is used in foamed

concrete, it should be handled and used in open spaces.

Health & Safety Product Data Sheet - Foamed Concrete Production - Revision 2 Composition

IBAA is the product of energy recovery at a range of temperatures from 800-1100°C, primarily from domestic and municipal wastes. In addition to fused and partially fused clinker, concrete, brick, ceramics there will be sharp metal objects, glass and a small quantity of partially burnt material. IBAA presents no known biological hazards.

Hazards Identification

a) Incinerator Bottom Ash Aggregate – contact with IBAA may cause: - 1. Irritant Contact Dermatitis 2. Allergic Contact Dermatitis

Avoid manual handling at all times as cuts, skin piercing, and abrasions can occur. b) When blending IBAA for the production of foamed concrete the following safety issues should be acknowledged:

1. Hydrogen can form in an alkaline environment, particularly in wet conditions. 2. Any gas liberation will have a finite life, which is normally a few days following

saturation. 3. Reducing the pH of the concrete blend will reduce hydrogen liberation significantly. 4. The use of some synthetic foaming agents (Poly Ethylene Glycol (PEG) based)

increases hydrogen production. 5. Protein based foaming agents can reduce hydrogen formation significantly. 6. The increase in temperature on large concrete pours has the potential to increase gas

liberation. 7. Adequate ventilation of all works should be provided to allow liberated gases to

escape safely.

c) IBAA Dust – cutting and surface treatment of materials produced from IBAA can create dust and flying fragments. The dust created could contain particles of respirable silica. Further advice on the silica content of IBAA is available via the head office upon request.

d) When the respirable dust contains silica, the risks are increased. Extended periods of exposure to high concentrations of any dust can be hazardous to health. IBAA contains trace elements, which are considered negligible in light of current knowledge.