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Beneficial Reuse of Industrial Byproducts in the Gulf Coast Region

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Beneficial Reuse of Industrial Byproducts in the Gulf Coast Region Beneficial Reuse of Industrial Byproducts in the Gulf Coast Region February 2008 U.S. Environmental Protection Agency Beneficial Reuse of Industrial Byproducts in the Gulf Coast Region Final February 2008 Prepared for: U.S. Environmental Protection Agency Office of Policy, Economics, and Innovation Sector Strategies Division Prepared by: ICF International 9300 Lee Highway Fairfax, VA 22031 (703) 934-3000 Table of Contents Executive Summary................................................................................................................ ES-1 1.0 Introduction.......................................................................................................................... 1 1.1 Objectives .................................................................................................................. 1 1.2 Research Scope and Boundaries ................................................................................ 1 1.2.1 Definition of Beneficial Reuse.................................................................... 1 1.2.2 Sectors Addressed in This Analysis............................................................ 2 1.2.3 Byproducts Addressed in This Analysis..................................................... 3 1.3 Data Sources and Methodology................................................................................. 4 1.4 Organization of the Report......................................................................................... 4 2.0 State Beneficial Reuse Programs and Regulations ........................................................... 5 2.1 Beneficial Reuse Regulations and Programs in the Gulf Coast States ...................... 5 2.1.1 Alabama ...................................................................................................... 5 2.1.2 Florida......................................................................................................... 7 2.1.3 Louisiana..................................................................................................... 9 2.1.4 Mississippi ................................................................................................ 10 2.1.5 Texas......................................................................................................... 12 2.1.6 Summary................................................................................................... 13 2.2 Federal Programs Encouraging State Program Improvements................................ 13 3.0 Sector Traits and Trends, Drivers and Barriers in Current Beneficial Reuse ............. 15 3.1 Cement Manufacturing (NAICS 327310)................................................................ 15 3.1.1 Beneficial Use Traits and Trends in the Cement Sector........................... 16 3.1.2 Beneficial Reuse Drivers and Barriers in the Cement Sector................... 23 3.1.2.1 Cement Kiln Dust ................................................................... 25 3.1.2.2 Alternative Fuels and Raw Materials from Other Industries Used in the Cement Industry................................................... 26 3.2 Chemical Manufacturing (NAICS 3251, 3252, 3253)............................................. 28 3.2.1 Beneficial Reuse Traits and Trends in the Chemical Manufacturing Sector ........................................................................................................ 28 3.2.2 Beneficial Reuse Drivers and Barriers in the Chemical Manufacturing Sector ........................................................................................................ 30 3.3 Construction and Demolition (NAICS 236, 23891) ................................................ 31 3.3.1 Beneficial Reuse Traits and Trends in the Construction and Demolition Sector ........................................................................................................ 31 3.3.2 Beneficial Reuse Drivers and Barriers in the Construction and Demolition Sector ..................................................................................... 33 3.3.2.1 General C&D Byproducts....................................................... 35 3.3.2.2 Asphalt Shingles ..................................................................... 37 3.3.3.3 Concrete .................................................................................. 39 3.3.3.4 Wood....................................................................................... 39 3.3.3.5 Gypsum Wallboard ................................................................. 40 3.4 Electric Power Generation at Fossil Fuel Plants (NAICS 221112) ......................... 41 Beneficial Reuse of Industrial Byproducts in the Gulf Coast Region i February 2008 3.4.1 Beneficial Reuse Traits and Trends Electric Power Generation at Fossil Fuel Plants ...................................................................................... 41 3.4.2 Beneficial Reuse Drivers and Barriers in Electric Power Generation at Fossil Fuel Plants ...................................................................................... 45 3.4.2.1 Fly Ash.................................................................................... 46 3.4.2.2 FGD Gypsum.......................................................................... 50 3.5 Forest Products: Pulp, Paper, and Paperboard (NAICS 3221) ................................ 50 3.5.1 Beneficial Reuse Traits and Trends in the Forest Products Sector........... 51 3.5.2 Beneficial Reuse Drivers and Barriers in the Forest Products Sector ...... 52 3.5.2.1 General Forest Products Beneficial Reuse.............................. 55 3.5.2.2 Wastewater Treatment Plant Residuals .................................. 55 3.5.2.3 Boiler Ash ............................................................................... 56 3.5.2.4 Causticizing Residues ............................................................. 57 3.6 Iron and Steel Mills (NAICS 3311) ......................................................................... 58 3.6.1 Beneficial Reuse Traits and Trends in Iron and Steel Mills ..................... 58 3.6.2 Beneficial Reuse Drivers and Barriers in Iron and Steel Mills................. 60 3.6.2.1 Slag ......................................................................................... 61 3.6.2.2 Electric Arc Furnace (EAF) Dust ........................................... 62 3.6.2.3 Spent Pickle Liquor................................................................. 63 3.7 Metal Casting – Foundries (NAICS 3315) .............................................................. 64 3.7.1 Beneficial Reuse Traits and Trends in Foundries..................................... 65 3.7.2 Beneficial Reuse Drivers and Barriers in Foundries................................. 66 3.7.2.1 Foundry Sands ........................................................................ 67 3.8 Oil and Gas Extraction (NAICS 211111, 211112, 212111, 213112)........................ 70 3.8.1 Beneficial Reuse Traits and Trends in Oil and Gas Extraction ................ 70 3.8.2 Beneficial Reuse Drivers and Barriers in Oil and Gas Extraction............ 71 3.8.2.1 Drill Cuttings .......................................................................... 72 3.8.2.2 Nonhazardous Tank Bottoms.................................................. 73 3.9 Petroleum Refining (NAICS 32411)........................................................................ 73 3.9.1 Beneficial Reuse Traits and Trends in Petroleum Refining...................... 74 3.9.2 Beneficial Drivers and Barriers in Petroleum Refining............................ 74 3.9.2.1 Sulfidic Caustics ..................................................................... 75 4.0 Discussion and Findings .................................................................................................... 76 4.1 Economic/Market Drivers and Barriers................................................................... 76 4.2 Regulatory/Programmatic Drivers and Barriers ...................................................... 80 4.3 Environmental Effects ............................................................................................. 83 Beneficial Reuse of Industrial Byproducts in the Gulf Coast Region ii February 2008 List of Tables Table ES-1: Gulf Coast Manufacturing Sectors Addressed in This Analysis Table ES-2: Byproducts Selected for Analysis, and Their Cross-Sector Beneficial Reuses Table ES-3: Drivers and Barriers Affecting Cross-Sector Beneficial Reuse Table 1-1: Gulf Coast Manufacturing Sectors Addressed in This Analysis Table 2-1: Summary of Gulf Coast State Regulatory Program Features Table 3-1: Number of Cement Manufacturing Facilities in the Gulf Coast States as Characterized by Cement America’s North American Cement Directory Table 3-2: Utilization of Fly Ash and Blast Furnace Slag in Cement Clinker and Portland Cement Production (1999 – 2005) Table 3-3: Byproducts from Cement Manufacturing (NAICS: 327310) Selected for Analysis Table 3-4: Chemical Manufacturing Industry in Gulf Coast States in 2006 as Characterized by the American Chemistry Council Table 3-5: Number of Chemical Manufacturing Facilities in Gulf Coast States as Characterized by U.S. Census 2004 County Business Patterns Table 3-6: Number of Construction and Demolition Establishments in Gulf Coast States as Characterized by U.S. Census 2004 County Business Patterns Table 3-7: Byproducts from Construction and Demolition (NAICS: 236 (Construction of Buildings), 23891 (Site Preparation Contractors)) Selected
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