Coal Ash Utilisation. over the world and in Europe. Hans-Joachim Feuerborn. European Coal Combustion Products Association
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1 Coal Ash Utilisation over the world and in Europe Hans-Joachim Feuerborn European Coal Combustion Products Association NCAB_workshop_Nov. 23/24,
2 ECOBA Mission ECOBA - European Coal Combustion Products Association represents Power Plant Operators producing CCPs and CCP marketing companies in Europe ECOBA s mission is to encourage the development of the use of CCPs to promote the mutual interests of their members within the framework of the European Organisations to develop the legal/regulatory measures for the recognition, acceptance and promotion of CCPs in Europe NCAB_workshop_Nov. 23/24,
3 ECOBA members Established in members from 13 European countries Represents more than 86 % of European CCP production Combines knowledge and experience within Europe NCAB_workshop_Nov. 23/24,
4 ECOBA affiliated members American Coal Ash Association (ACAA) Canadian Industries Recycling Coal Ash (CIRCA) Japan Coal Energy Center (JCOAL) National Coal Ash Board of Israel (NCAB) United Kingdom Quality Ash Association NCAB_workshop_Nov. 23/24,
5 Content 1. Introduction role of coal in energy mix 2. Production and utilisation of CCPs -overtheworld - in Europe 3. Selected examples of CCP utilisation 4. Environmental benefits of CCP utilisation 5. Concluding Remarks NCAB_workshop_Nov. 23/24,
6 Introduction role of coal in energy mix World Energy consumption 2004 NCAB_workshop_Nov. 23/24, 2005 Source: BP Statistical Review of World Energy 6
7 Introduction role of coal in energy mix Primary energy consumption of fossil fuels NCAB_workshop_Nov. 23/24,
8 Introduction role of coal in energy mix Coal reserves of the world Source: WCI NCAB_workshop_Nov. 23/24,
9 Introduction role of coal in energy mix Hard coal maritime traffic 2004: 685 million tonnes Source: VDKI, Hamburg NCAB_workshop_Nov. 23/24,
10 Introduction role of coal in energy mix About 490 mill. t/a and 550 mill t/a lignite in Europe Source: EURACOAL NCAB_workshop_Nov. 23/24,
11 Introduction role of coal in energy mix Cross power generation Source: EURACOAL NCAB_workshop_Nov. 23/24,
12 Introduction role of coal in energy mix NCAB_workshop_Nov. 23/24,
13 Introduction role of coal in energy mix Clean Coal Technology Improvement of efficiency of power generation Reduction of CO 2 emissions Abatement of emissions of pollutants to air and water Production (and utilisation) of minerals (CCPs) NCAB_workshop_Nov. 23/24,
14 Introduction role of coal in energy mix 750 MW el Coal-Fired Power Plant 6000 Hours Full Load Furnace Chimney NH 3 DENOX Coal 1 Million Tonnes Bottom Ash ESP Fly Ash Lime FGD FGD Gypsum Tonnes Tonnes Tonnes NCAB_workshop_Nov. 23/24,
15 2. Production and utilisation of CCPs Fly Ash Boiler Slag Bottom Ash NCAB_workshop_Nov. 23/24,
16 2. Production and utilisation of CCPs NCAB_workshop_Nov. 23/24,
17 2. Production and utilisation of CCPs NCAB_workshop_Nov. 23/24,
18 2. Production and utilisation of CCPs NCAB_workshop_Nov. 23/24,
19 2. Production and utilisation of CCPs Ash production and sales in Australia NCAB_workshop_Nov. 23/24,
20 2. Production and utilisation of CCPs Ash production and sales in Australia NCAB_workshop_Nov. 23/24,
21 2. Production and utilisation of CCPs Ash production and utilisation in Japan NCAB_workshop_Nov. 23/24,
22 2. Production and utilisation of CCPs 15% 2% 7% Cement r aw mater i al 4% 8% 5% 59% Cement addi tive Ci vi l engi neer i ng f i el d Constr uction f i el d Agr icultur e Other s Landf i l l Utilization fields in 2003 Ash utilisation in Japan NCAB_workshop_Nov. 23/24,
23 2. Production and utilisation of CCPs World-wide Annual Production of Ashes Estimation 3/2002, Based on Figures Published by O. Manz) Total 480 million tonnes India Russia China Japan North America Others Eastern Europe European Union South Africa NCAB_workshop_Nov. 23/24,
24 2. Production and utilisation of CCPs Worldwide Coal Combustion Product Network.. The name, Worldwide Coal Combustion Ash Network, embodies the essential elements of the expected results opportunities for organizations throughout the world to increase the exchange of information about coal ash, or CCPs. The role of the Worldwide Coal Combustion Product Network will be to create opportunities for international stakeholders to exchange information with peers not only through face-to-face meetings, but, and perhaps primarily, through electronic networking. NCAB_workshop_Nov. 23/24,
25 2. Production and utilisation of CCPs Production of CCPs: 63 million tonnes in Europe (EU 15) Production of CCPs: about 30 million tonnes in new EU member states Estonia Latvia Lithuania Poland Czech Republik Slovakia Hungary Slovenia Malta Cyprus NCAB_workshop_Nov. 23/24,
26 2. Production and utilisation of CCPs About 490 mill. t/a and 550 mill t/a lignite in Europe Source: EURACOAL NCAB_workshop_Nov. 23/24,
27 2. Production and utilisation of CCPs Production of CCPs in Europe (EU 15) in 2003 [million tonnes] Fly Ash Bottom Ash Boiler Slag, 2.1 FBC Ash, 1.1 SDA Product, FGD Gypsum (total production: 65 million tonnes) NCAB_workshop_Nov. 23/24,
28 2. Production and utilisation of CCPs Utilisation and disposal of CCPs in Europe (EU 15) in 2003 [million tonnes] Utilisation in Construction Industry and Underground Mining Temporary Stockpile Disposal 23.7 Restoration of Open Cast Mines, Quarries and Pits (total production: 65 million tonnes) NCAB_workshop_Nov. 23/24,
29 2. Production and utilisation of CCPs Utilisation of fly ash in the construction industry and in underground mining in Europe (EU 15) in 2003 Concrete Addition Concrete Blocks 27.8% 5.8% Blended Cement 11.3% 23.4% Road Construction, Filling Application 25.9% Cement Raw Material Infill, 3.3% Others, 2.5% (total utilisation 21.1 million tonnes) NCAB_workshop_Nov. 23/24,
30 3. Development of CCP utilisation in Europe utilization rate in % Development of the utilisation rate of fly ash and bottom ash in the construction industry in Europe (EU 15) from 1993 to 2003 FA FA Fly Ash BA Bottom BA NCAB_workshop_Nov. 23/24,
31 3. Development of CCP utilisation in Europe Utilisation of Fly Ash in the cement and concrete industry in Europe (EU 15) from 1993 to 2003 utilization in million tonnes clinker raw material blended cement concrete NCAB_workshop_Nov. 23/24,
32 2. Production and utilisation of CCPs Demands of the construction market availability of huge amounts of material constant quality (continuous process) sufficient product properties (grain size distribution, surface, research work and pilot projects teaching of CCP properties, education installation of silo capacity long term availability beneficiation of fly ash to increase meeting of technical availability in summer requirements time (re-drying environmental compatibility facilities) Re-drying facility Lünen / Germany NCAB_workshop_Nov. 23/24,
33 2. Production and utilisation of CCPs Technical regulations beneficial utilization of CCPs over decades led to - acceptance as construction materials by industries and authorities - standards and specifications for CCPs as construction materials specific requirements for CCPs as cement raw materials EN for fly ash as constituent in blended cement EN 450 for fly ash for use as concrete addition Quality criterias for FGD gypsum, published by (EUROGYPSUM) Planatovryssi Dam, Greece NCAB_workshop_Nov. 23/24,
34 2. Production and utilisation of CCPs EN Fly ash for concrete Part 1: Definitions, specifications and conformity criterea AnyCo Ltd, PO Box 21, B CPD EN EN Fly ash for concrete Part 2: Conformity evaluation Fly ash for concrete Fineness Category: N Declared value of fineness in case of category N: 25 % Loss on ignition Category : A Particle density: 2300 kg/m 3 Dangerous Substance: NL, F NCAB_workshop_Nov. 23/24,
35 3. Selected examples of CCP utilisation The Puylaurent dam in France. It was completed at the end of Its maximum height is 73 meters over the foundation, with a crest length of 220 meters NCAB_workshop_Nov. 23/24,
36 3. Selected examples of CCP utilisation Platanovryssi dam in Greece NCAB_workshop_Nov. 23/24,
37 3. Selected examples of CCP utilisation Great Belt Bridge, Denmark NCAB_workshop_Nov. 23/24,
38 3. Selected examples of CCP utilisation Construction of a bridge over Main-Donau canal / Germany NCAB_workshop_Nov. 23/24,
39 3. Selected examples of CCP utilisation Use of fly ash and bottom ash in concrete blocks NCAB_workshop_Nov. 23/24,
40 3. Selected examples of CCP utilisation Use of fly ash in road construction Soil stabilisation Landscaping Dams and embankments Hydraulically bound bearing layers Asphalt filler Additions to concrete NCAB_workshop_Nov. 23/24,
41 3. Selected examples of CCP utilisation Soil amendment with calcereous fly ash NCAB_workshop_Nov. 23/24,
42 3. Selected examples of CCP utilisation CCPs in road construction Sochaczew Bypass road / Poland NCAB_workshop_Nov. 23/24,
43 3. Selected examples of CCP utilisation Filler in Asphalt stabilises the mixture increases the viscosity of the bituminous binder reduces sensitivity of the mixture to temperature improves adhesion of bitumen to the aggregates NCAB_workshop_Nov. 23/24,
44 3. Utilisation of CCPs Utilisation of bottom ash in the construction industry and in underground mining in Europe (EU 15) in % Road Construction, Filling Application 48.2% 4.6% 10.4% Others Concrete Blocks 3.7% Concrete Cement (total utilisation 2.7 million tonnes) NCAB_workshop_Nov. 23/24,
45 3. Selected examples of CCP utilisation Utilisation of Boiler Slag in the construction industry and as blasting grit in Europe (EU 15) in 2003 Road Construction, Filling Application 31.3% Blasting Grit 47.3% 6.0% Grouting 7.6% Concrete 7.8% Other Uses (total utilisation 2.1 million tonnes) NCAB_workshop_Nov. 23/24,
46 3. Selected examples of CCP utilisation Boiler Slag as a filling material for road construction NCAB_workshop_Nov. 23/24,
47 3. Selected examples of CCP utilisation Use of processed Boiler Slag as blasting grit NCAB_workshop_Nov. 23/24,
48 4. Environmental benefits of CCP utilisation Environmental considerations saving of natural resources -mining - processing - transport reduction of energy demand reduction of emissions (CO 2 ) needed for or result from manufacturing process of products which are replaced CCPs are fine grained raw materials CO 2 reduction in - cement production (0.7 to 1.2 kg CO 2 per kg clinker, dep. on fuel) - concrete when fly ash is used as conc. add. saving of drying energy when fly ash is used to dry wet raw materials Limestone mine NCAB_workshop_Nov. 23/24,
49 5. Conclusion (1) - Coal will play an important role in future energy mix. - About 480 million tonnes of Coal Combustion Products are produced in the world (estimate). - In 2003, 65 million tonnes of CCPs were produced in Europe (EU 15). - Including the 10 new EU member states the amount was increased to about 95 milion tonnes (EU-25) from NCAB_workshop_Nov. 23/24,
50 5. Conclusion (2) - CCPs are mainly utilized in building materials industry, in civil engineering, in road construction, for construction work in underground mining, for recultivation and restoration purposes. - CCPs are produced to meet requirements for different fields of applications. - Production and utilisation of CCPs is influenced by e.g. liberalization of electricity market, by European and national regulations and the construction market. NCAB_workshop_Nov. 23/24,
51 5. Conclusion (3) - CCPs are used as a replacement for natural materials. Therefore, they contribute to sustainable development as they - avoid the need to quarry or mine natural resources, - help to reduce energy demand as well as emission to atmosphere during production - replace part of the cement in blended cement and concrete. - CCPs will be available as valuable raw materials as coal will continue to play an important role as important source of primary energy. NCAB_workshop_Nov. 23/24,
52 Thank you for your attention! Hans-Joachim Feuerborn European Coal Combustion Products Association NCAB_workshop_Nov. 23/24,
Coal ash utilisation over the world and in Europe
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