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Energy from Waste What about the leftovers? Opportunities for bottom ash recycling David York MD Ballast Phoenix Ltd.

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Presentation on theme: "Energy from Waste What about the leftovers? Opportunities for bottom ash recycling David York MD Ballast Phoenix Ltd."— Presentation transcript:

1 Energy from Waste What about the leftovers? Opportunities for bottom ash recycling David York MD Ballast Phoenix Ltd

2 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.

3 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!

4 A Sustainable Cycle? Asphalt Concrete Unbound Residual C&I and MSW Energy Steam & Electricity IBA 22% of MSW IBA Aggregates Metals Organics

5 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

6 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

7 IBA aggregates What can IBAA be used for? Many applications

8 800 series: A component in Clause 803 Type 1 sub-base and can be used as HBM & CBM aggregate 900 series: A component in bituminous mixes 900 series: A component in bituminous mixes BS 3797: Lightweight aggregate for masonry HIGHWAYS AGENCY - Specification for Highway Works 500 series: Pipe Bedding - Drainage Media 600 series: Numerous fill specifications including 6F2 Capping

9 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

10 IBAA used for a piling mat

11 Backfill for a utility trench

12 CBM Aggregate for a port project

13 Sub base to an industrial floor

14 Capping layer for site development

15 Incinerator Bottom Ash Aggregates IBAA 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

16 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.

17 A Sustainable Aggregate <1% non-ferrous <10% ferrous <0.5% organic ~90% IBAA Low Density -fewer transport movements. -urban quarry Negative carbon footprint Unbound mixtures, Type 1, pipe bedding Asphalt <30% Foamed conc/asphalt CBGM and HBMs Lightweight aggs. IBAAIBACARBONPRODUCTS

18 Local Government Sustainable Procurement 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

19 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

20 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.

21 Energy and Carbon Savings on delivery of 2000 m3 of aggregate

22 IBAA Carbon Sequestration CO 2 is absorbed from atmosphere Similar to concrete – carbonation >8% by weight of CO 2 can be absorbed IBA Aggregates have a negative footprint

23 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.

24 The process - but Safety first!

25 Fresh IBA

26 Fresh IBA is matured for weeks

27 Loading the feed hopper

28 Indoor process

29 Elevated control room

30 Aggregate sizing

31 Aggregate stream

32 0-10mm Aggregate

33 10-40mm Aggregate

34 Recovered metals

35 Handpicked oversize

36 Stockpiled aggregate products

37 Lagoon to store site drainage

38 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 1 st March 2009, outlining responsibilities! The Water Framework Directive is designed to ensure that groundwater and water courses are not polluted.

39 ‘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

40 Example of EA’s Groundwater Protection Zones

41 Contact: David York Tel: 01778 423345 or 07860 230006 Email: Address: Victoria Stables South Rd BOURNE PE10 9JX

42 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.




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