Covanta Metals Management - nyfederation.org · Covanta Metals Management Non-ferrous Separation...
Transcript of Covanta Metals Management - nyfederation.org · Covanta Metals Management Non-ferrous Separation...
Covanta Metals Management Metals and Ash Reuse
NY Solid Waste and Recycling Conference
May 21st, 2019
Agenda
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• Introduction: Covanta Metals Management
• Timeline of accomplishments
• Vertical integration of non-ferrous
• Total Ash Processing System (TAPS)
Covanta Metals Management Areas of Responsibility
Business Management and Development: • Project development at EFW facilities and mobile assets • Total Ash Processing System development and deployment • Aggregate product testing and market penetration • Ash test plan to determine remaining value propositions
Strategy and Marketing Efforts: • EFW generated metal sales for +600,000 tons • Commodity sales for regional ferrous and central non-ferrous operating assets • Off-take agreements for aggregate products • Strategic Plan for European IBA and FA disposal options
Continuous Improvement and Optimization: • Improve recovery efficiency at energy-from-waste assets • Achieve fleet goal of 2% non-ferrous by end 2020
Engineering/Project Execution: • Regional operations; EFW plant retrofits; Total Ash Processing installations and operations
Covanta Metals Management Since 2012, CVA has invested in over 70 individual metal enhancement projects
Ferrous – Ferrous (Fe) drum installations/upgrades – Shredder and air classification systems – Regional ferrous processing facilities (non-shred)
Non-Ferrous – Nonferrous (NFe) separation systems (ECSs) focused on +/- 10mm fraction sizes – Sensor sorter test installations and ECS rotor upgrades – Bottom and fly-ash separation for improved metal recovery – Central non-ferrous processing facility
Landfill – Mobile landfill metal recovery operations for fresh and mined ash – Installation of permanent system in Peabody, Ma.
Total ash processing system (TAPS) – Wash plant for combined ash – Beneficial reuse products for resale
Improved metal recycling (and avoided landfilling) by nearly 200,000 tons per year
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2012 - 2013 CMM is formed; Focus on Fe & NFe Metals Recovery
2014 Ash Reuse Evaluations
2015 Ash Pilot Plant built @ 3rd Party Research Facility
2016 & 2017 Ferrous Processing Facility and Non-Ferrous Facility Start Ups – Fairless Hills
2018 and Beyond PADEP issues Ash Reuse Permit; CVA builds Total Ash Processing Facility at Fairless; Operates first Mobile Ash Processing system
Covanta Metals Management Overview and Accomplishments
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CMM: MODERN DAY PROSPECTING
Covanta gross metal tons recovered from EFW operations
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415,264 418,583
456,316
495,264
538,218 524,559
[VALUE]
16,814 22,322
33,004
37,025
41,923 44,707
[VALUE]
400,000
425,000
450,000
475,000
500,000
525,000
550,000
575,000
600,000
625,000
2012 2013 2014 2015 2016 2017 2018
Gross Tons Recovered: EFW Facilities
Ferrous Non-Ferrous
Improved metal recycling (as a % of ash) by over 35%
Metal Recovery Efficiency 2019 & EFW Metal Recovery Runway
Volume and Recovery Efficiency Improvements
– Recovery records established for 7 consecutive years on both ferrous and non-ferrous
– Field engineers focused on seasonal adjustments of equipment, product enhancements and project execution
EFW Facilities EFW Facilities 0.00%
0.50%
1.00%
1.50%
2.00%
2.50%
3.00%
3.50%
4.00%
Non-Ferrous Metal Recovery Actual % of Combined Ash
YTD 2019 February
Ash (%) YTD 2019 Average 2013 Avg
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
Ferrous Metal Recovery Actual % of Combined Ash
YTD 2019 February
Ash (%) YTD 2019 Average 2013 avg
Covanta Metals Management Fe Processing / Enhancement Facility – Fairless Hills, PA
• Operational Summary – Operational since November 2015
– Services up to 15 plants in 6 states
– Processed over 600,000 tons to date
– Removes ash and fractionalizes Fe
– Separates Non-ferrous & sealed units from the Fe
• Benefits of Internalized Ferrous – Reduces dependency on 3rd Party processors
– Assures receivable in all markets
– Higher quality control leads to more quality outlets
– Environmental control of ash and storm water
– Easy to replicate in other markets
• Upgraded Credit Worthiness of Buyers – Ability to sell to domestic steel mills
– Rail shipments to the Ohio Valley steel mills
– Ocean containers for armatures and sealed units
– Baled wire sold to local processors
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Covanta Metals Management Non-ferrous Separation Facility – Fairless Hills, PA
• Operational Summary – Separates heavy from light non-ferrous metal units
– Operational since May 2017
– Services over 30 plants across 15 states
– Processed over 125,000 tons to date
– Removes ash and creates several particle sizes to maximize density separation
• Benefits of Internalized Non-Ferrous – Traditional buyers did not pay for metal units <6mm
– Broker model isolated us from compositional make-up of metals
– Maximum value creation through commodity separation
– Diversified portfolio of buyers including international smelters
– Coin value captured as part of separation
– Environmental control of ash and storm water
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Material testing
Aluminum “Twitch” Ready for Shipment
Coins recovered-post cleaning
Covanta Metals Management Total Ash Processing System (TAPS) : Pilot Plant
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2014: CVA commenced an ash reuse initiative – Evaluation of chemical & geotechnical properties,
processing technologies, potential use in different products
– Consulted with several European companies regarding aggregate production and road use
– Bottom ash reuse as road base in Pasco County, FL (regulatory approval)
Findings: – Ash contains positive attributes for reuse – Remaining metal content would be a limiting factor – Remaining “fines” will requires innovative
technology for recovery & removal – Wet screening and separation would seemingly
provide improved results
Results: – Successfully demonstrated wet technology to
process combined ash – All waste products passed non-hazardous
leaching tests – Mineral fractions (with further processing)
could meet construction specifications for aggregate
– Next step: full scale facility for enhanced metal recovery and aggregate production
Covanta Metals Management Pilot plant results: ash constituents
CEMENT
CONCRETE
GLASS
POTENTIAL MARKETS
ASPHALT
Fe NFe Low-grade Fe
Metal Concentrate
Medium [CATEGORY
NAME]
Large Aggregate Fine
Aggregate (sand)
[CATEGORY NAME]
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Clean Ferrous Metal
Clean Non-Ferrous Metal
STEEL
LANDFILL
Ash
Total Ash Process System Aggregate
Aggregate
Filter Cake
SMELTING
Ash
Ash
Total Ash Processing System (TAPS): What is it?
Modular batch feed system comprised of: • Washing and crushing circuit for effective particle separation and fine fraction removal • High intensity magnets & eddy currents to separate and polish large aggregates • Specialty equipment to remove organics from fine metal particles and sand • Water treatment and decanting equipment
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Covanta Metals Management Reuse Applications
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Covanta Metals Management Aggregate Research
• Physical property evaluations conducted in partnership with local universities
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Physical Property Specification Test
Standard
Gradation Meets ASTM C33 ASTM C136
Bulk Specific Gravity >2.40 ASTM C128
Absorption <2.0% ASTM C128
Soundness <5.0% ASTM C88
Clay Lumps and Friable Particles <5.0% ASTM C142
Organic Impurities Lighter than Standard 11 ASTM C40
Fine Aggregate Angularity >45% ASTM C1252
Sand Equivalent >45% ASTM C2419
Testing indicates that our products can meet Department of Transportation specification requirements for asphalt applications
Covanta Metals Management Course Aggregate in Cement Applications
• Cement – low grade ferrous as iron replacement
– Raw materials used for cement: limestone, sand, bauxite/clay, iron oxide – Certain solid fractions contains iron oxide – Successful full-scale test completed at cement plants in PA and FL – Letter of Intent and working on commercial agreement
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• Iron oxide content hit mix design targets • Silica content was favorable • Alkalis were “in-line”
Cement Plant QC Manager statement: “As far as I’m concerned, the test was a success.”
Covanta Metals Management PADEP Permitting – Total Ash Processing Project at Fairless Hills
• PA General Environmental Permit issued: March 23, 2018
– First of its kind in the United States
• Covanta permit application submitted June 1, 2018
– Allows for the beneficial use of aggregate recovered from EFW ash
• Fabrication and site construction timetable 6 months
• Planned start-up late 2019
• Replicate plant strategically (Long Island, New England, etc)
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Covanta Metals Management
Questions/Comments?
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