Foody, Kevin

Ploetz, Joe

English

University of Kentucky

CCR Beneficial Use Data Capture and Reporting Joe Ploetz1, Kevin Foody1 1Waste Management (WM) CCP Solutions, 4228 Airport Road, Cincinnati, OH 45226  Key Words.  Data monitoring, CCR management, customized, audits, auditing, data management, reporting ABSTRACT Waste Management (WM) developed custom software to capture valuable CCR data and is designed to improve efficiency in billing and customer data management. Current and historical information are databased allowing for trend and operational analysis. Topics presented include the road map design of the software solution, the efficiency and accuracy created, and the ability for the electric utilities to use the cloud-based system for tracking, reporting, and auditing purposes. We will explore customizations, where WM can modify the customer interface to provide a customized experience.     ASH MARKETING BASICS Ash marketing is an environmentally friendly way to turn one industry’s trash into another industry’s treasure. By taking coal combustion residuals generated as waste from coal-burning power generation facilities, concrete companies and gypsum wallboard manufacturers re-purpose the materials as feedstock for their processes. CCR substitutions reduce consumption of mined materials and have been determined by the US EPA to have lower environmental releases than the native raw materials. Typical Coal Combustion Byproducts and End Uses   While there are environmental and economic advantages to marketing the waste material for sale as feedstock, there are also costs, logistics, and infrastructure needs associated with the process. First, a dedicated space at the facility is needed for CCR temporary or long term storage, with the requisite transportation from the point of generation. Storage facilities vary based on type of CCR and handling needs (e.g., silos for fly ash versus storage building for FGD/synthetic gypsum) and the commensurate equipment needed for the size and scope of the operation (e.g., skid steer versus front end loader). Along with the facilities and equipment, the operation must be staffed by dedicated site personnel and supported onsite while remotely managed by administrative and sales personnel. Finally, to successfully market CCRs, a laboratory or other analytical support is needed to understand the material’s physical and chemical properties and match each CCR to an appropriate end user. DATA NEEDS As with any business and process, information goes hand-in-hand with physical products. In order to market ash, a process for handling data must run from the point of CCR generation through handling and sales and on to delivery and billing. Some information is needed by only one entity, while other information is used by a variety of people. Table 1 provides examples of the data used during ash marketing as well as each data initiator and end user. Table 1. Data Needs for Ash Marketing  Historically, this information was tracked through simple spreadsheets and paper Bills of Lading (BOLs). Information lagged at each step of the process, and each stakeholder had to find and manipulate the data into what they needed. The spreadsheets grew more complex, added more rows, and were accessed by more users. Paper BOLs were damaged or lost in transit, and the records weren’t readily available to the customers who needed them. As each person wanted to put their own spin on the data, a new table was created, and the numbers were re-typed and re-calculated. As the business grew, information sharing created a half dozen touch points for each data point, and data entry errors as expected were prevalent throughout the business.  Before and After: Electronic BOLs Reduce Errors    CREATING AUTOMATION AND EFFICIENCY Opportunities arose for WM CCP Solutions to take advantage of economies of scale. While administrative functions such as accounting and human resources had infrastructure and procedures in place for handling larger datasets and business growth, the manual, spreadsheet-based ash data tracking persisted and grew unmanageable. To realize the benefits associated with a more robust system, WM CCP Solutions understood the need to investigate options to streamline and automate data entry and information sharing.  Based on the range of stakeholders who create, enter, and retrieve data and the geographic distribution of facilities, a cloud-based platform was conceptualized to manage ash marketing information. WM CCP Solutions developed a framework for data entry, storage, and retrieval of the commonly used information.  Development goals included:  Automated data entry. WM uses a scale interface that weighs and records each truck leaving the facility. By tying the scale information to the data management software, a direct transfer is possible that eliminates the possibility of typos during data entry.  Single source data retrieval. Through a common data repository, each user draws from the same information, eliminating data errors propagated by repeated entry of the same data point in multiple systems.  Transparency and visibility. Data access can be granted to utility owners, WM operations and administrative personnel, CCR customers, and trucking operators. Within these categories, data visibility can be customized for a facility to simplify retrieval options. Facility Dashboard View   Record retention and availability. Based on a data repository model, records for each facility are maintained in full and available to the designated stakeholders. A cloud storage system greatly increases the availability by shifting to an on-demand platform rather than user-level spreadsheet access. Consistency and scalability. Establishing a single data sharing system for all WM CCP Solutions facilities provides consistent information availability across operations. In areas that common transporters are used, it is possible to maintain all the records in one place under one company identity. For BOLs, facility and end customer identities are consistent to support material tracking. Data security. Establishing user permissions, each stakeholder is granted access to view or manipulate data only as necessary. This reduces the risk of inadvertent data changes or corruption. Operational efficiency. Daily inventory verification paired with production and sales tracking, provides information assisting sales and operations personnel. Automated scales and weight calculations identify overweight loads to prevent permit exceedance. The built-in calculations increase accuracy and decrease data processing workloads. Material quality monitoring. WM CCP Solutions performs periodic field analysis and laboratory analysis on managed ash. To efficiently communicate analysis results, an ash quality dashboard was integrated into the software. This provides a reliable method for customers to verify the material meets specifications.  Product Quality Dashboard   Customization. Managing multiple facilities operated by multiple utility clients and selling to multiple customers, WM established customization options built within the base interface.  ADDITIONAL BENEFITS AND FUTURE ROADMAP WM’s efforts to improve operational efficiency provided benefits that exceeded the project goals. Providing better access to a wide range of ash marketing data, stakeholders are able to evaluate the data trends that matter for their operation.  Following system integration, data errors have been reduced from six percent to one-half percent. WM can rely on real time ash inventory and truck load data when engaging customers for sales, transport, and billing. The increased confidence and reliability is passed on to the utility through strengthened customer relationships. Information transparency has provided the utilities with the ability to track ash from cradle to jobsite. As the manufacturer/generator of the material, the utility maintains environmental liability for marketed ash. By reporting the transporter and purchaser for each sale, the utility now has the confidence and can verify that ash is marketed commensurate with the ash marketing contract and environmental policies.  A common data repository enables ash quality trending and analysis. Because ash samples are identified for specific loads leaving a facility, and the time each load departs is known, quality issues can be tracked to the source. With that level of increased detail, additional material testing can be completed to determine corrective actions, and all customers can be notified if necessary.  Exploring ways to reduce data errors and support operations, WM CCP Solutions discovered customer benefits through enhanced information sharing. As part of our drive for sustainability, data analysis provides an increase in the service we provide to both the utilities and end users, WM continues to identify additional information that will boost future ash utilization. Plans are in place to expand the silo management module, enhance user customizations and access, and provide historical QC record lookups. Through our data-driven ash utilization process, WM continues to lead the way to a scalable, sustainable improvement in the coal ash industry. 

CCR Beneficial Use Data Capture and Reporting

https://uknowledge.uky.edu/context/woca/article/1239/viewcontent/0478_0692_000268.pdf

CCR Beneficial Use Data Capture and Reporting

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