Beneficiation ya Triboelectrostatic ya nchi kujazwa na Ponded kuruka majivu

PREPRINT- Makala ya kuchapishwa katika ACAA Ash katika kazi, Suala la II 2015

Triboelectrostatic Beneficiation of

Land Filled and Ponded Fly Ash

By Lewis Baker, Abhishek Gupta, Stephen Gasiorowski, and Frank Hrach

Marekani ya makaa ya mawe Ash chama (ACAA) utafiti wa mwaka wa uzalishaji na matumizi ya makaa ya mawe kuruka majivu taarifa kuwa kati ya 1966 na 2011, juu ya 2.3 billion short tons of fly ash have been produced by coal-fired utility boilers.1 Of this amount approximately 625 tani milioni zimetumika manufaa, zaidi kwa ajili ya uzalishaji wa saruji na saruji. Hata hivyo, iliyobaki 1.7+ tani bilioni kimsingi hupatikana katika avfallsdeponierna au kujazwa ponded impoundments. While utilization rates for freshly generated fly ash have increased considerably over recent years, with current rates near 45%, takriban 40 million tons of fly ash continue to be disposed of annually. While utilization rates in Europe have been much higher than in the US, considerable volumes of fly ash have also been stored in landfills and impoundments in some European countries.

Hivi karibuni, interest in recovering this disposed material has increased, partially due to the demand for high-quality fly ash for concrete and cement production during a period of reduced production as coal-fired power generation has decreased in Europe and North America. Concerns about the long-term environmental impact of such landfills are also prompting utilities to find beneficial use applications for this stored ash.

LAND FILLED ASH QUALITY AND REQUIRED BENEFICIATION

While some of this stored fly ash may be suitable for beneficial use as initially excavated, the vast majority will require some processing to meet quality standards for cement or concrete production. Since the material has been typically wetted to enable handling and compaction while avoiding airborne dust generation, drying and deagglomeration is a necessary requirement for use in concrete since concrete producers will want to continue the practice of batching fly ash as a dry, fine powder. Hata hivyo, assuring the chemical composition of the ash meets specifications, most notably the carbon content measured as loss-on-ignition (WA), is a greater challenge. As fly ash utilization has increased in the last 20+ miaka, most “in-spec” ash has been beneficially used, and the off-quality ash disposed. Thus, LOI reduction will be a requirement for utilizing the vast majority of fly ash recoverable from utility impoundments.

LOI REDUCTION BY TRIBOELECTRIC SEPARATION

While other researchers have used combustion techniques and flotation processes for LOI reduction of recovered landfilled and ponded fly ash, Vifaa vya ST & Technologies (STET) has found that its unique triboelectrostatic belt separation system, long used for beneficiation of freshly generated fly ash, is also effective on recovered ash after suitable drying and deagglomeration.

STET researchers have tested the triboelectrostatic separation behavior of dried landfilled ash from several fly ash landfills in the Americas and Europe. This recovered ash separated very similarly to freshly generated ash with one surprising difference: the particle charging was reversed from that of fresh ash with the carbon charging negative in relation to the mineral.2 Other researchers of electrostatic separation of fly ash carbon have also observed this phenomena.3,4,5 The polarity of the STET triboelectrostatic separator can easily be adjusted to allow rejection of negatively charged carbon from dried landfilled fly ash sources. No special modifications to the separator design or controls are necessary to accommodate this phenomena.

TECHNOLOGY OVERVIEW – FLY ASH CARBON SEPARATION

In the STET carbon separator (Kielelezo 1), material is fed into the thin gap between two parallel planar electrodes. Chembe ni za kiumeme zinazoshtakiwa na mawasiliano ya mchanganyiko. The positively charged carbon and the negatively charged mineral (in freshly generated ash that has not been wetted and dried) ni kuvutia kwa electrodes kinyume. The particles are then swept up by a continuous moving belt and conveyed in opposite directions. Ukanda husonga chembe karibu na kila uchaguzi wakipanda kuelekea mwisho wa mgawanyiko. Kasi ya ukanda wa juu pia inawezesha njia za juu sana, hadi 36 tani kwa saa kwenye kitenganishi kimoja. Mwanya mdogo, high voltage field, kabiliana na mtiririko wa sasa, vigorous particle-particle agitation and self-cleaning action of the belt on the electrodes are the critical features

PREPRINT- Makala ya kuchapishwa katika ACAA Ash katika kazi, Suala la II 2015

of the STET separator. Kwa kudhibiti vigezo mbalimbali vya mchakato, kama vile kasi ya ukanda, kulisha pointi, and feed rate, the STET process produces low LOI fly ash at carbon contents of less than 1.5 kwa 4.5% from feed fly ashes ranging in LOI from 4% zaidi kwa 25%.

Mtini. 1 STET Separator processing dried, landfilled fly ash

The separator design is relatively simple and compact. Mashine iliyoundwa kwa mchakato 40 tani kwa saa ni takriban 30 ft. (9 m.) muda mrefu, 5 ft. (1.5 m.) pana, na 9 futi., m (2.75 m.) juu. Ukanda na rollers kuhusishwa ni sehemu tu ya kusonga. Ya electrodes ni stationary na linajumuisha ya vifaa na muda mrefu ipasavyo. The belt is made of non-conductive plastic. The separator’s power consumption is about 1 kilowati kwa tani moja ya vifaa vya kusindika na wengi wa nguvu zinazotumiwa na motors mbili kuendesha ukanda wa.

Mchakato ni kavu kabisa, requires no additional materials other than the fly ash and produces no waste water or air emissions. The recovered materials consist of fly ash reduced in carbon content to levels suitable for use as a pozzolanic admixture in concrete, and a high carbon fraction useful as fuel. Matumizi ya mito yote miwili ya bidhaa hutoa 100% ufumbuzi wa matatizo ya utupaji wa majivu.

PROASH® RECOVERED FROM LAND FILLS

Four sources of ash were obtained from landfills: sample A from a power plant located in the United Kingdom and samples B, C, and D from the United States. All these samples consisted of ash from the combustion of bituminous coal by large utility boilers. Due to the intermingling of material in the landfills, no further information is available concerning specific coal source or combustion conditions.

The samples as received by STET contained between 15% na 27% water as is typical for landfilled material. The samples also contained varying amounts of large >1/8 inchi (~3 mm) material. To prepare the samples for carbon separation, the large debris was removed by screening and the samples then dried and deagglomerated prior to carbon beneficiation. Several methods for drying/deagglomeration have been evaluated at the pilot-scale in order to optimize the overall process. STET has selected an industrially proven, feed processing system that offers simultaneous drying and deagglomeration necessary for effective electrostatic separation. A general process flow sheet is presented in Figure 2.

PREPRINT- Makala ya kuchapishwa katika ACAA Ash katika kazi, Suala la II 2015

Kielelezo 2: Process Flow Diagram

The properties of the prepared samples were well within the range of fly ash obtained directly from normal utility boilers. The most relevant properties for both the separator feeds and products are summarized in Table 2 along with recovered product.

CARBON SEPARATION

Carbon reduction trials using the STET triboelectric belt separator resulted in very good recovery of low LOI products from all four landfill fly ash sources. The reverse charging of the carbon as discussed above did not degrade the separation in any way as compared to processing fresh ash.

The properties of the low LOI fly ash recovered using the STET process for both freshly collected ash from the boiler and ash recovered from the landfill is summarized in Table 1. The results show that the product quality for ProAsh® produced from landfilled material is equivalent to product produced from fresh fly ash sources.

Jedwali 1: Properties of feed and recovered ProAsh®.

PREPRINT- Makala ya kuchapishwa katika ACAA Ash katika kazi, Suala la II 2015

PERFORMANCE IN CONCRETE

The properties of the ProAsh® generated from the reclaimed landfill material were compared to that of ProAsh® produced from fresh fly ash generated by the utility boilers from the same location. The processed reclaimed ash meets all the specifications of ASTM C618 and AASHTO M250 standards. The following table summarizes the chemistry for samples from two of the sources showing the insignificant difference between the fresh and reclaimed material.

Jedwali 2: Ash Chemistry of low LOI ash.

Strength development of a 20% substitution of the low LOI fly ash in a mortar containing 600 lb cementitious/ yd3 (Tazama Jedwali 3 below) showed the ProAsh® product derived from landfilled ash yielded mortars with strength comparable to mortars produced using ProAsh® from fresh fly ash produced at the same location. The end product of the beneficiated reclaimed ash would support high end uses in the concrete industry consistent with the highly valuable position ProAsh® enjoys in the markets it currently serves.

Jedwali 3: Compressive strength of mortar cylinders.

PROCESS ECONOMICS

The availability of low cost natural gas in the USA greatly enhances the economics of drying processes, including the drying of wetted fly ash from landfills. Jedwali 4 summarizes the fuel costs for operations in the USA for 15% na 20% yaliyomo ya unyevu. Kutokuweko kawaida ya kukausha ni pamoja na katika thamani mahesabu. Gharama ni kuzingatia wingi wa vifaa baada ya kukausha. The incremental costs for drying fly ash for STET triboelectrostatic separation processing are relatively low.

Jedwali 4: Kukausha gharama misingi ya Misa kavu.

PREPRINT- Makala ya kuchapishwa katika ACAA Ash katika kazi, Suala la II 2015

Even with the addition of feed drying costs, the STET separation process offers a low cost, industrially proven, process for LOI reduction of landfilled fly ash. The STET process for reclaimed fly ash is one-third to one-half of the capital cost compared to combustion based systems. The STET process for reclaimed fly ash also has significantly lower emissions to the environment compared to combustion or flotation based systems. Since the only additional air emission source to the standard STET process installation is a natural gas-fired dryer, permitting would be relatively simple.

RECOVERED FUEL VALUE OF HIGH-CARBON FLY ASH

In addition to the low carbon product for use in concrete, brand named ProAsh®, the STET separation process also recovers otherwise wasted unburned carbon in the form of carbon-rich fly ash, branded EcoTherm™. EcoTherm™ has significant fuel value and can easily be returned to the electric power plant using the STET EcoTherm™ Return system to reduce the coal use at the plant. When EcoTherm™ is burned in the utility boiler, the energy from combustion is converted to high pressure / high temperature steam and then to electricity at the same efficiency as coal, typically 35%. The conversion of the recovered thermal energy to electricity in ST Equipment & Technology LLC EcoTherm™ Return system is two to three times higher than that of the competitive technology where the energy is recovered as low-grade heat in the form of hot water which is circulated to the boiler feed water system. EcoTherm™ is also used as a source of alumina in cement kilns, displacing the more expensive bauxite which is usually transported long distances. Utilizing the high carbon EcoTherm™ ash either at a power plant or a cement kiln, maximizes the energy recovery from the delivered coal, reducing the need to mine and transport additional fuel to the facilities.

STET’s Talen Energy Brandon Shores, SMEPA R.D. Kesho, NBP Belledune, RWEnpower Didcot, EDF Energy West Burton, RWEnpower Aberthaw, and the Korea South-East Power fly ash plants all include EcoTherm™ Return systems.

STET ASH PROCESSING FACILITIES

STET’s separation process has been used commercial since 1995 for fly ash beneficiation and has generated over 20 million tons of high quality fly ash for concrete production. Controlled low LOI fly ProAsh®, is currently produced with STET’s technology at eleven power stations throughout the U.S., Kanada, the U.K., Polandi, and Republic of Korea. ProAsh® fly ash has been approved for use by over twenty state highway authorities, as well as many other specification agencies. ProAsh® has also been certified under Canadian Standards Association and EN 450:2005 viwango vya ubora katika Ulaya. Ash processing facilities using STET technology are listed in Table 5.

PREPRINT- Makala ya kuchapishwa katika ACAA Ash katika kazi, Suala la II 2015

Jedwali 5. Fly Ash Processing facilities using STET separation technology

PREPRINT- Makala ya kuchapishwa katika ACAA Ash katika kazi, Suala la II 2015

CONCLUSIONS

After suitable scalping of large material, drying, and deagglomeration, fly ash recovered from utility plant landfills can be reduced in carbon content using the commercialized STET triboelectric belt separator. The quality of the fly ash product, ProAsh® using the STET system on reclaimed landfill material is equivalent to ProAsh® produced from fresh feed fly ash. The ProAsh® product is very well suited and proven in concrete production. The recovery and beneficiation of landfilled ash will provide a continuing supply of high quality ash for concrete producers in spite of the reduced production of “fresh” ash as coal-fired utilities reduce generation. Hayo, power plants that need to remove ash from landfills to meet changing environmental regulations will be able to utilize the process to alter a waste product liability into a valuable raw material for concrete producers. The STET separation process with feed pre-processing equipment for drying and deagglomerating landfilled fly ash is an attractive option for ash beneficiation with significantly lower cost and lower emissions compared to other combustion and flotation based systems.

MAREJEO

[1]American Coal Ash Coal Combustion products and Use Statistics: http://www.acaa- usa.org/Publications/Production-Use-Reports.

[2]ST internal report, Agosti 1995.

[3]Li,T.X,. Schaefer, J.L., Ban, H., Neathery, J.K., and Stencel, J.M. Dry Beneficiation Processing of Combustion Fly Ash, Kesi ya DOE UNCTAD na kaboni Unburned kwenye shirika kuruka jivu, Mei 19 20, Pittsburgh, PA, 1998.

[4]Baltrus, J.P., Diehl, J.R., Soong, Y., Changarawe, W. Triboelectrostatic mgawanyo wa kuruka majivu na ubatilishaji wa malipo, Mafuta 81, (2002) pp.757-762.

[5]Cangialosi, F., Notarnicola, M., Liberti, L, Stencel, J. Jukumu la weathering juu ya usambazaji wa malipo ya kuruka majivu wakati triboelectrostatic beneficiation, Shajara ya vifaa hatari, 164 (2009) pp.683-688.

AUTHORS

Lewis Baker is the European Technical Support Manager for ST Equipment & Teknolojia (STET) based in the United Kingdom

Abhishek Gupta is a Process Engineer based at the Separation Technologies pilot plant and lab facility, STET Technical Center, 101 Hampton Ave, Haja ham MA 02494 +1-781-972-2300

Dr. Stephen Gasiorowski, Ph.D. is a Senior Research Scientist for ST Equipment & Teknolojia (STET) based in the New Hampshire.

Frank Hrach is Vice President of Process Engineering based at the Separation Technologies pilot plant and lab facility, STET Technical Center, 101 Hampton Ave, Haja ham MA 02494 +1-781-972-2300