york-#1283434-v1-dongara presentation to …archives.york.ca/councilcommitteearchives/pdf/rpt 3 pres...
TRANSCRIPT
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Presentation to York Region Environmental Services Committee
November 11, 20099:00 am
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Dongara is committed to ensuring that our process will
be sustainable over the 20 year contract to service the needs
of York Region
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Showing Our Commitment
Additional Capital Investment targeting Throughput, Pellet Quality and Dust Control
Emphasis on Manufacturing Excellence Addition of Personnel in Key RolesManufacturing Procedural Improvements
Aggressive Recycling Program regarding electronic waste
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Additional Capital Investments
A multimillion dollar Capital Investment Plan, focused on improving throughput, pellet quality and dust control, is being considered by the Board this afternoon
Improvements to mechanical sorting of waste, including improved finding and removal of e-wasteAdditional investment in lab testing equipment and environmental control / isolation Increased dust collection; capacity & pick-up pointsCompletion – early Q2, 2010
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Emphasis on Manufacturing ExcellenceAddition of Personnel in Key Roles
Duncan McTavish, P. Eng., MBAInterim CEO, effective October 28, 2009
Domenic Stalteri, P. Eng., MBA VP Operations, effective November 2, 2009
Manufacturing Operations Manager and Senior Manufacturing Engineering professional with 15 years of experience with Woodbridge Foam Corporation, a Canadian automotive manufacturing component supplier with 45 plants in 20 countriesProfessional Engineer (PEO) with a Bachelor of Mechanical Engineering, MBA (2009) with a focus on Strategy, Leadership and Change FocusResident of York Region
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Operational Improvements including:Preventative Maintenance ProgramLEAN Manufacturing Approach
Workplace organizationData-driven decision making and improved reportingPlanning
Shop Floor employee involvement
New Weekly Reporting Forms for York Region staff – improved transparencyMore efficient procedure with UEM for York Region to identify unacceptable material
Emphasis on Manufacturing ExcellenceProcedural Improvements
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Aggressive and Immediate Program on Electronic Waste
The new capital improvements will include additional finding and collection equipment
Dongara urges York Region to develop their e-waste recycling program that will collect e-waste before it gets to the black bag
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Pellet UsersDongara is committed to producing a consistent quality pellet
All pellets are shipped to approved sites onlyOff spec pellets to CovantaSpec and near-spec pellets to REMASCO for testingTesting at other permitted, in-province and out-of-province sites
Currently, we do not have any further shareable emissions data
Pellet Quality is inconsistent primarily due to excess e-waste that the additional capital improvements and recycling programs will target
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Together, York Region and Dongara will achieve:
Diversion of up to 100,000 tonnes of waste per year into a premier processing facility Provision of a clean, green energy fuel for fossil fuel users to improve their carbon foot printMinimization of the need for incineration and landfill (delaying the need for extended use of landfill)Reduction in the amount of truck traffic on highwaysProvision of local employment
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Provincial Certificate of ApprovalRules We Must Follow
Receive only municipal waste, including domestic residential waste, additives and source separated blue box materialTypically receive Monday to Saturday 7am to 7pm
24 hour receiving upon notification to the MOE in respect of emergency or seasonal issuesNo restriction on shipping out of waste, pellets, or otherwise
MSW received at the site must be processed within 48 hours. Waste shall be removed from the loading/unloading area for disposal within 48 hours during emergency situations, mechanical failure or process upsetsOnly 150 tonnes of residual waste on-site at any one time
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Process Flow
Designated Plastic
Tip Floor Shredding
Selected Materials for Pellets
Remove Recyclables
Aluminum
Other Metal
Glass
Moisture is removed as a
result of handling throughout the
Process
It is treated and reused to wash
equipment.
Gasifier
Kiln
High CalorificAdditive
Residual to Disposal
Incoming Waste
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Sort Area
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Four major issues affecting operations over the last 16 months
Electronics and Stainless Steel
Bulky Items
Moisture
Dust Control
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Electronics/Stainless SteelElectronics – mercury and lead, chlorine from the spray
Stainless Steel – mainly chromium issues, pellet equipment damage
Originally not able to identify where these contaminates were coming from. They were not in the audits we received, but we have been refining the audits and it is becoming more evident
What we have done to date:
Added magnets and relocated magnets to more strategic locations
Refined our audits to locate the root problems
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Waste Material VariablesComparison Between Studies/Audits(Markham Study Fall '04; Dongara/Sentinel Audit Winter '09; Dongara/Torcan Fall '09)
Stream/Materials Markham Study Dongara/Sentinel Dongara/TorcanALL PAPER 14.70% 24.74% 18.69%ALL PLASTIC (including hard and film) 15.70% 17.65% 18.66%ALL GLASS (coloured and clear) 2.50% 3.59% 2.63%ALL METALS (incl aluminum cans) 6.70% 3.93% 6.09%ORGANICS (incl yard waste, sanitary, diapers, wood etc…) 39.10% 24.25% 15.08%OTHER CONTAMINENTS (wood, textiles etc...) 18.30%TEXTILES (clothes, blankets etc... ) 5.06% 7.88%NON PROCESSABLE (stone, concrete, electronics, hazardous etc…) 8.87%NON PROCESSABLE (C&D, hazardous) 4.93%RESIDUE (soil etc….) 5.26% 14.21%BULKY ITEMS 3.30% 5.25%CONSUMER ELECTRONICS 3.33%MEDICATIONS (medical supplies, syringes etc….) 0.89%
Please not that the material streams in these audits are a bit different based on time and knowledge not all streams areidentical from audit to audit and some those that did not exist in other audits are marked in yellow.
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Bulky ItemsBulky items like mattresses and sofas were not able to be processed at the plant
We were, by contract, obligated to accept them
What we have done to date:
Last February we tested shredders which are working
Improved shredders are required
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Unacceptable Materialas defined in the York Contract
Oversized BrushAppliancesOversized LumberTiresConsumer ElectronicsHazardous WasteConstruction and Demolition wasteRadioactive MaterialsPropane and Freon cylinders
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Pictures of unanticipated waste that Dongara is obligated to accept
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Moisture
Issues with the pellet mills, lowers the temperature and effects pellet density
Causes breakdowns from clogging, sticks to belts and equipment
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Fire Department ConcernsDust Control
The Vaughan Fire and Rescue have two major concerns:
Staff at Dongara did not follow safety procedures as set out by our own report
The existing debris and dust sitting on the floor around the equipment, on the equipment and on the vents in the factory
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The Dongara Board and Senior staff believe that the additional capital investments, the personnel and
procedural changes will ensure a sustainable long term success to
service York Region and produce a consistent, quality product for pellet
customers