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
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 2
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
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 3
Source: BP Statistical Review of World Energy
Introduction – role of coal in energy mix
World – Energy consumption 2004
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 4
Global primary energy mix and global power
generation by primary energy source, 2010
cited in EURACOAL
Introduction – role of coal in energy mix
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 5
Global hard coal and lignite reserves
Introduction – role of coal in energy mix
Cited in: EURCOAL
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 6
Introduction – role of coal in energy mix
Hard coal seaborn trade in 2010 - over 1 bn tonnes
(2004: 685 million tonnes)
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 7
Introduction – role of coal in energy mix
Total EU:
Hard coal: 192 mt
Import: 236 mt
Lignite: 521 mt
Lignite production, hard coal production and imports in 2010, mt
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 8
Introduction – role of coal in energy mix
Role of coal in EUROPE
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 9 Source: EURACOAL
Introduction – role of coal in energy mix
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
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 10
• 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)
Introduction – role of coal in energy mix
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 11
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
Introduction – role of coal in energy mix
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 12
Fly Ash
Bottom Ash
Boiler Slag
Production and utilisation of CCPs
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 13
Production and utilisation of CCPs
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 14
Production and utilisation of CCPs
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 15
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.
Production and utilisation of CCPs
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 16
Production and utilisation of CCPs
Information
by WWCCPN
member
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 17
China – via Coal Ash Asia
Production and utilisation of CCPs
Information
by WWCCPN
member
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 18
Korea – by MIRECO
Production and utilisation of CCPs
Information
by WWCCPN
member
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 19
Russia /MPEI
Production and utilisation of CCPs
Information
by WWCCPN
member
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 20
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
Production and utilisation of CCPs
Information
by WWCCPN
member
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 21
NCAB
Production and utilisation of CCPs
Information
by WWCCPN
member
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 22
JCOAL – Report
Y. Ishikawa
Production and utilisation of CCPs
Information
by WWCCPN
member
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 23
CIRCA – no own statistics, National Resource
Canada compilation on a 3 years term
Production and utilisation of CCPs
Information
by WWCCPN
member
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 24
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
Production and utilisation of CCPs
Calculation
for the
WWCCPN
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 25
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)
Production and utilisation of CCPs
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 26
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
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 27
Platanovryssi dam in Greece
Selected examples of CCP utilisation
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 28
Great Belt Bridge, Denmark
Selected examples of CCP utilisation
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Construction of a bridge over Main-Donau canal / Germany
Selected examples of CCP utilisation
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 30
Use of fly ash
and bottom ash
in
concrete blocks
Selected examples of CCP utilisation
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 31
Soil amendment with calcereous fly ash
Selected examples of CCP utilisation
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 32
CCPs in road construction – Sochaczew Bypass road / Poland
Selected examples of CCP utilisation
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 33
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
Selected examples of CCP utilisation
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 34
Use of processed
Boiler Slag
as blasting grit
Selected examples of CCP utilisation
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 35
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
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 36
- 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
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 37
- 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
WEACAU-III: WS Env. Aspects on Coal Ash Utilisation, December 11/12, 2012, Tel Aviv, Israel 38
Thank you for your attention!
European Coal Combustion Products Association