We Energies Coal Combustion Products ... - The White House

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Figure 1-2: Bottom ash "cinders" from We Energies’ Wells Street Power Plant destined for road surfacing and other applications. In the 1920's, more effective methods of firing power plant boilers were invented. These new processes involved burning pulverized coal instead of lump coal. While the process was a more efficient method of firing, the process generated an increased stream of fine combustion products and lower quantities of cinders. This fine combustion product is called fly ash, and the cinders that are relatively finer are called bottom ash. As environmental awareness and landfilling costs have grown, CCP generators and government regulators have encouraged the beneficial use of industrial by-products, including coal ash. According to the American Coal Ash Association (ACAA), combustion of coal in the United States alone generated approximately 128.7 million tons of coal combustion products in 2002, including approximately 76.5 million tons of fly ash, 19.8 million tons of bottom ash, 29.2 million tons of flue gas desulfurization (FGD) materials, and 1.9 million tons of boiler slag (1). Of the fly ash produced, approximately 12.6 million tons were used in cement, concrete, and grout applications; and another 14.1 million tons were used in various other applications. In some parts of the world, CCP utilization rates are much higher than that of the United States. For example, in the Netherlands CCP utilization is about 104% (Netherlands imports ash, as their supply is less than demand). CCP utilization in Denmark is approximately 90% and in Belgium over 73%. CCP utilization in other parts of Europe varies widely from around 10% to 60%. We Energies 2 Coal Combustion Products Utilization Handbook
The United States is the world's second largest producer of fly ash (second only to China). However, CCP utilization in the United States is relatively low. This presents opportunities to make use of this valuable mineral resource (2). By 2002, approximately 45.5 million tons (35.4%) of coal combustion products were used in the United States. This percentage is expected to increase, as a result of the new uses for CCPs, increased awareness of proven technologies, and global focus on sustainable development. 800,000 700,000 600,000 500,000 Tons 400,000 300,000 200,000 100,000 Coal Ash Produced (Tons) Coal Ash Util. (Tons) 0 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 Year Figure 1-3: We Energies Coal Ash Production and Utilization *Data collected up to 2003 and forecast through 2005 Coal fired power generation has gone through several process modifications to improve efficiency, control the quality of air emissions, and to improve the quality of combustion products. The variety of coal that is burned influences the chemistry of combustion products significantly. The introduction of low sulfur coal has improved the quality of air emissions and also generally improved the quality of fly ash. The provisions of the Clean Air Act Amendments have also affected nitrogen oxide (NO X ) emissions and their controls for the electric utility industry. In November 2002, the Wisconsin DNR promulgated Rule NR 428 to control NO X emissions for several source categories, including coal-fired utility boilers, to provide for a regional NO X control strategy to address the 1-hour 3 We Energies Coal Combustion Products Utilization Handbook
Page 1 and 2: Ramme - Tharaniyil Second Edition A
Page 3 and 4: This book is dedicated to all the i
Page 5 and 6: Contents Chapter 5 Controlled Low-S
Page 7 and 8: Contents Appendix A Product Data Sh
Page 9: Chapter 1 Background and History o
Page 13 and 14: are currently installed on about 25
Page 15 and 16: problems. In the late 1920’s, cin
Page 17 and 18: Chapter 2 CCPs and Electric Power
Page 19 and 20: for loading dry bulk semi tankers o
Page 21 and 22: Figure 2-2: Basic Diagram of an IGC
Page 23 and 24: Properties of Fly Ash Fly ash is a
Page 25 and 26: for air entraining admixtures, maki
Page 27 and 28: Fly ash is an artificial pozzolan.
Page 29 and 30: Table 2-6: Geotechnical Properties
Page 31 and 32: Table 2-9 shows the chemical compos
Page 33 and 34: Table 2-12: Typical Chemical Compos
Page 35 and 36: The following coal fired power plan
Page 37 and 38: All bottom ash is removed as necess
Page 39 and 40: ottom ash is removed by a hydraulic
Page 41 and 42: Chapter 3 Properties of We Energie
Page 43 and 44: that distribute and test fly ash to
Page 45 and 46: Physical, Chemical and Mechanical P
Page 47 and 48: However, some engineering propertie
Page 49 and 50: ----------------------------U.S. ST
Page 51 and 52: Results of Testing to AASHTO Standa
Page 53 and 54: Table 3-8: Summary of We Energies B
Page 55 and 56: Chapter 4 Concrete and Concrete Ma
Page 57 and 58: alumina in the pozzolan may also re
Page 59 and 60: Dunstan summarized his work in term
Page 61 and 62:
The level of shrinkage strains depe
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strength tests were performed at va
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Discussion of Test Results - 4,000
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Other important observations from t
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Figure 4-3: Compressive Strength vs
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300 290 AMOUNT OF WATER, lbs 280 27
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Table 4-8: PPPP ASTM C618 Class C F
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The final setting time for 5000 psi
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Table 4-12: Length Change* NON-AIR-
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Table 4-14: Freeze-Thaw Tests* (Air
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Abrasion resistance tests were perf
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Table 4-16: Compressive Strength Te
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4 DEPTH OF WEAR, mm @ 60 Minutes 3.
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Table 4-19: Mixture Proportions Usi
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12000 COMPRESSIVE STRENGTH, PSI 100
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Table 4-21: Air Permeability Test R
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Table 4-22: Water Permeability Test
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Table 4-23: Chloride Permeability T
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Tax Incremental Financing (TIF) was
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Figure 4-20 : Maple Avenue roadway
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Figure 4-22: Finishing touch to We
Page 103 and 104:
Table 4-26: Concrete Mixture and Si
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6. The high-volume Class C fly ash
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Table 4-31: Average Tensile Strengt
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Table 4-35: Changes in Ultrasonic P
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Table 4-38: Results of De-Icing Sal
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Table 4-40: Abrasion Resistance of
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Summary Based on the data recorded
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3.00 M 101.5 MM WRAPPED UNDERDRAIN
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mixture and concrete mixture. Also,
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Testing Program The testing program
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Test Results Table 4-46 shows the c
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Fly Ash Concrete for Precast/Prestr
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Table 4-49: Concrete Mixture Propor
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Figure 4-27: Electrical Resistance
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Table 4-51: Electrical Properties o
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fly ash by weight of total cementit
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Table 4-53: Compressive Strength of
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Chapter 5 Controlled Low-Strength
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Table 5-1: Mixture Proportions and
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1800 COMPRESSIVE STRENGTH, psi 1600
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Table 5-3: Chemical and Fineness Te
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1800 COMPRESSIVE STRENGTH, psi 1600
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and corresponding compressive stren
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conductivity tests were conducted u
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It can be concluded from this resea
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Table 5-13: Compressive Strength of
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(4) Compatible with copper, aluminu
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Mechanical Properties The compressi
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Figure 5-10: Electrical permeabilit
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Pilot Projects Using We Energies CL
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WisDOT Low Permeability CLSM with W
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material for foundations, changing
Page 167 and 168:
Chapter 6 Commercial Applications
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The report also evaluated frost sus
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Field Study Following the initial s
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Figure 6-3: Bottom ash base course
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Table 6-2: Permeability and Drainag
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Bottom Ash as an Aggregate in Aspha
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Table 6-4: Total Elemental Analysis
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We Energies Bottom Ash as a Soil In
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The coal combustion materials landf
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The only other compounds detected t
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affect combustion. The resulting fl
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Table 6-7: Dry-Cast Concrete Block
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Table 6-10 Compressive Strength of
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Chapter 7 Fly Ash Stabilized Cold
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Using the back-calculated SN values
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Falling Weight Deflectometer tests
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unconfined compressive strength of
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Chapter 8 Fly Ash Metal Matrix Com
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The green density of the aluminum f
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Table 8-1: Alloy Samples Tested in
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Cenospheres Cenospheres are hollow,
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Chapter 9 Environmental Considerat
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judgment is required for new applic
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Table 9-2: NR 538 Fly Ash Analysis
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Table 9-3: NR 538 Fly Ash Analysis
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Table 9-4: NR 538 Bottom Ash Analys
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Table 9-5: NR 538 Bottom Ash Analys
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Table 9-7: ASTM D3987 Extraction An
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Table 9-8: Typical Heavy Metals Fou
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The voluntary C 2 P 2 Challenge Pro
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General Usage - NR 538 Applicabilit
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* Use Property Owner Notification -
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Mercury Removal-Ash Beneficiation (
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the air slide inlet was set at 538
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equired removal temperatures of 813
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Chapter 10 Minergy LWA - Structura
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Chapter 11 Sample Specifications
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Part 2 - Products 2.01 Concrete Mat
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3.02 Embedded Items A. All sleeves,
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C. Provide adequate number of units
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B. Reinforce or replace deficient w
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show the strength of masonry strong
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3.02 Bottom Ash Placing and Compact
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3. The CLSM shall meet the followin
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3.02 CLSM Depositing A. CLSM shall
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11.5 Sample Specification for We En
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D. Basis of Payment This item, meas
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If the reprocessed asphaltic base-f
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Chapter 12 References 1. American
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33. University of Wisconsin-Milwauk
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69. Naik, T.R., Kraus, R.N., and Si
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Appendix A Product Data Sheets Min
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Personal Protective Equipment Speci
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FirstAid Eyes Inhalation Ingestion
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Appendix B Radioactivity in Coal a
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annual number of curies of each of
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is divided among cosmic (30 mrem),
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constructed with fly ash building m
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Appendix C Field Guide for Recycli
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‣ Blend the fly ash and prepared
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Index AASHTO See American Associati
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Index Backfill material, 6, 43, 138
Page 291 and 292:
Index Disposal costs, 5 See also La
Page 293 and 294:
Index Pavement, 26, 109, 187; botto
Page 295 and 296:
Index Size, boiler slag, 22; bottom
Page 297:
About the Authors Bruce W. Ramme B
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