Coal Ash Utilisation over the world · WEACAU-III: WS Env. Aspects on Coal Ash Utilisation,...

WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 1

Coal Ash Utilisation

over the world

Joachim Feuerborn

European Coal Combustion Products Association


Content

1. Introduction – role of coal in energy mix

2. Production and utilisation of CCPs

(WWCCPN members, worldwide)

3. Selected examples of CCP utilisation

4. Environmental benefits of CCP utilisation

5. Concluding Remarks


Source: BP Statistical Review of World Energy

Introduction – role of coal in energy mix

World – Energy consumption 2004


Global primary energy mix and global power

generation by primary energy source, 2010

cited in EURACOAL



Global hard coal and lignite reserves


Cited in: EURCOAL



Hard coal seaborn trade in 2010 - over 1 bn tonnes

(2004: 685 million tonnes)



Total EU:

Hard coal: 192 mt

Import: 236 mt

Lignite: 521 mt

Lignite production, hard coal production and imports in 2010, mt



Role of coal in EUROPE

WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 9 Source: EURACOAL


0 20 40 60 80 100

EU 27

Sweden

France

Austria

Belgium

Spain

Italy

Slovakia

Hungary

Netherlands

Finland

Ireland

Portugal

United Kingdom

Slovenia

Romania

Germany

Denmark

Bulgaria

Greece

Czech Republic

Poland

Coal is a major fuel

for energy and

steam production

in European coal-

fired power plants,

especially in single

EU member states .

Role of coal in EUROPE


• Improvement of efficiency of power generation

• Reduction of CO2 emissions

• Abatement of emissions of pollutants

to air and water

Clean Coal Technology

• Production (and utilisation) of minerals (CCPs)



Bottom Ash

Coal

Furnace

FGD

Fly Ash

ESP

DENOX

FGD Gypsum

Chimney

Lime

NH 3

1 Million

Tonnes

16.000 Tonnes 84.000 Tonnes 54.000 Tonnes

750 MWel Coal-Fired Power Plant 6000 Hours Full Load



Fly Ash

Bottom Ash

Boiler Slag

Production and utilisation of CCPs






SACAA: BREAKDOWN OF SA FLY ASH MARKET

The South African market for fly ash differs substantially from elsewhere

in the world.

Currently, very little fly ash is used outside the cement and construction

industry and 72% is used for producing blended cements.




Information

by WWCCPN

member


China – via Coal Ash Asia


Information

by WWCCPN

member


Korea – by MIRECO


Information

by WWCCPN

member


Russia /MPEI


Information

by WWCCPN

member


Fly ash utilization has increased from 1

Mn.T/year during 1994 to 100

Mn.T/year during 2011, primarily as an

out come of concerted efforts under Fly

Ash Mission-India.

Current annual generation of about 200

Mn. tonne fly ash from about 100 util-ity

and 40 captive coal /lignite based

thermal power plants of 120,000 MW

(approx) capacity is projected to grow to

around 1000 Mn. T/year by 2031-32 with

ex-panding power sector.

India – via MPEI workshop and database


Information

by WWCCPN

member


NCAB


Information

by WWCCPN

member


JCOAL – Report

Y. Ishikawa


Information

by WWCCPN

member


CIRCA – no own statistics, National Resource

Canada compilation on a 3 years term


Information

by WWCCPN

member


Int’l production & utilisation data for WWCCPN

CCPs Production Utilised (Sold)

Fly Ash (FA, PFA)1 183030 66480

Cenospheres2 22 12

Furnace Bottom Ash (BA, FBA)3 25218 12331

Boiler Slag (BS)4 3523 2609

Fluidized-bed Combustion Ash

(FBC)5

11212 9360

Semi Dry Absorption Ash (SDA)6 306 270

Flue Gas Desulfurisation (FGD)7 33001 19993

others 10393 1287

Total 266705 112361


Calculation

for the

WWCCPN


China India

Russia

Eastern

Europe 8

South Africa

Others

European

Union EU 27

North America

Total about 780 million tonnes

330

98

120

27

3747

104

Japan 12

World-wide Annual Production of Coal Ashes

(rough estimation 5/2011 - prepared by ECOBA for the WWCCPN)



Selected examples of CCP utilisation

The Puylaurent

dam in France.

It was completed

at the end of

1995.

Its maximum

height is 73

meters over the

foundation,

with a crest

length of 220

meters


Platanovryssi dam in Greece



Great Belt Bridge, Denmark



Construction of a bridge over Main-Donau canal / Germany



Use of fly ash

and bottom ash

in

concrete blocks



Soil amendment with calcereous fly ash



CCPs in road construction – Sochaczew Bypass road / Poland



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



Use of processed

Boiler Slag

as blasting grit



saving of natural resources

- mining

- processing

- transport

reduction of energy demand

reduction of emissions (CO2)

needed for or result from

manufacturing process of

products which are replaced Limestone mine

CCPs are fine grained

raw materials

CO2 reduction in

- cement production (0.7

to 1.2 kg CO2 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

Environmental considerations


- Coal plays an important role in energy mix worldwide

- About 780 million tonnes of Coal Combustion

Products are produced in the world (estimate).

- 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.

Concluding Remarks


- 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.

Concluding Remarks


Thank you for your attention!

European Coal Combustion Products Association

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Coal Ash Utilisation over the world · WEACAU-III: WS Env. Aspects on Coal Ash Utilisation,...

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