Professional Documents
Culture Documents
Hans-Joachim Feuerborn
European
Coal Combustion
Products Association
NCAB_workshop_Nov. 23/24, 2005
Content
1. Introduction
2. Regulations for use of coal ash in
- cement production
- concrete
- road construction
3. Environmental regulations
4. Concluding remarks
Introduction
9.3 %
17.2 %
FGD Gypsum
SDA Product, 0.8%
Bottom Ash
Boiler Slag, 3.2 %
FBC Ash 1.7 %
Introduction
Utilisation of CCPs in Europe (EU-15) in 2003
Utilization in construction Industry
and Underground Mining
52.4%
Restoration of Open
Cast Mines, Quarries
and Pits
35.9%
Disposal, 3.7%
Temporary stockpile, 8.0%
Introduction
Introduction
Utilisation of fly ash in the construction industry and in
underground mining in Europe (EU 15) in 2003
Concrete
Addition
Concrete Blocks
27.8%
Blended
Cement
11.3%
5.8%
23.4%
Road
Construction,
Filling
Application
25.9%
Cement
Raw Material
Infill, 3.3%
Others, 2.5%
Introduction
Utilisation of Bottom Ash in the Construction Industry
and Underground Mining in Europe (EU 15) in 2003
Road Construction,
Filling Application
33.1%
4.6%
48.2%
Others
10.4%
Cement
Concrete
Blocks
3.7%
Concrete
Introduction
Utilisation of Fly Ash in the cement and concrete
industry in Europe (EU 15) from 1993 to 2003
clinker raw material
blended cement
concrete
16
14
12
10
8
6
4
2
0
1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003
NCAB_workshop_Nov. 23/24, 2005
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
K 2O
0,5 6
0,1 2
Na2O
0,1 3,5
0,01 2
SO3
0,1 2,1
1 15
W2
5 % by mass
Loss on ignition
Reactive calcium oxide1)
10 % by mass
1 % by mass 2)
10 15 % by
mass
15 % by mass
25 % by mass
10 N/mm
Expansion5)
10 mm
1)
10
11
Requirements
Test Frequency
Loss On Ignition
SO3
Cl
CaOfree
d:
w:
m:
daily
once per week
once per month
1)
12
Requirements
Test Frequency
Soundness 1)
max. 10 mm
Fineness 2)
max. 40 w.-%
Fineness variation
3) 10 w.-%
after 28 days
min 75 %
2m
after 90 days
min 85 %
2m
3) 150 kg/m3
Activity index
Density variation
d : daily
w: once per week
m: once per month
2 m: twice per month
NCAB_workshop_Nov. 23/24, 2005
1)
13
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
14
15
16
Category
LOI in % by mass
min
max
5.0
2.0
7.0
4.0
9.0
17
Amount retained on a
0.045 mm mesh sieve
in% by mass
40
10
12
no requirement
18
Animal meal
Paper sludge
Petroleum coke
19
K1 A1 + K 2 A 2 + .... + Kn An
10 %
M = 100
K c A c + (K1 A1 + K 2 A 2 + .... + Kn An )
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
NCAB_workshop_Nov. 23/24, 2005
20
blending
selection
grinding
sieving
carbon
reduction
drying
21
United Kingdom
22
The Netherlands
(source: Vliegasunie)
23
France
24
Germany
capacity
60.000 tpa
NCAB_workshop_Nov. 23/24, 2005
(source: SEG)
25
DIN EN 450-1:2005-05
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)
1)
2)
26
DIN EN 450-1:2005-05
SiO2,
Al2O3,
Fe2O3,
CaO
amount of SiO2,
Al2O3, Fe2O3,
CaO to be provided
on request
amount of
SiO2, Al2O3, Fe2O3 70 % by
mass1)
Na2Oeq
to be provided on
request
MgO
P2O5soluble
100 mg/kg1)
1)
27
EN 450:1994-09
fineness
40 % by mass
(residue on
45 m mesh sieve)
fineness variations 10 % by mass
1)
(deviation from
declared value)
density variation
1)
1)
150 kg/m
DIN EN 450-1:2005-05
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)
1)
200 kg/m
28
EN 450:1994-09
DIN EN 450-1:2005-05
soundness1)
activity index
after 28 days
after 90 days
75 %
85 %
75 %
85 %
water demand
1)
2)
3)
4)
5)
29
DIN 18990
Fly ash for concrete
Attestation of conformity
EN 450-2
Fly ash for concrete - Part 2:
Conformity evaluation
NCAB_workshop_Nov. 23/24, 2005
30
Producer
Factory production control
Certification body
Initial inspection
Evaluation of results of autocontrol testing
Audit testing of fly ash samples
NCAB_workshop_Nov. 23/24, 2005
31
Producer
operator of a production plant
or
a person (natural or legal) authorised
by the production plant
32
33
=
internal
quality
control
+
responsibility
power plant operator
FGD
DENOX
KAT
ESP
internal
fly ash
quality control
- fineness
silo 1 EN
- LOI
450
non
EN
450
silo 2
Q II
QI
autocontrol
testing
NCAB_workshop_Nov. 23/24, 2005
final product
auto-control
testing
fly ash
responsibility producer
34
EN 450-1
Fly ash for concrete
Part 1: Definitions,
specifications and
conformity criterea
EN 450-1
EN 450-2
Fly ash for concrete
Part 2:
Conformity evaluation
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
35
36
Soil stabilisation
Landscaping
Asphalt filler
Additions to concrete
37
38
part 4:
39
Hydraulically bound mixtures- Specifications Part 4: Fly ash for hydraulically mixtures
Particle size
Particle size
Loss on Ignition
Soundness
water content
water content
pozzolanic activity
hydraulic activity
Environmental Regulations
41
Environmental Regulations
42
Environmental Regulations
Requirements for bound and unbound use of CCPs by Dutch BMD
The Building Materials Decree of the Netherlands (BoustoffBesluiten) contains rules relating to the use of building
materials and earth in construction and other works. The aim
of 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..
NCAB_workshop_Nov. 23/24, 2005
43
Environmental Regulations
Requirements for bound and unbound use of CCPs by Dutch BMD
Unbounded
utilisation
Percolation (column) test
according NEN7343
Bounded utilisation
Immission in mg/m2
Element
Antimoon
Arseen
Barium
Cadmium
Chroom
Cobalt
Koper
Kwik
Lood
Molybdeen
Nikkel
Seleen
Tin
Vanadium
Zink
Sb
As
Ba
Cd
Cr
Co
Cu
Hg
Pb
Mo
Ni
Se
Sn
V
Zn
Fluoride
Chloride
Sulfaat
Bromide
F
Cl
SO4
Br
> 10 m
0,03
0,83
2,20
0,02
0,36
0,23
0,33
0,02
0,99
0,17
0,70
0,03
0,08
1,10
2,30
3,80
560
1090
3,40
Element
Antimoon
Arseen
Barium
Cadmium
Chroom
Cobalt
Koper
Kwik
Lood
Molybdeen
Nikkel
Seleen
Tin
Vanadium
Zink
Sb
As
Ba
Cd
Cr
Co
Cu
Hg
Pb
Mo
Ni
Se
Sn
V
Zn
Fluoride
Chloride
Sulfaat
Bromide
F
Cl
SO4
Br
max
39
435
6300
12
1500
300
540
4,5
1275
150
525
15
300
2400
2100
14000
30000
45000
90
44
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
NCAB_workshop_Nov. 23/24, 2005
45
Environmental Regulations
Requirements for selected CCPs for use in earthworks and road construction by
German LAGA (leaching criteria)
Fly Ash
wet bottom
boiler
class
fluid.bed
combustion
source/process
Bottom Ash
dry bottom
boiler
CCP
Z2
Z2
Z2
ZO
Z 1.1 Z 1.2
Grate Ash
Z2
ZO
Boiler
Slag
Z 1.1 Z 1.2/
Z2
ZO
parameter
1)
1)
x
1)
x
colour
clouding
smell
x
1)
x
1)
1)
1)
x
1)
x
1)
1)
x
1)
x
1)
1)
x
1)
x
1)
1)
x
1)
x
1)
1)
x
1)
x
1)
1)
x
1)
x
1)
pH-value
8-13 10-13 8-13 10-12 10-12 10-12 10-12 7-12
conductivity S/cm 5000 10000 5000 500 1000 1000 1000 500
As
100
40
100
10
10
40
100
10
Pb
20
40
20
Cd
10
10
10
2
2
2
Crtot
350
300
350
15
30
15
Cu
g/l
50
50
50
Ni
40
50
40
Hg
0.2
0.2
1
2
0.2
Zn
100
100
100
Cl
mg/l
50
100
50
10
20
50
50
10
SO3
mg/l 1000 2000 1000
50
75
200
200
50
1)
1)
x
1)
x
1)
7-12
1000
10
40
2
30
50
50
0.2
100
20
75
1)
x
1)
x
1)
x
1)
x
7-12
1000
40
6-9
200
1)
1
20
200
46
Environmental Regulations
Requirements for selected CCPs for use in earthworks and road construction by
German LAGA (content of trace element)
Bottom Ash /Grate Ash
CCP
source/process
class
ZO
parameter
colour
clouding
smell
As
Pb
Cd
Crtot
Cu
Ni
Hg
Zn
1)
1)
1)
mg/kg
x
1)
x
20
100
0.6
50
40
40
0.3
120
Z 1.1
1)
1)
x
1)
x
30
200
1
100
100
100
1
300
= to be declared
47
Environmental Regulations
DIBt-insignificance threshhold values for evaluation of building products
unit
insignificance
threshold values
Antimon
Sb
10
Arsen
As
10
Blei
Pb
25
Cadmium
Cd
Chrom gesamt
Cr
50
CrVI
Kobalt
Co
50
Kupfer
Cu
50
Molybdn
Mo
Nickel
Ni
50
Quecksilber
Hg
Selen
Se
10
Zink
Zn
500
Zinn
Sn
40
Cyanid gesamt
CN-
50
CN-
10
F-
750
Chromat
Fluorid
g/l
50
48
Environmental Regulations
DIBt-insignificance threshhold values for evaluation of building products
unit
insignificance
threshold values
PAK, gesamt
Naphthalin
0,2
2
LHKW, gesamt
10
Aldrin
0,1
g/l
DDT
0,1
PCB, gesamt
0,05
Minerallkohlenwasserstoffe
200
BTX
- Benzol als Einzelstoff
20
1
Phenole
20
49
Environmental Regulations
DIBt-evaluation procedure for building products
(for technical approval with use of industrial by-products in concrete, only!
Building Material
step 1
yes
requirement
not met
Criteria met?
no
information on
environmental compatibility
comparison with
similar products
Restriction
Toxic substances (R-crierias)
NCAB_workshop_Nov. 23/24, 2005
yes
requirement
met
Dangerous substances
LAGA criterias Z2
50
Environmental Regulations
step 2
production of leachate/
realistic situation!
2.1
requirement
not met
yes
harmful changes by
general characteristics
2.2
determination of trace element content
no
requirement
not met
param. ecotox.
concerned
2.3
threshhold insignificance
values, TOC met
yes
requirement
met
requirement
not met
yes
ecotoxicological
no
requirement
met
51
Environmental Regulations
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)
52
Environmental Regulations
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
Aluminium
Antimony
Arsenic
Barium
Cadmium
Chromium
Iron
Lead
Manganese
Mercury
Nickel
Selenium
Silver
NCAB_workshop_Nov. 23/24, 2005
Al
Sb
As
Ba
Ca
Cr
Fe
Pb
Mn
Hg
Ni
Se
Ag
max. allowable
concentration
[g/l]
200
10
50
1000
5
50
200
50
50
1
50
10
10
53
Environmental Regulations
parameter
Provisional limit
Limit values
regardin
g table
1
[mg/kg]
Limit values
regarding
table 2
[mg/kg]
Limit values
for fly
ash
[mg/kg]
antimony
Sb
20
40
arsen
As
30
80
10
lead
Pb
100
500
300
cadmium
Cd
chrome total
Cr
200
500
300
copper
Cu
200
500
200
nickel
Ni
200
500
200
mercury
Hg
0.5
thallium
Th
0.5
Zinc
Zn
400
1000
1000
tin
Sn
30
80
30
barium
Ba
1500
beryllium
Be
10
cobalt
Co
100
selen
Se
vanadium
300
BUWAL
recommendation
(BUWAL =
Ministry for
Environment,
Forestry and
Agriculture)
Cr VI
54
Concluding Remarks
55
Concluding Remarks
The new standard for fly ash for concrete introduces a
quality control system including
56
57