wec energy group - michigan · 2017. 6. 6. · fly ash utilization -concrete -cement production...
TRANSCRIPT
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WEC Energy Group
Combustion Product Beneficial Use April 26, 2017 Upper Peninsula Solid Waste Forum Marquette, MI Bob Meidl, WEC Energy Group, Combustion Products Team
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Agenda
n Intro: WEC Energy Group – Who are we? n Combustion Products – What are they? n Beneficial Use of Combustion Products – How? n Overcoming obstacles to utilization n Resources
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Electric Distribution Electric Transmission
60% ownership
Natural Gas Distribution Electric Generation
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WEC Energy Group
n 4.4 million customers n 1.6 million electric customers n 2.8 million gas customers
n 60% ownership of ATC
n 70,000 miles of electric distribution
n 44,000 miles of gas distribution
n 9,400 MW of power plant capacity
We Energies Michigan Gas Utilities Corporation Minnesota Energy Resources Corporation North Shore Gas Company The Peoples Gas Light and Coke Company Wisconsin Public Service Corporation
Service Territory Company Statistics
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Coal Trains
Coal Pile
Coal Crusher House
Unit Coal Silos
Coal Pulverizers
Unit Boiler
Main Furnace
Boiler Backpass
Fabric Filter or Precipitator
(Removes > 99.9% of the Fly Ash)
Bottom Ash for use
Fly Ash SiloChimney
FGDScrubber
Fly Ash for use
Spray Dryer
Absorber
Lime/ReagentAddition
Gypsum for use
Limestone/ReagentAddition
Steam to Turbine Generator
Coal Feeders
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Tail Wagging the Dog
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Bottom Ash “Sand”
FGD Gypsum
Combustion Products
Fly Ash
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We Energies / WPS Combustion Products Approximate Annual Production (Tons)
Plant Fly Ash Bottom Ash Gypsum n Weston 127,000 23,000 - n Pulliam 14,000 5,000 - n Presque Isle 44,000 9,000 - n Pleasant Prairie 182,000 40,000 64,000 n Elm Road 172,000 26,000 180,000 n Oak Creek 84,000 15,000 32,000 n Rothschild 13,000 18,000 - Total 636,000 136,000 276,000 *Production varies with Fuel sources and electrical demand
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Waste or Resource?
“A WASTE is not a waste until you waste it.” Dr. Tarun Naik (UWM Center for Byproducts Utilization)
Better option is to find productive uses for materials that provide resources and benefits to society.
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Be a positive impact - do not leave problems
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Combustion Product Regulations n Federal – Coal Combustion Products (Residuals)
n Non-Hazardous waste when going to disposal n Self implementing rules related to management of CCR in disposal
setting (landfills and surface impoundments) n Ability for states to manage disposal permits n Language identifying beneficial use of CCR
n State – Michigan, Wisconsin and other states n Most have rules allowing specific beneficial uses including
ingredient in product (concrete, cement, wallboard), structural fill, stabilization agent, and some agricultural applications
n Test byproducts to categorize for allowable uses
Well thought out regulations are protective of the environment and help facilitate beneficial use.
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Landfilling
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Beneficial Use of Combustion Products
n Goal is to maximize the productive beneficial use of combustion products and minimize the need to landfill materials
-Improve sustainability practices -Reduce need for mining materials -Improve construction practices/products -Save money n National average for beneficial use of
combustion products is approximately 52%
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0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1980
1981
1982
1983
1984
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
Com
bust
ion
Prod
ucts
(Ton
s)
We Energies/WPS Combustion Products*Production & Utilization (1980 - 2016)
CP Produced (Tons)
CP Utilized (Tons)
* Includes WPS starting in 2015
Chart1
19801980
19811981
19821982
19831983
19841984
19851985
19861986
19871987
19881988
19891989
19901990
19911991
19921992
19931993
19941994
19951995
19961996
19971997
19981998
19991999
20002000
20012001
20022002
20032003
20042004
20052005
20062006
20072007
20082008
20092009
20102010
20112011
20122012
20132013
20142014
20152015
20162016
CP Produced (Tons)
CP Utilized (Tons)
Combustion Products (Tons)
We Energies/WPS Combustion Products* Production & Utilization (1980 - 2016)
399300
18200
524000
12300
458600
8300
495780
14980
488006
41375
427545
83500
378065
143058
412628
243708
542812
239727
564045
239181
499842
232878
512652
221175
521778
225336
633890
265318
701824
337427
725880
362910
708360
400513
712949
428497
680796
445333
680155
544654
681084
577312
694385
586896
664224
632004
662400
646400
705900
657400
714000
638000
684000
682000
774000
764740
791300
756745
671677
649039
795368
871104
915562
906547
615199
608780
818229
1015485
978920
1001673
1102189
970699
1060121
1061853
Sheet1
YearCP Produced (Tons)Fly Ash Produced (Tons)Bottom Ash Produced (Tons)CP Utilized (Tons)Fly Ash Util. (Tons)Bottom Ash Util. (Tons)RecoveredFGD ProducedFGD UtilizedToxecon ProducedToxecon Utilized% Utilization
1980399,300341,20058,10018,20018,20000.05
1981524,000445,50078,50012,30012,30000.02
1982458,600389,80068,8008,3008,30000.02
1983495,780423,66072,12014,98014,98000.03
1984488,006402,99885,00841,37541,37500.08
1985427,545363,67163,87483,50069,95213,5480.20
1986378,065318,69159,374143,058132,10810,9500.38
1987412,628345,65266,976243,708231,40512,3030.59
1988542,812441,859100,953239,727226,86412,8630.44
1989564,045446,553117,492239,181221,78917,3920.42
1990499,842393,406106,436232,878207,63325,2450.47
1991512,652413,85198,801221,175211,3759,8000.43
1992521,778419,457102,321225,336217,1968,1400.43
1993633,890516,419117,471265,318247,97717,3410.42
1994701,824581,388120,436337,427297,69739,7300.48
1995725,880603,399122,481362,910309,68353,2270.50
1996708,360586,064122,296400,513345,33955,1740.57
1997712,949581,256131,693428,497326,669101,8280.60
1998680,796559,016121,780445,333333,707111,6260.65
1999680,155553,900126,255544,654430,696113,9580.80
2000681,084549,349131,735577,312441,127136,1850.85
2001694,385564,583129,802586,896463,518123,3780.85
2002664,224538,299125,925632,004484,209125,62022,1750.95
2003662,400554,900107,500646,400430,90084,30028,2000.98
2004705,900590,400115,500657,400547,800104,8004,8000.93
2005714,000597,000117,000638,000523,000108,0007,0000.89
2006684,000565,000117,000682,000531,000117,00032,0002,0002,0001.00
2007774,000574,000127,000764,740556,000126,0009,74073,00073,0000.99
2008791,300585,900127,400756,745543,000123,30012,44578,00078,0000.96
2009671,677476,898106,339649,039438,963101,68520,68388,44087,7080.97
2010795,368519,568105,573871,104491,426100,481109,934170,227169,2631.10
2011915,562534,131103,140906,547532,800100,996411278,291272,3400.99
2012615,199368,91076,228608,780357,31072,9859,906169,696168,57936500.99
2013818,229480,13698,2951,015,485471,87596,714208,950239,414237,94638401.24
2014978,920525,797121,0291,001,673523,456111,28637,842331,590329,08950401.02
20151,102,189687,369159,990970,699563,774154,2790254,206252,64662400.88
20161,060,121636,346139,4261,061,853599,382180,9220283,049281,5491,30001.00
Total through 201423,337,34418,476,3263,950,04916,473,19412,404,7852,571,056504,0861,967,9131,952,1203,17700.71
2015
WE904,288526,349123,109894,587524,364117,577- 0254,206252,646624- 00.99
WPS197,901161,02036,88176,11239,41036,7020.38
TOT1,102,189687,369159,990970,699563,774154,279- 0254,206252,646624- 00.88
2016
WE890,521494,941111,231875,773493,074101,150- 0283,049281,5491,300- 00.98
WPS169,600141,40528,195186,080106,30879,7721.10
TOT1,060,121636,346139,4261,061,853599,382180,922- 0283,049281,5491,300- 01.00
Sheet2
Sheet3
Sheet4
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Bottom Ash Utilization
Base/subbase/structural fill under roads, buildings, and parking lots
Mineral ingredient in cement manufacture
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Gypsum Utilization
Gypsum wallboard
Agricultural soil amendment
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Calatrava Art Museum
Miller Park
Marquette Interchange I-794
Fly Ash Utilization -Concrete -Cement production -Stabilization
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Fly Ash Use in Concrete
n Replace a percentage of Portland Cement in mix designs
n Reduce use of mined materials (conserve resources)
n Improve durability of concrete structures and products
n Lower cost of concrete n Improve sustainable practices (“Green
Concrete”)
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Roman Concrete Structures – Volcanic Ash
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Green Concrete
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Green Concrete
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Common sense in design?
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Specification Title Application
ASTM D242-04 Mineral Filler for Bituminous Paving Mixtures Asphaltic concrete
AASHTO M 172 Mineral Filler for Bituminous Paving Mixtures Asphaltic concrete
ASTM C593-06 Fly Ash and Other Pozzolans for Use with Lime Soil stabilization
ASTM D 5239-04 Practice for Characterizing Fly Ash for Use in Soil Stabilization Soil stabilization
ASTM E2277-03 Guide for Design and Construction of Coal Ash Structural Fills Structural fill
ACI 232.2R Use of Fly Ash in Concrete Portland cement concrete
ASTM C311-05 Sampling and Testing Fly Ash or Natural Pozzolans in for Use in Portland-Cement Concrete Portland cement concrete
AASHTO M 295 ASTM C618
Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Concrete
Portland cement concrete
ASTM C6103-04 Test Method for Flow Consistency of Controlled Low Strength Material (CLSM) Flowable fill
ACI 229R Controlled Low Strength Materials (CLSM) Flowable fill
ASTM D6024-02 Ball Drop on Controlled Low Strength Material to Determine Suitability for Load Application Flowable fill
Industry Specifications
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Fly Ash Quality Assurance Testing n Ash handling and sales handled by LafargeHolcim n Fly ash regularly tested for loss on ignition, strength
development, size, consistency, and conformance with specifications for use
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Feedback Loop Key to success: n Results of Fly Ash quality testing are regularly
shared with Plant Operating, Maintenance and Engineering Teams
n When possible, Plant personnel consider
byproduct quality impacts and balance multiple priorities of Plant operation with consideration for maintaining beneficial use of byproducts
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Feedback Loop
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Overcoming Obstacles: Presque Isle Fly Ash Quality Challenge
n Change to PIPP Unit operation resulted in development of rock like material mixed in with fine powder fly ash
n While percentage of oversized material was small, it caused problems for the main customer that was utilizing the ash (plugged lines and process)
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Overcoming Obstacles: Presque Isle Fly Ash Quality Challenge n Customer looked to other sources of material to
meet their needs n PIPP Plant Team and Combustion Products
Team investigated options to improve quality, find other uses for the fly ash, or landfill the ash
n Based on interest of satisfying and maintaining the ash customer, avoiding landfilling of the material and overall improved economics of beneficial use, the Team implemented a high capacity screening process that could handle large volume transfers
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Success!!
Overcoming Obstacles: Presque Isle Fly Ash Quality Challenge
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Overcoming Obstacles: Winter Fly Ash Production Storage
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Fly Ash Storage
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When byproducts do not meet specifications for use – Beneficiate (Make them better)
n Economics n Quality = Customer Satisfaction n Supplement Supply n Avoid Landfilling and Expense n Sustainability
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Reburn High Carbon Ash
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Ash Fuel Reburn Process
Coal
High Carbon Ash From Other Plants
Power Plant
Energy
Building Materials
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Reburn Ash – Recover Fuel Value and Produce High Quality Fly Ash
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Reburn and Displaced Coal Annual Totals
Displaced more than 2,900 railcars of coal since 2000!
336,000 Tons coal equivalent
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
Ash Reburned
Coal Displaced
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Overcoming Obstacles: Invest in technology and process – Air Emission Control
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Overcoming Obstacles: When things do not seem easy – Innovation may be the key
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Demonstrate uses on in-house projects
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Future Challenge and Opportunity n Production versus demand for materials Resource recovery: Develop safe and economical ways to recover previously landfilled materials for beneficial use in a resource constrained society.
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Research
n Recovery/production of rare earth elements and precious metals from combustion products (DOE project)
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Keys to Success
n Plant employee engagement – view materials as PRODUCTS
n Bring stakeholders together and welcome variety of expertise (industry, regulators, marketers, customers and researchers)
n Work to get past challenges and obstacles n Be active in and fund research and innovation
efforts n Be active in industry associations and work
groups
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Beneficial Use of Byproducts – Can the tail wag the dog?
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n http://www.we-energies.com/environmental/recycle_coalash.htm
Resources - Questions
http://www.we-energies.com/environmental/recycle_coalash.htm
Slide Number 1AgendaSlide Number 3WEC Energy GroupSlide Number 5Tail Wagging the DogBottom Ash “Sand”We Energies / WPS Combustion Products �Approximate Annual Production (Tons)Waste or Resource?Be a positive impact - do not leave problemsCombustion Product RegulationsLandfillingBeneficial Use of Combustion ProductsSlide Number 14Bottom Ash UtilizationGypsum UtilizationSlide Number 17Fly Ash Use in ConcreteRoman Concrete Structures – Volcanic AshGreen ConcreteGreen ConcreteCommon sense in design?Industry SpecificationsFly Ash Quality Assurance TestingFeedback Loop Feedback Loop Overcoming Obstacles: Presque Isle Fly Ash Quality ChallengeOvercoming Obstacles: Presque Isle Fly Ash Quality ChallengeOvercoming Obstacles: Presque Isle Fly Ash Quality ChallengeOvercoming Obstacles: Winter Fly Ash Production Storage�Fly Ash StorageWhen byproducts do not meet specifications for use – Beneficiate (Make them better)Reburn High Carbon Ash Ash Fuel Reburn ProcessReburn Ash – Recover Fuel Value and Produce High Quality Fly Ash Slide Number 36Overcoming Obstacles: Invest in technology and process – Air Emission ControlOvercoming Obstacles: When things do not seem easy – Innovation may be the key Demonstrate uses on in-house projectsFuture Challenge and OpportunityResearch Keys to SuccessBeneficial Use of Byproducts – Can the tail wag the dog?Resources - Questions