[PPT] - Regulations regarding Coal Ash Utilisation in Europe Hans-Joachim PowerPoint Presentation

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Regulations regarding Coal Ash Utilisation in Europe

Hans-Joachim Feuerborn European Coal Combustion Products Association

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Content

1. Introduction
2. Regulations for use of coal ash in
cement production
concrete
road construction
3. Environmental regulations
4. Concluding remarks

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Production of CCPs in Europe (EU-15) in 2003

Fly Ash Bottom Ash Boiler Slag, 3.2 % FBC Ash 1.7 % FGD Gypsum SDA Product, 0.8% 67.8 % 9.3 % 17.2 %

Introduction

total amount 65 million tonnes

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Utilisation of CCPs in Europe (EU-15) in 2003

total amount 65 million tonnes

52.4% 35.9% Utilization in construction Industry and Underground Mining Restoration of Open Cast Mines, Quarries and Pits Disposal, 3.7% Temporary stockpile, 8.0%

Introduction

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Demands of the construction market availability of huge amounts of material constant quality (continuous process) sufficient product properties (grain size distribution, surface,reactivity, ...) long term availability meeting of technical requirements environmental compatibility

Introduction

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25.9% 11.3% 27.8% 5.8% 23.4% Cement Raw Material Blended Cement Concrete Addition Concrete Blocks Road Construction, Filling Application Infill, 3.3% Others, 2.5%

Utilisation of fly ash in the construction industry and in underground mining in Europe (EU 15) in 2003 (total utilisation 21.1 million tonnes)

Introduction

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48.2% 33.1% Concrete Blocks Cement Others Road Construction, Filling Application 10.4% 3.7% Concrete 4.6%

(total utilisation 2.7 million tonnes) Utilisation of Bottom Ash in the Construction Industry and Underground Mining in Europe (EU 15) in 2003

Introduction

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Utilisation of Fly Ash in the cement and concrete industry in Europe (EU 15) from 1993 to 2003

2 4 6 8 10 12 14 16 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 utilization in million tonnes clinker raw material blended cement concrete

Introduction

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Chemical parameters of fly ashes from coal and lignite

Parameter Fly ash from Coal Fly Ash from Lignite SiO2 36 – 60 18 – 80 Al2O3 23 – 35 1 – 19 FeO3 3 – 17 1 – 22 CaO 0,3 – 8,5 2 – 52 CaOfrei 0,1 – 25 MgO 0,5 – 5,4 0,5 – 11 K2O 0,5 – 6 0,1 – 2 Na2O 0,1 – 3,5 0,01 – 2 SO3 0,1 – 2,1 1 – 15

Regulations for use of coal ash for cement

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Parameter siliceous fly ash calcareous fly ash V W 1 W 2 Loss on ignition ≤ 5 % by mass Reactive calcium oxide1) ≤ 10 % by mass 10 – 15 % by mass ≥ 15 % by mass Free calcium oxide ≤ 1 % by mass 2) Reactive silicon dioxide3) ≥ 25 % by mass

Compressive strength at 28d4)
≥ 10 N/mm²

Expansion5)

≤ 10 mm

1) CaOreactiv = total CaO reduced by fraction calculated as CaCO3 and CaSO4 2) CaOfree-= amount up to 2,5 % by mass accepted when soundness is given (see 5)) 3) SiO2reactiv = fraction of SiO2 which is soluble after treatment with HCl and boiling KOH-solution 4) mortars with ground fly ash as binder, amount < 40µm between 10 and 30 % by mass 5) mixture of 30 % by mass ground fly ash, 70 % by mass cement

Requirements for Siliceous and Calcareous Fly Ash by DIN EN 197-1 Regulations for use of coal ash for cement

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Utilisation of fly ash as an addition to concrete has

a long history in several countries.

In 1994, the first European Standard EN 450

"Fly Ash for Concrete" was published.

About 6 million tonnes of fly ash are used

as concrete addition every year in Europe.

In May 2005, the harmonized standard EN 450 part 1

and part 2 was published. This standard has to be introduced to national law in 2006. Regulations for use of coal ash in concrete

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Parameter Requirements Test Frequency Loss On Ignition

max. 5.0 w.-%

d SO3

max. 3.0 w.-%

m Cl

max. 0.01 w.-%

m CaOfree

max. 2.5 w.-%1)

w d : daily

1) fly ash with CaOfree higher than 1 w.-% but less

w: once per week than 2.5 w.-% must comply with the requirements m: once per month for soundness

Chemical Requirements for Fly Ash for Concrete by EN 450 Regulations for use of coal ash in concrete

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Parameter Requirements Test Frequency Soundness 1)

max. 10 mm

w Fineness 2)

max. 40 w.-%

d Fineness variation ⌧ 3) ± 10 w.-% d Activity index after 28 days after 90 days min 75 % min 85 % 2 m 2 m Density variation ⌧ 3) ± 150 kg/m3 m d : daily

1) required only if CaOfrei > 1,0 w.-%

w: once per week

2) mass proportion in % of the ash retained when wet sieved

m: once per month

n a 0,045 mm mesh sieve

2 m: twice per month

3) average value as declared by the producer

Physical Requirements for Fly Ash for Concrete by EN 450 Regulations for use of coal ash in concrete

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EN 450-1 Fly ash for concrete - Part 1: Definition, specifications and conformity criteria EN 450-2 Fly ash for concrete - Part 2: Conformity evaluation

Regulations for use of coal ash in concrete

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Definition of fly ash fine powder of mainly spherical particles, derived from burning of pulverized coal, with or without co-combustion materials, which has pozzolanic properties and consists essentially of SiO2 and Al2O3,...

Reactive SiO2 min 25 % by mass
Reactive CaO max 10 % by mass

EN 450-1: Fly ash for concrete Regulations for use of coal ash in concrete

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Introduction of three categories of loss on ignition Introduction of two categories of fineness Acceptance of fly ash obtained from co-combustion Consideration of processing plants as

production plants

New items of EN 450

EN 450-1: Fly ash for concrete Regulations for use of coal ash in concrete

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Category LOI in % by mass min max A

5.0

B 2.0 7.0 C 4.0 9.0

LOI Categories of EN 450-1

EN 450-1: Fly ash for concrete Regulations for use of coal ash in concrete

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Fineness Categories of EN 450-1

Category Amount retained on a 0.045 mm mesh sieve in% by mass Fineness variation from declared value in percentage points N 40 ± 10 S 12 no requirement

EN 450-1: Fly ash for concrete Regulations for use of coal ash in concrete

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Types of Co-combustion Materials

1 Vegetable material like wood chips, straw, olive shells and other vegetable fibres 2 Green wood and cultivated biomass 3 Animal meal 4 Municipal sewage sludge 5 Paper sludge 6 Petroleum coke 7 Virtually ash free liquid and gaseous fuels EN 450-1: Fly ash for concrete Regulations for use of coal ash in concrete

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Minimum percentage of coal (Kc) shall not be less than 80 % by mass of the fuel Maximum proportion of ash from co-combustion materials (M) shall not be greater than 10 % by mass of the fly ash

) A K .... A K A K ( A K A K .... A K A K M

n n c c n n

≤ ⋅ + + ⋅ + ⋅ + ⋅ ⋅ + + ⋅ + ⋅ ⋅ = 10 % 100

2 2 1 1 2 2 1 1

Ki and Kc are the proportions of co-combustion materials and coal being fired Ai and Ac are the ash contents of the co-combustion materials and the coal

Limitation of Co-combustion Materials

Regulations for use of coal ash in concrete

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The new standard covers also fly ash produced by:

classification
selection
sieving
drying
blending
grinding
carbon

reduction

EN 450-1: Fly ash for concrete Regulations for use of coal ash in concrete

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United Kingdom

classification (BS 3892)
carbon reduction (ST I - process)

Processing Plants in Europe Regulations for use of coal ash in concrete

STI separation unit installed at:

Longannet Power

Station (Scotland)

Didcot Power

Station (England)

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The Netherlands

silo, mixing and sieving installation

(SMZ centre, Rotterdam)

(source: Vliegasunie)

Processing Plants in Europe Regulations for use of coal ash in concrete

SMZ Center in Maasflakte near Rotterdam construction in 1995 capacity 250.000 tpa

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France • re-drying facilities (Carling, Hornaing)

(source: Surschiste)

Processing Plants in Europe Regulations for use of coal ash in concrete

Hornaing; capacity 50 tph Carling; capacity 80 tph

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Germany

re-drying facility (Lünen)

(source: SEG)

Processing Plants in Europe Regulations for use of coal ash in concrete

capacity 60.000 tpa

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1) if CaOfree-amount is > 1.0 % by mass soundness has to be proven 2) requirement to be fulfilled for fly ash obtained from co-combustion

EN 450:1994-09 DIN EN 450-1:2005-05

Comparison of the chemical requirements of EN 450: 1994 / 2005

LOI ≤ 5.0 % by mass

cat. A: ≤ 5.0 % by mass
cat. B: ≥ 2.0 and ≤ 7.0 % by mass
cat. C: ≥ 4.0 and ≤ 9.0 % by mass

Cl ≤ 0.1 % by mass ≤ 0.1 % by mass SO3 ≤ 3.0 % by mass ≤ 3.0 % by mass CaOfree ≤ 2.5 % by mass1) ≤ 2.5 % by mass1) CaOreactive ≤ 10 % by mass ≤ 10 % by mass SiO2reactive ≥ 25 % by mass, based on definition ≥ 25 % by mass2)

Regulations for use of coal ash in concrete

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Comparison of the chemical requirements of EN 450: 1994 / 2005

EN 450:1994-09 DIN EN 450-1:2005-05 SiO2, Al2O3, Fe2O3, CaO amount of SiO2, Al2O3, Fe2O3, CaO to be provided

n request

amount of SiO2, Al2O3, Fe2O3 ≥ 70 % by mass1) Na2Oeq to be provided on request ≤ 5.0 % by mass (as Na2Oeq)1) MgO

≤ 4.0 % by mass (as Na2Oeq)1)

P2O5soluble

≤ 100 mg/kg1)

1) requirement to be fulfilled for fly ash obtained from co-combustion

Regulations for use of coal ash in concrete

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Comparison of the physical requirements of EN 450: 1994 / 2005

1) average value as declared by the producer

requirement EN 450:1994-09 DIN EN 450-1:2005-05 fineness (residue on 45 µm mesh sieve) fineness variations

1) (deviation from

declared value) ≤ 40 % by mass ≤ ± 10 % by mass

cat. N: ≤ 40 % by mass
cat. S: ≤ 12 % by mass,
cat. N: ≤ ± 10 % by mass
cat. S: -

(note: the ± 10 % percentage points are not applicable) density variation

1) ± 150 kg/m³ 1) ± 200 kg/m³

Regulations for use of coal ash in concrete

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Comparison of the physical requirements of EN 450: 1994 / 2005

requirement EN 450:1994-09 DIN EN 450-1:2005-05 soundness1)

max. 10 mm (50/50)2) max. 10 mm (30/70)3)

activity index after 28 days after 90 days ≥ 75 % ≥ 85 % ≥ 75 % ≥ 85 % initial setting time

≤ 120 min more than cement

paste with test cement 4)5) water demand

category N: not valid

category S: ≤ 95 % of that for test cement alone

1)

required only if amount of free calciumoxide is > 1 % by mass

2)

paste made from 50 % by mass of fly ash and 50 % by mass of cement

3)

paste made from 30 % by mass of fly ash and 70 % by mass of cement

4)

paste made from 25 % by mass of fly ash and 75 % by mass of cement

5)

requirement is assumed to be met for fly ash produced by combustion of pure coal

Regulations for use of coal ash in concrete

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DIN 18990 Fly ash for concrete Attestation of conformity EN 450-2 Fly ash for concrete - Part 2: Conformity evaluation

Regulations for use of coal ash in concrete EN 450-2 "Conformity evaluation"

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Producer

Factory production control
Internal quality control
Autocontrol testing of fly ash samples

Certification body

Initial inspection
Evaluation of results of autocontrol testing
Audit testing of fly ash samples

EN 450-2 "Conformity evaluation"

Regulations for use of coal ash in concrete

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Producer „operator of a production plant“

r

„a person (natural or legal) authorised by the production plant“ The producer is named in the certificate

f conformity !

Regulations for use of coal ash in concrete EN 450-2 "Conformity evaluation"

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... The producers documentation and procedures for the production control shall be described in a works quality

manual. The manual has to contain:
statement on aims and organisation structure,

responsibilities and powers of responsible staff

production and quality control techniques,

processes and systematic actions that will be used

inspections and tests during and after production,

and test frequency Regulations for use of coal ash in concrete EN 450-2 "Conformity evaluation"

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responsibility power plant operator responsibility producer scope of the production control according to EN 450-2 = responsility of the producer / owner of certificate

boilerl DENOX KAT ESP silo 1 Q I EN 450 fly ash FGD stack silo 2 Q II

non EN 450

final product fly ash internal quality control

fineness
LOI

auto-control testing

production control internal quality control auto- control testing + =

Regulations for use of coal ash in concrete

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EN 450-1 „Fly ash for concrete“ Part 1: Definitions, specifications and conformity criterea EN 450-2 „Fly ash for concrete“ Part 2: Conformity evaluation

01234

AnyCo Ltd, PO Box 21, B-1050 05 01234-CPD-00234 EN 450-1

Fly ash for concrete

Fineness Category: N Declared value of fineness in case of category N: 25 % Loss on ignition Category : A Particle density: 2300 kg/m3 Dangerous Substance: NL, F

Regulations for use of coal ash in concrete

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EN 12620 “Aggregates for Concrete“ EN 13055 “Lightweight Aggregates for Concrete“ These standards contain characteristics of aggregates and conformity criteria. As harmonized standards categories are defined which allow restriction based on national experience! National application documents in Germany!

DIN 20000-104: Aggregates for concrete
DIN 20000-105:

Lightweight aggregates for concrete. Regulations for use of coal ash Use of fly ash as aggregate (harmonized)

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Use of fly ash in road construction

Soil stabilisation
Landscaping
Dams and embankments
Hydraulically bound bearing layers
Asphalt filler
Additions to concrete

Regulations for use of coal ash

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Principal use of CCPs in road construction

Soil beneficiation Base layer Hydraulic bound layers Filler in asphalt / concrete addition

Regulations for use of coal ash

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prEN 14227 “Hydraulically Bound Mixtures“

part 3:

Fly ash bound mixtures

definitions of mixtures for roads, airfields and other trafficked areas

part 4: Fly ash for hydraulically bound mixtures

definitions of specification on physical and chemical properties of fly ash

part 13: Soil beneficiation with fly ash

Regulations for use of coal ash Use of fly ash in road construction

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EN 14227- 4 Hydraulically bound mixtures- Specifications - Part 4: Fly ash for hydraulically mixtures

Siliceous Fly Ash

Particle size Loss on Ignition Free calcium oxide/soundness water content pozzolanic activity

Calcereous Fly Ash

Particle size Soundness reactive calcium oxide water content hydraulic activity DIN V ENV 13282 Hydraulic Road Binders - Composition, specifications and conformity criteria

Regulations for use of coal ash

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European Construction Products Directive (1988)

requires activities of the authorities regarding emissions

f dangerous substances from construction products
Emissions to air, surface water and ground water
CEN is mandated to develop harmonised assessment

methods and harmonized approaches regarding dangerous substances Environmental Regulations

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Limiting values on leaching of heavy metals and
rganics are set nationally in several EU member states
Leaching limit values restrict the utilisation of CCPs

in certain applications like unbound use in road construction (e.g. embankments, grouting, filling)

Tightening up of limiting values by some EU member

states is threatening further applications of CCPs Environmental Regulations

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Environmental Regulations

Requirements for bound and unbound use of CCPs by Dutch BMD

The “Building Materials Decree” of the Netherlands (Boustoff-

Besluiten) contains rules relating to the use of building materials and earth in construction and other works. The aim

f the Decree is to establish a general level of protection for

soil and surface waters.

The Decree accords the reuse of materials such as construction

and demolition waste and residues recovered from industrial processes a full place in the building industry by setting clear conditions on which their use is permitted.

The immission of anorganic leachable constituents to soil and

water is calculated by the emission of the constituent. The calculation includes leaching behaviour of the building material, also factors as temperatur, thickness of the building material, degree of contact to ground water, isolation measures, a.o..

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Unbounded utilisation Bounded utilisation Percolation (column) test according NEN7343 Diffusion test (standtest) according NEN 7345 percolation at L/S=10 in mg/kg Immission in mg/m2

Element

> 10 m

Element

max

Antimoon Sb

0,03

Antimoon Sb

39

Arseen As

0,83

Arseen As

435

Barium Ba

2,20

Barium Ba

6300

Cadmium Cd

0,02

Cadmium Cd

12

Chroom Cr

0,36

Chroom Cr

1500

Cobalt Co

0,23

Cobalt Co

300

Koper Cu

0,33

Koper Cu

540

Kwik Hg

0,02

Kwik Hg

4,5

Lood Pb

0,99

Lood Pb

1275

Molybdeen Mo

0,17

Molybdeen Mo

150

Nikkel Ni

0,70

Nikkel Ni

525

Seleen Se

0,03

Seleen Se

15

Tin Sn

0,08

Tin Sn

300

Vanadium V

1,10

Vanadium V

2400

Zink Zn

2,30

Zink Zn

2100

Fluoride F

3,80

Fluoride F

14000

Chloride Cl

560

Chloride Cl

30000

Sulfaat SO4

1090

Sulfaat SO4

45000

Bromide Br

3,40

Bromide Br

90

Requirements for bound and unbound use of CCPs by Dutch BMD

Environmental Regulations

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Environmental Regulations

Requirements for selected CCPs for use in earthworks and road construction by German LAGA (leaching criteria) (German federal states working group of waste)

In the requirements of LAGA different classes for

utilisation of industrial residuess in earthworks and road construction (Z 0 to Z 2), and for disposal areas (Z 3 to Z 5) are defined. Class “Z0”: unrestricted use

Class “Z1.1”: restricted open use and
Class “Z1.2”: restricted open use with defined technical

safety measurements

Class “Z2”: restricted use with defined technical safety

measurements

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NCAB_workshop_Nov. 23/24, 2005 46 CCP Boiler Slag source/process dry bottom boiler fluid.bed combustion wet bottom boiler class Z 2 Z 2 Z 2 Z O Z 1.1 Z 1.2 Z 2 Z O Z 1.1 Z 1.2/ Z2 ZO parameter colour x1) x1) x1) x1) x1) x1) x1) x1) x1) x1) x1) clouding x1) x1) x1) x1) x1) x1) x1) x1) x1) x1) x1) smell x1) x1) x1) x1) x1) x1) x1) x1) x1) x1) x1) pH-value 8-13 10-13 8-13 10-12 10-12 10-12 10-12 7-12 7-12 7-12 6-9 conductivity µS/cm 5000 10000 5000 500 1000 1000 1000 500 1000 1000 200 As 100 40 100 10 10 40 100 10 10 40 Pb 20 40 20 40 Cd 10 10 10 2 2 2 2 Crtot 350 300 350 15 30 15 30 Cu µg/l 50 50 50 50 Ni 40 50 40 50 Hg 0.2 0.2 1 2 0.2 0.2 1 Zn 100 100 100 100 Cl mg/l 50 100 50 10 20 50 50 10 20 20 SO3 mg/l 1000 2000 1000 50 75 200 200 50 75 200 Fly Ash Bottom Ash Grate Ash

Environmental Regulations

Requirements for selected CCPs for use in earthworks and road construction by German LAGA (leaching criteria)

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Requirements for selected CCPs for use in earthworks and road construction by German LAGA (content of trace element)

CCP source/process class Z O Z 1.1 parameter colour x1) x1) clouding x1) x1) smell x1) x1) As 20 30 Pb 100 200 Cd 0.6 1 Crtot 50 100 Cu mg/kg 40 100 Ni 40 100 Hg 0.3 1 Zn 120 300

1) = to be declared

Bottom Ash /Grate Ash

Environmental Regulations

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unit insignificance threshold values Antimon Sb 10 Arsen As 10 Blei Pb 25 Cadmium Cd 5 Chrom gesamt Cr 50 Chromat CrVI 8 Kobalt Co 50 Kupfer Cu 50 Molybdän Mo 50 Nickel Ni 50 Quecksilber Hg 1 Selen Se 10 Zink Zn 500 Zinn Sn 40 Cyanid gesamt CN- 50 Cyanid leicht freisetzbar CN- 10 Fluorid F- 750 µg/l

Environmental Regulations

DIBt-insignificance threshhold values for evaluation of building products

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unit insignificance threshold values PAK, gesamt Naphthalin 0,2 2 LHKW, gesamt 10 Aldrin 0,1 DDT 0,1 PCB, gesamt 0,05 Mineralölkohlenwasserstoffe 200 BTX

Benzol als Einzelstoff

20 1 Phenole 20 µg/l

Environmental Regulations

DIBt-insignificance threshhold values for evaluation of building products

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NCAB_workshop_Nov. 23/24, 2005 50 Building Material Determination of trace element content Criteria met? yes no information on environmental compatibility comparison with similar products yes requirement met requirement not met

step 1

Environmental Regulations

DIBt-evaluation procedure for building products

(for technical approval with use of industrial by-products in concrete, only!

Restriction Dangerous substances Toxic substances (R-crierias) LAGA criterias Z2

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NCAB_workshop_Nov. 23/24, 2005 51 production of leachate/ realistic situation! determination of general parameters harmful changes by general characteristics determination of trace element content threshhold insignificance values, TOC met determination of biological parameters ecotoxicological

step 2 2.1 2.2 2.3

yes requirement not met no yes requirement met

param. ecotox.

concerned requirement not met yes requirement not met no requirement met ecotox.harmlessness not proven

Environmental Regulations

no

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NCAB_workshop_Nov. 23/24, 2005 52 test: +, no test: - 1)test to be performed only when fly ash is used 2)test to be performed only when organic additives are used 3)test only for mortar

Areas of application and tests required for cement bound products in drinking water areas German Technical and Scientific Association of Gas and Water (DVGW)

tests to be performed drinking water supply raw-water supply and products in drinkingwater-area I products in drinkingwater-area II+III migration test Appearance + + + TOC-loss + +

Arsen-loss1)

+ + + Lead-loss + + + Chrom-loss + + + mikrobiological test DVGW-working paper W2702) + +

3)

Environmental Regulations

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UK: Water supply regulations: This regulation has requirements for materials, such as cementitious materials, for use in contact with public drinking water supply. Specifications of testing is covered by BS 6920, which gives limiting values for certain metals leachates from such material.

BS 6920

max. allowable

concentration [µg/l] Aluminium Al 200 Antimony Sb 10 Arsenic As 50 Barium Ba 1000 Cadmium Ca 5 Chromium Cr 50 Iron Fe 200 Lead Pb 50 Manganese Mn 50 Mercury Hg 1 Nickel Ni 50 Selenium Se 10 Silver Ag 10

Environmental Regulations

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Provisional limit values for table 1 and table 2 of the BUWAL recommendation (BUWAL = Ministry for Environment, Forestry and Agriculture)

parameter Limit values regardin g table 1 [mg/kg] Limit values regarding table 2 [mg/kg] Limit values for fly ash [mg/kg] antimony Sb 5 20 40 arsen As 30 80 10 lead Pb 100 500 300 cadmium Cd 1 2 2 chrome total Cr 200 500 300 copper Cu 200 500 200 nickel Ni 200 500 200 mercury Hg 0.5 1 1 thallium Th 0.5 1 3 Zinc Zn 400 1000 1000 tin Sn 30 80 30 barium Ba 1500 beryllium Be 10 cobalt Co 100 selen Se 5 vanadium V 300 Cr VI 2

Environmental Regulations

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Concluding Remarks 52.4 % of the total CCPs produced in Europe is produced to meet technical requirements to replace natural materials in construction. CCPs are accepted as raw materials due to their chemical, mineralogical and physical properties. The acceptance is based on more than thirty years of experience. For nearly every field of application technical regulations or requirements have to considered.

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Concluding Remarks The new standard for fly ash for concrete introduces a quality control system including

internal quality control by the producer
audit testing by a certification body notified by the

building authorities. In order to avoid any negative impact on the environment and on human health environmental regulations have been developed in some European countries for

raw materials (trace elements, leaching behaviour)
products (prediction models for bound applications).

As a result of the environmental regulations no negative impact on the environment or on human health by the utilisation of CCPs has been reported so far.

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Thank you for your attention!

Hans-Joachim Feuerborn

European Coal Combustion Products Association www.ecoba.org