Waste-to-Energy Plant
Ash Reclamation & Recycling Services
Prepared By: Bob Brickner
Executive Vice President
Gershman, Brickner & Bratton, Inc. (GBB)
Fairfax, VA USA
Presented: ISWA Beacon – Hamburg, Germany October 14, 2015
1
GBB – Quality – Value – Ethics – Results
Note: Mr. Brickner in Foreground
• Solid Waste Management and
Technology Consultant established
in 1980 (35 years ago!)
• Independent & Helping Clients
Turn Problems into Opportunities
• www.gbbinc.com
2
Project Sponsor:
Lancaster County Solid Waste Management
Authority (LCSWMA)
• LCSWMA manages Municipal Solid Waste (MSW) and recyclables for
Lancaster County, PA (USA) as well as the MSW for Dauphin County,
PA
• Their integrated system includes four facilities; they manage 900,000
tons of waste each year, and are continually recognized for their
innovative approach to managing waste.
• LCSWMA continually evaluates business opportunities that can
maximize the value of the waste streams it manages.
3
Authority Location in Pennsylvania (between NYC and Washington DC)
New York City
Philadelphia PA
Washington DC
4
Leaders of Project Opportunity Development
o LCSWMA – GBB’s Client
• Jim Warner, CEO
• Tom Adams, Senior Manager – Business Development
o Procurement RFP Consultant/Advisor
• Gershman, Brickner & Bratton, Inc. (GBB)
5
LCSWMA Owns 2 WTE Plants
• 800 Tons Per Day (TPD)
of MSW at Susquehanna
Resource Management
Complex (SRMC) in City
of Harrisburg PA (300
TPD of ash)
• 1200 TPD Lancaster
WTE facility (350 TPD of
ash)
6
LCSWMA Facility Locations
(also includes a landfill and transfer station)
7
Current Ash Management Process at SRMC
Ash Produced
from Waste
Combustion
Ash Hauled to
On-Site Landfill and
Stored for 2-3 Days
(No Capacity in Landfill)
Ferrous Removed
by Electrically
Charged Magnet
Ferrous
Marketed by
LCSWMA
8
Goals of RFP- Select Proposer To:
• Recover metals to extract value from SRMC ash.
• Enter into a 10-20 year agreement for processing:
− 300 tons per day of daily ash from the SRMC WTE Facility;
− 300 tons per day of landfilled ash (Current ash landfill contains
approximately 750,000 tons from WTE facility operations since
1990)
9
Anticipated Metal Recovery Results
LCSWMA believed there was considerable metal in the SMRC WTE ash
that was and is being landfilled:
Material As A Percent of Total Sample Weight
Sample
Sample Size
(lbs)
Ferrous
Weight (lbs)
Non-Ferrous
% of Sample Weight (lbs)
Ferric Oxides
Ash
% of Sample
Weight (lbs)
% of Sample
Weight (lbs)
% of Sample
SRMC Daily Ash
1 inch minus
2
0.56%
5
1.41%
38
10.70%
251
70.70%
1 inch plus
4
1.13%
4
1.13%
7
1.97%
44
12.39%
6
1.69%
9
2.54%
45
12.67%
295
83.09%
1 inch minus
8
1.71%
12
2.57%
168
35.97%
202
43.25%
1 inch plus
8
1.71%
3
0.64%
20
4.28%
46
9.85%
16
3.42%
15
3.21%
188
40.25%
248
53.10%
Total
355
SRMC Landfill Ash
Total
467
Material Recovery Summary ‐ Material Analyzed 8/19/14 by Steinert Material Testing
10
Ash Flow to Proposed Project Site
Residue Transported Off-Site
In-Place Ash:
Total of
750,000 Tons
and mineable)
Goal : Process
Annually:75,000 TPY
Fresh + 75,000 TPY
Mined
Option : Process 90,000 TPY fresh from Lancaster WTE facility
11
Primary Services Solicited through RFP
(RFP was issued October 10, 2014)
1. Proposer required to process a minimum of 150,000 tons per year of ash,
with approx. 50% from daily ash and 50% from the ash monofill.
2. Proposer will design, permit, finance, own, construct, operate and maintain
the project.
3. Proposer will process and market recovered metals.
NOTE: Ash Residuals from the recovery project will be loaded,
transported by and disposed of by LCSWMA
12
RFP Information: The Ash Processing Site
• LCSWMA will lease up to 2 acres of the 4.5 acre area on the SRMC site
to proposer.
• Site has access to electric, water and sewer.
• LCSWMA assumed ash processing facility will be located on-site, but
may submit an off-site ash processing location.
• Permitting of the project would be done through a minor permit
modification to LCSWMA’s existing landfill permit.
• Equipment must be under roof.
13
Proposer Requirements - Qualifications
• Proposer must be operating at least one reference facility, and that
facility must have been operating for a minimum of one year.
• Reference facility must be capable of processing a minimum of 200
tons per day.
14
Proposer Requirements – Operational
• Mass balance detailing all inputs and outputs.
• Conceptual layout of processing facility.
• Contract Term: 10 years with two - 5 year options
• Target Commercial Operation: 3rd Quarter of 2016
15
Proposer Requirements – Financial
• Detailed Capital Costs & O&M Expenses
• Detailed financial arrangement describing the cost
or payment to LCSWMA for ash processing services
• Any proposed metal revenue sharing arrangements
with LCSWMA.
16
Results of the RFP Process
Five (5) Proposals Received on Jan. 23, 2015 from:
•
•
•
•
•
1St Response Rail Service Inc.
American Ash Recycling Corp. of Pennsylvania
Covanta Metals Recovery, LLC
Inashco North America, Inc.
LAB USA Corp.
17
Roles and Responsibilities
• Authority’s primary responsibilities:
−
−
−
−
Deliver acceptable ash to a designated delivery point
Accept residue
Provide suitable site at no cost
Support permitting and permit compliance
• Inashco primary responsibilities:
−
−
−
−
−
Full service project: Design, Build, Own, Operate and Finance the facility
Permitting and permit/regulatory compliance
Process, recover and guarantee the off-take purchase of the metal products
Deliver mineral residue to a designated delivery point
Pay the Authority a fixed per ton fee for ash delivered and share of revenues
based on a formula reflecting metals market pricing
18
Proposer Selected: Inashco
• Activities Conducted Once Inashco Selected;
– MOU Signed June 2015
– Additional SRMC Ash Shipped to Inashco Putman,
Connecticut 600 TPD Facility for additional testing
– Initial Testing showed Quantity of Ferrous and NonFerrous Materials Recovered were LESS than expected
– Lower estimates of Metal, and hence the Recovered
Metals Worth, impacted the financial Inashco project
proforma's versus that assumed.
– Project Ash Quality and Metals Content are being further
evaluated by Vendor and LCSWMA
19
Why Inashco?
•
•
•
•
•
•
Global Leader in Metals Recycling: nearly 4,000,000 Tons/Year
Use Best Available Technology (BAT)
Broad/long Operating Expertise with Combined Ash
Public‐Private Partnerships (P3) Experience
Global Metals Marketing
One-stop-shop: design / permit / build / operate / test / upgrade
/ test again / trade
20
Inashco Value To Project
They know which metals are in the ash
•
•
They know the metal value
•
They know how to get metals out
•
They manage metal Market Risks
21
Inashco focus is on the Fine Fraction
100%
Recovery
Rate (%)
Inashco
Technology
Traditional ash treatment
0%
0
4
8
12
16
20
Size (mm)
22
Overall Process Flow Summary
1.
Fe
3.
Cu
Fe
Al
Al
Metals
Fe
Fe
Cu
Cu
Cu
Cu
Al
Al
Al
Al
Min
erals
Min
Min
erals
Min
Fe
Fe
Min
Fe
erals
2.
Fe
Fe
Fe
Cu
Cu
Al
Al
Cu
Cu
Cu
Cu
Cu
Cu
Al
Al
Al
Al
Al
Min
Min
Min
Min
Min
Al
Min
Min
WTE ash
Magnet - Screen - ECS
Magnet - ADR - ECS
Upgrading
Sell
Sink-Float / Smelting
Products
Analyze
Coarse Extraction
Fine Extraction
Sort
Trade
Recycle
Re-use
23
23
Taking Ash Recycling to the Next Level
No
treatment
Landfilling
12 - 40mm
Fe and NF
metals
to S / F
magnet &
ECS
12 - 40 mm
minerals
to road
construction
Magnet & ECS
0-12 mm minerals
0 - 40 mm
0 - 12 mm
ADR
Conventional
In-plant processing
Inashco
added value
Moist & fine
minerals
0 - 2 mm
cement
ADR
Concentrate
2 -12
minerals
concrete
products
magnet &
ecs
metal
concentrate
upgrading
24
30
Recovered Products
Fine minerals
( 0 – 2 mm )
Non-ferrous concentrate
( 1 - 12 mm and 12 - 50 mm )
Mineral aggregates
( 2 - 50 mm )
Ferrous concentrate
( 12 – 50 mm )
25
Heavy Non-Ferrous Scrap Products
Size:1 - 12 mm; 95 - 99% pure metal scrap
26
ADR Plant (Located in Putnam, Connecticut)
27
Preliminary Facility Design
Ability for Complete
Roof coverage
Modular building for
maintenance disassembly
Roll-up side tarps
28
Preliminary Facility Design
Structured and efficient flow of feedstock and products
29
Preliminary Facility Design – Receiving Ash
30
Preliminary Facility Design - Processing
31
24 of 30
Preliminary Facility Design - Loadout
32
Lancaster Project - Current Status
1.
2.
3.
4.
5.
6.
7.
8.
Deal structure : agreed
System basic design : finalized
Contract templates : draft set ready
EPC contractors : pre-selected
Permitting : ongoing
Extra sampling : ongoing, expected results by end of Oct. 2015
Final site selection and logistical flows : pending
Contract finalization : December 2015
33
Additional Project Questions
• Please direct questions concerning the current Project status to:
Tom Adams
Senior Manager - Business Development
Lancaster County Solid Waste Management Authority
1299 Harrisburg Pike
Lancaster, PA 17603
phone (717) 735-0180
tadams@lcswma.org
34