why corex - coal ash and steel slag
TRANSCRIPT
Sustainable Minerals Manufacturing
Overview
Frank A. Karbarz [email protected]
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oreX M
aterials, Inc. All R
ights Reserved
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oreX M
aterials, Inc. All R
ights Reserved
Founded in 2011. Corporate Office in Texas.
CoreX’s globally patented process enables coal ash and residual slag fines to be upgraded into more valuable co-products.
CoreX produces PCC and fine aggregates.
PCC is Precipitated Calcium Carbonate: a manufactured mineral with high performance and cost-saving benefits for diverse manufacturers with a $4B global market
Fine aggregate is a component in Portland cement concrete and other construction applications
About Us
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oreX M
aterials, Inc. All R
ights Reserved
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Executive Summary
Precipitated Calcium Carbonate “PCC”
• PCC is the fastest growing component of the functional filler minerals segment
• PCC exhibits superior particle shapes and size distributions when compared to alternatives such as talc, kaolin, titanium dioxide, or ground calcium carbonate
• World PCC market doubled in 10 years to 17 million tons in 2012 and is expected to grow at a CAGR of 3.9% though 2019
• Filler grade CaCO3 (both PCC and GCC) > 76 million tons in 2012
• PCC price ranges: $150/ton for pulp/paper - $1,500/ton for pharma
Pulp Paper – Whiter, brighter, better ink absorptionExtruded Plastics (PVC) – stiffness, strengthInjected Plastics –flowability, fire resistanceAdhesives –viscosityCoatings – pigment base extenderRubber – abrasion resistance, stiffnessWater Treatment – corrosion control, remineralizationPharmaceuticals – mild abrasive, tablet delivery, anti-acidFood – mineral fortification, animal feedAir Emissions – acid rain preventionOil & Gas - well drilling fluid, proppant
Why make PCC?Global Demand for:
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oreX M
aterials, Inc. All R
ights Reserved
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oreX M
aterials, Inc. All R
ights Reserved
Performance Fillers Overview
PCC market has doubled in volume over 10 years
PCC captures wide performance / value spot between TiO2 and GCC
Paper39%
Plastics18%
Paint7%
Rubber6%
Adhesives/ Sealants
10%
Other 20%
PCC & GCC Applications
Kaolin; 26
GCC; 89
PCC; 19
Talc; 7.2 TiO2; 7.2
Volume (mm tons)
Sources: USGS, Roskill, GIA, CoreX
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oreX M
aterials, Inc. All R
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• CoreX reduces the $100/ton manufacturing cost to $15/ton
• PCC price ranges: $150/ton for pulp/paper - $1,500/ton for pharma
• PCC is the fastest growing segment of the functional filler market
• PCC has superior particle shapes and size distributions vs. talc, kaolin, titanium dioxide, or ground calcium carbonate
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The Corex Clean Manufacturing ProcessProduces PCC at 80% Lower Cost
We convert coal ash and slag into useful materialsTwo feedstocks - Coal ash or Steel slag and CO2
Two products - Precipitated Calcium Carbonate (PCC)
- Fine cement aggregate or formed goodsAdvantages for coal ash & slag management
• Low Energy - Ambient Temperature/Pressure• Low Cost - Catalytic• High Throughput• Clean manufacturing processes• Reduce ash & slag inventory• Direct emissions reductions
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Corex Process Highlights
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oreX M
aterials, Inc. All R
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• Traditional PCC uses a ‘dirty’, energy intensive manufacturing process
MINELimestone
CRUSH HEAT
1700 F
Calcium + CO2
DRY
CoreX eliminates these steps with lower operating cost, proprietary processes, & coal ash and slag clean-up.
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Prevailing PCC Production Process
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oreX M
aterials, Inc. All R
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oreX M
aterials, Inc. All R
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Slag and Coal Ash can be very Carbon-Friendly
Limestone supports Steel and Power Production
CoreX separates lime from the ash and/or slag and then adds CO2 to produce PCC
Coal Ash and/or
Steel Slag
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oreX M
aterials, Inc. All R
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CoreX SSS* Process
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• Ph-swing chemistry• Liquid/solid separation• High throughput, filterless• Rapid, Catalytic reaction• Ambient pressure, temp• Commercial pilot ready• Flexible
• Modular• Scalable• Mobile
* Sequential Separation and Sequestration
Carbon Dioxide20,000 tons annually
1. Reduce mineral inventory problems2. Sell value to pulp, cement, & plastic factories3. Offer potential to recover residual iron in slag4. Exceed environmental goals
Estimated Direct BenefitsFor a two million ton p.a. Steel Mill
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High-calcium slag200,000 tons annually from converter-typesteel slag
PCC
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Cement/ Aggregate
Metals
CO2Credits
1. Reduce ash inventory2. Enable marketable product streams3. Potential to create a limestone loop4. Realize low-cost carbon reductions
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Estimated Direct Benefits For a 600 Megawatt Circulating Fluidized Bed Plant
Cement Aggregate
Carbon co-product122,000 tons annually
CO2Credits
Mineral co-product750,000 tons annual top and bottom ash
PCC
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oreX M
aterials, Inc. All R
ights Reserved