This project is funded by
the European Union
Circular economy in heavy industryZero Waste Coal Power approach
Tomasz SzczygielskiInstitute for Applied ResearchWarsaw University of Technology
21.02.2017
Goals of ZWCP
Beneficiate anthropogenicminerals to products
Implement CircularEconomy in resource-
intensive sectors
Reduce costs and risks in powersector
WORLD ENERGY CONSUMPTION
BY ENERGY SOURCE (1990-2040)(quadrillion Btu)
Source:
International Energy
Outlook 2016,
Energy-related CO2
emissions
Terminology proliferation…
Waste from combustion processes;
Coal ash, coal fly ash, fly ash, bottom ash;
Pulverized fuel ash (PFA);
Coal Combustion By-products (CCB);
Coal Combustion Product (CCP);
Anthropogenic Minerals (AM).
Registration Evaluation
Authorisation andRestriction of
Chemicals
In Europe, non registered substances can not be placed
on the market after 1st June 2008 any more!
Each producer or importer of coal combustion products (CCPs) placed on
the market as construction materials have to register their substances.
The registration requires i.a. comprehensive information about human
toxicology and ecotoxicology of the substances.
LEGAL ISSUES – REACH
REACH Information requirements – tests
JI TEFRA Project
binders capable of effectively replacing
cement and lime
in geotechnical applications
www.grupaekotech.pl
www.grupaekotech.pl
THE PRODUCTION FACILITIES FOR TEFRA PRODUCTS
ARE BASICALLY SOPHISTICATED MIXING PLANTS
OF LITTLE ENVIRONMENTAL IMPACT
Konin Production Plant plant is located in theimmediate proximity of large retention silos forfly ash in Konin Power Plant in Central Poland,capable of producing up to 90m3 of product perhour. The ready product is loaded directly tothe silo-trucks by a screw conveyor.
Warsaw ProductionPlant is located in Żerań Power Plant.
The ready product is loaded gravitationally from the mixing chamber directly into the silo-trucks parked underneath.
The unit has a throughput of 100m3/hour.
www.grupaekotech.pl
TEFRA 15a weak binder for treatment of soil before any road and other purpose
embankments may be constructed on a poorly bearing grade.
• The Polish Standard PN-S-96011 Roads for vehicles, Soil stabilization for
roads with lime stipulates typical amount of lime added for the upper layer of
treated subgrade of between 3% and 7% by mass,
• typical amount of TEFRA 15 binder in the same scope of application is in the
range of 5% to 10% by mass,
• based on the above it was assumed, that 1 unit of TEFRA 15 replaces
0.6 unit of cement/lime,
• using in a geotechnical structure one ton of TEFRA 15 allows for claiming
savings of emission of at least 0.6 x 0.832 Mg (reference Portland clinker
CO2 emission) = 0.494 Mg CO2
www.grupaekotech.pl
Lime= 800kg/t Cement = 700kg/t TEFRA = 120kg/t
GLOBAL MATERIAL EXTRACTIONBY MATERIAL CATEGORY (1980-2013)
Source: Global Material Flows Database, set up and administrated by the Vienna University of Economics and Business (WU)
Source: IEEP, building on Figure 2 from Ellen MacArthur Foundation (2012)Key: Regulation – yellow, Market based instruments – orange, Information tools – blue, Principles – purple, Strategies – light green
Circular Economy in EU
CIRCULAR ECONOMY CHANGES TRADITIONAL VALUE CHAINS BY MOVING UP IN THE WASTE HIERARCHY
Key elements of the process:
a) Perceive the potential of anthropogenic minerals;
b) Develop technologies of beneficiation within the parent
processes in which they arise;
c) Prepare the entry into the markets on which beneficiated
anthropogenic minerals may and should be placed;
d) Product standards;
e) CCP-based products including geotechnical and
agricultural;
f) Implementation of rules for non-ETS.
Zero Waste Coal Power – areas of beneficiation
Areas of optimisation of the anthropogenic minerals
Treatment in power engineering:
I. Ashes at the stage of:
1) Handling and transport of fuel:
a) pre-treatment of fossil fuel by crushing and homogenisation,
b) special additions to fuel,
i. lime from calcium carbide processing,
ii. ground burnt lime,
iii. other (as needed to modify ash properties in desirable scope);
2) Combustion of fuel in power boiler:
a) optimisation of flow of air/fuel mixture in combustion chamber by
balancing burners’ operation and steering primary/secondary air to control
LOI in CCPs,
b) other;
3) Capturing CCPs from combustion chamber to silos:
a) breaking-up ash particles conglomerates,
b) disintegration of ash particles by contact with water at approx. 300o C,
c) pre-hydration and drying of particles on their way to ESP and a silo,
d) separation of particles into a set of fractions,
e) other;
4) Storage and despatching of CCPs:
a) selective storage of varieties of CCPs,
b) mixing with other materials, including ashes,
c) air-separation,
d) granulation,
e) other;
5) Processing in a special installation nearby the power plant;
6) Employing CCPs properties to CO2 capture in a dedicated installation.
II. Gypsum:
1) Additional de-watering;
2) Adding other materials to lime slurry;
3) Mixing of FGD gypsum;
4) Granulation.
DIAGNOSIS
&MODELLINGSTANDARDISATION ENGINEERING TECHNOLOGIES
PUBLIC
PROCUREMENTEXTRACTION MANUFACTURING CONSUMPTION RECOVERY
LAW
identify areas of CE
indicate barriers for CEand means of overcoming
technical and product standards in CE
extended responsibility for products
end-of-waste criteria
REACH
objectives of resource protection
anthropogenic indicators
criteria for sectors,producersand products
CE orienteddesign and engineering
evaluation of public ordersin the framework of CE
objectives for CE and methods of implementation
standards for extractive activities
product standards
goals of protection
process standards
technical standards
implementation of anthropogenic indicators
goals of protection
regulations on use of primaryand secondaryresources
recovery indicators
goals of protection
product and processstandards
end-of-waste criteria
Secondary-First
goals of protection
ECO
NO
MY
validation of areasand methods of intervention
indication of product-, sectoral-and nationalobjectives
drivingand restraining financial stimuli
implementation of standards into economic practice
drivingand restraining financial stimuli
data bases on anthropogenic
resources
environmental footprints of products
implementation of priority for secondary
regional arrangementsand transforming waste into products
preparing economy for absorptionof resources and processes
environmental footprints of products
drivingand restraining financial stimuli
comprehensive analysis of costs of extraction and reclamation of landfills
drivingand restraining financial stimuli
optimisation and innovationin manufacturing
drivingand restraining financial stimuli
extended responsibility for products
upgrading waste into product
anthropogenic indicators
drivingand restraining financial stimuli
implementation of priority for secondary
CO
MM
UN
ICA
TIO
N
identify partnersand agree on principles of collaboration
CE Roadmap for Poland
educate designers in new standards
educateand communicateCE-driven standards
marking of products
educate designers and contractors in new standards
promote CE-oriented technologies
educatein optimisationand processes
communicate extensivelyon public procurementin CE
promote protection of resourcesand educate on costs of extraction
promote protection of resourcesand educate on costs of extraction
educate and promote
marking
marketing
educate and promoterecovery
data bases on recovery
TOWARDS ROADMAP
Implementation of ZWCP
a) Partners in the project:
Ministry of Development;
Ministry of Environment;
Ministry of Infrastructure;
Ministry of Energy;
Road and Bridge Research Institute,
Building Technique Institute;
General Directorate for National Roads and Motorways;
Sector of power and distribution Mining sector;
Warsaw University of Technology.
Key regulations (for Poland)
Circular Economy package;
Strategy for Responsible Development in Poland;
National Resource Strategy in Poland.
CONCLUSIONS
1) Global Energy Consumption/Production will continue to grow.
2) Prospects of coal disappearing from the energy mix are unreal.
3) The Circular Economy approach calls for a disruptive rethinking
& reengineering product-waste perspective.
4) Practice of utilization of Coal Combustion Products as a foundation
for (low-emission) Zero Waste Coal Power.
5) Anthropogenic minerals can replace part of natural minerals and
support low emission economy.
6) Roadmap is the key method for implementation of the Zero Waste
Coal Power.
How to contact The project team can be contacted at personal e-mail addresses
[email protected] and: [email protected]
Clima East Office, c/o Milieu Ltd
Chaussée de Charleroi No. 1121060 Brussels (Belgium)
Tel: +32 2506 1000
Website:
English: www.climaeast.eu - Russian: http://russian.climaeast.eu/
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