Eco·Systems, Inc.

Beneficial Reuse of Industrial Byproducts

Definition- turning an industrial byproduct into a valuable commodity

Examples– Coal Combustion Products (CCPs)– Foundry Sand– Pulp and Paper Bio-solids, Boiler Ash

Benefits of Reuse

Environmental

– Reduces waste disposed of in landfills– Conservation of virgin material

Economic

– Reduction of disposal costs– Potential revenue stream

Barriers Against Beneficial Reuse

Lack of Market Awareness– Disconnect between byproduct generators and potential

end users

Convenience of Landfill Disposal

Byproduct Consistency/Quantity

Lack of Standards/Specifications

Barriers Against Beneficial Reuse (cont’d)

Transportation/Location– Transportation costs

Environmental Concerns– Stigma associated with industrial byproducts

Corporate Mindset

Alabama’s Beneficial Reuse Program

No organized beneficial reuse program

Foundry Sand Reuse– Site Specific– Used for fill material– Waste must exhibit less than 50% of the RCRA toxicity

characteristic (tc) of the Toxicity Characteristic Leaching Procedure (TCLP)

Case by case basis on other materials

Tennessee’s Beneficial Use

Established Foundry Sand Reuse Program

Testing Required, TCLP

Site Specific

Case by Case basis

Georgia’s Beneficial Reuse Program

No organized beneficial reuse program

60% of stockpiled material must be recycled within 90 days so not to be considered a solid waste

Gypsum board recycling

Flyash reuse

Mississippi’s Beneficial Reuse Program

Organized program with dedicated regulations

Must be used to replace an existing product

Requires chemical and physical characterization

Yearly reporting and testing required

Not Site Specific

Overview

Byproduct Characterization

Market– Existence– Location

Regulatory Programs

Reuse Program Implementation– Logistics (Transportation, Storage, etc)– Record keeping– Additional testing

1001 South 4th AvenueLaurel, MS 39441

601-649-6000

Rebecca M. Morgan

Environmental Specialist

•In Masonite’s efforts to reduce the amount of waste being placed in landfills we began exploring opportunities to reduce, re-use, or recycle.

•One of our waste streams, ash and de-watered fiber, immediately became a topic of interest.

•We generate on the average of 500 tons per week of this waste material. So reducing this amount would not only save money but drastically reduce our landfill waste.

• The ash and de-watered fiber are generated independently of each other and have been mixed together in the past for easier shipping to the disposal facility.

• The ash is generated from the two (2) wood burning boilers that Masonite uses to produce steam.

• The fiber is generated by clarifying our process water before that water is sent back into the system to be re-used.

Boiler Ash De-Watered Fiber

• Until 2006 Masonite had several on-site landfills where this material was disposed.

• During the course of that year we began closing these landfills and going all off site to a local facility for disposal.

• After going off-site for nearly two years, we started to explore a permanent beneficial use for this waste stream to offset some of the cost of disposal and to reduce the amount of waste being sent to landfills.

• Knowing the results we had with our closures we had a great starting point.

• After reviewing possible uses of this material we wanted to explore a public give-away program that would benefit the local area and regional farmers.

• Our final goal was to offer a material to the public that would provide a cost effective alternative to what they were already purchasing.

• In mid 2007 we employed the services of Eco-Systems, Inc of Jackson, MS to assist with this project and to explore what options were available.

• After sharing historic information with Eco-Systems and discussing with them what we would like to accomplish the project began the extensive testing phase.

• Samples were taken over the course of several weeks. These samples were taken on both boilers to cover all elements of the process.

• Historic analytical from the landfill closure project was compared to the new analytical to provide process stability.

• Once the analytical was completed Eco-Systems, Inc. prepared three Beneficial Use Applications to the Mississippi Department of Environmental Quality.

• Application #1 was for the boiler ash as a liming agent.

• Application #2 was for the de-watered fiber as a landscaping soil amendment.

• Application #3 was for the combination material (ash and de-watered fiber mixed) as a landscaping soil amendment.

• Approval has been granted on Application #1 and #2 with pending approval on Application #3.

• The last phase to this project is to have dewatered fiber approved for agricultural use. Such as being added to farming soil to improve organics that are lost over years of harvesting, soil depletion, and erosion.

• In order to provide local farmers with beneficial information as to best application techniques of this material, Masonite will conduct a demonstration project in conjunction with the MDEQ.

• This trial will be monitored by the MDEQ. Our end results will provide local farmers with more information as to how to obtain the best results with this material.

• This material has also been approved by the MDEQ to be used as daily landfill cover at a local disposal facility.

ASH

• Liming agent

• Alternative Cover

• Combined with De-watered fiber as a soil amendment*

De-Watered Fiber• Landscaping amendment

• Alternative Cover

• Combined with Ash as a soil amendment*

• Agricultural soil amendment based on results of demonstration project

* Pending approval