Advanced Methodologies for Ash Utilization in Mines vis-à-vis Environment Protection: A Glimpse of Few Cases from United StatesDr. Shiv Kumar DubeSenior Fellow , TERI, New Delhi &Ex-General ManagerAsh ManagementNTPC Limited3rd Annual International Summit on “Fly Ash Utilization”Mission Energy Foundation, New DelhiDecember 17, 2013

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Welcome

Profile(a) Ph.D. IIT Delhi 1981 on Metal Oxide Catalysts:

Petroleum Hydrocarbons (Petrol) from Methyl Alcohol likewise.

(b) Ex- faculty to Southern Illinois University at Carbondale, Illinois USA and University of Pittsburgh, Pittsburgh, Pennsylvania, USA.

(c) 6 Patents including the “Development of the process for the “Manufacture of pond ash based un-sintered light weight aggregates”.

(d) Chaired a Session Chair in an important event like 15th International American Coal Ash Association Symposium at St. Petersburg, Florida, USA.

(e) Had been invited for three consecutive years from 1996 to 1998 to Chair Sessions in American Power Conference, Illinois Institute of Technology, Chicago.

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LORD SHIVA IS THE FIRST PERSON IN THE UNIVERSE TO USE SISTER OF FLY ASH – THE ASH

HE APPLIED IT TO HIS BODY

Translation of new ideas given in NTPC

turned into reality:

Year 1985 and onwards……

Responsible for Accomplishing First time in NTPC:

 Introduced the Concept of Fly ash bricks by showing Fly ash bricks in 1985: Introduced the Fly ash bricks concept to NTPC vide “R&D Project F-401, 1983”, completed by me at National Council for Cement and Building Materials (NCB, New Delhi).

 Manufacture of fly ash bricks: Completed first trials of manufacture of fly ash bricks at BTPS ash pond in 1987 and then produced steam-cured bricks in 1988-1990 at M/s Hindustan Pre-fab Limited , New Delhi.

 Clay Fly Bricks: By conducting studies it was proved in 1992-1993 that BTPS and Korba ash are suitable for the manufacture of Clay Fly bricks.

Responsible for Accomplishing First time in NTPC:

Fly ash based Road: By constructing Test Track (road) at BTPS ash dyke, it was proved that there is saving of about 60% and 9% in the construction of sub-base course and base course respectively, as a CBIP Project-1993.

 Fly ash based lightweight aggregates: Developed the process for the manufacture of lightweight aggregates for making concrete using fly ash (PATENT No. 187951).

Introduction of Cenosphere Concept, 1988.

Responsible for Accomplishing First time in NTPC:

Mine filling: based on the experience acquired in USA, arranged to initiate and then accomplished the Systematic study for filling ash in mines for the first time.

 Based on the exhaustive work of “Ash Utilization Cell of R&D Department- Group Head- Dr. S. K. Dube”; NTPC created a New Department known as

“Ash Utilization Division” in 1991.

Certain Technical Developments (New Products And Processes) and Patents etc.(I):

Development of Oil well cements using fly ash for class G and class J for the applications up to the depths of 4000 & 8000 meter (1982).

Development of non-shrinking (expansive) cement(1982) Development of fly ash bricks manufacture in 1983. Development of process for manufacture of fly ash

bricks for the fly as produced from Singrauli, Korba, Ramagundam and Farakka stations of NTPC. 1987-88

Development of a process for the manufacture of lightweight aggregates for making concrete using fly ash (PATENT No. 187951-1995/2003).

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Certain Technical Developments (New Products And Processes) and Patents etc. (II):

The Construction of road using fly ash and bottom ash and bringing down the expenditure by more than 55%.

Development of Grouts for backfilling of underground mines.

Development of Lightweight jute bags for packing cement for implementation in the cement industry.

Development of Process for the manufacture of oxalic acid using Sarkanda (Sacchrum-Munja: a type of wild grass) with yield level of 40%.

Successful pilot plant trials for the manufacture of Geo-Polymer Fly ash bricks. 10

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Innovative Applications of Coal Ash

1. “Ash along with OB” filling in Mines2. Ash-Bitumen wearing Course3. Fly ash Geo-Polymer Concrete4. Fly ash based foamed Concrete/ AAC5. Fly Ash - Aluminum Composites / Foam6. Resonance Shock Compression Technology7. Cold Setting Technology: Building Bricks8. Flux Bonded Technology: Building Bricks9. Ash Based Wooden Components

Management & Administration of Research & Study Projects Conducted/ being conducted

1. Canal lining work, IIT Kanpur, (Singrauli)

2. Ceramic Products – NIIT, Trivandrum, (Ramagundam)

3. High Performance Concrete NCB, Ballabhgarh, Unchahar

4. Development of Fly ash based HDPE Products, Vindhyacal

5. Development of Poly Propylene Products, (Rihand)

6. Manufacture of Reef Balls, (Simhadri).

7. Railway Concrete Sleepers IIT, Kanpur

8. Removal of Toxic Elements: Chromium, Fluoride, Arsenic Cobalt from Effluents of Cottage Textile Industries (Tanda-NEERI)

9. Agriculture and waste land development work, (Vindhyachal-Tropical Research Institute, Jabalpur.

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Activities for Ash filling in MinesBottom ash stowing in Singreni Collieries

Company Limited (SCCL)Design of Grouts for filling in Springfield

mine and Peabody Coal mines in Illinois,USAProject Manager, Gorbi Mine Ash Haul Back

project, NCL, Singrauli: US AID/ NETL/ WVU/ PSU/ CMPDI Support (pH 3.2)

TOR/ (SOW) Development for South Balanda Mines, MCL,Angul District, Orissa (100% Ash Utilization since the year 2006)

Associated with the Activities for Ash filling in Mines

Assessment of Ash haul back for Thermal Power Station in West Virginia, Pennsylvania and Maryland; USA

TOR for random filling of ash with Overburden, SCCL mines, Ramgundam,(A.P.)

Handling for initiating Mine filling activities for Gevra Mines, SCCL

Interface with Ministry of (i) Envt. & Forests, (ii) Coal, (iii) Power, DGMS, CPMDI, EAC etc.

                                                                                                  

                                   

Certain data of Coal on USA(million short ton)

Year Coal Production Coal Consumption

2005 1,131.5 1,126.02006 1,162.7 1,112.32007 1,146.6 1,128.02008 1,171.8 1,120.52009 1,074.9 997.52010 1,084.4 1,051.32011P 1,094.3 1,003.1

Ref: http://www.eia.gov/totalenergy/data/monthly/#coal

ACAA: 2011/2012 Coal Combustion Product (CCP), Prod. and Use ton),

Total CCPs – Cat.I (Dry) & II (Ponded)

Fly Ash(A)

Bottom Ash(B)

Boiler Slag(C)

FGD Material(D)

Production(Ton)

59,900,00025,100,000

16,500,00014,100,000

2,002,7641,720,945

25,000,00024,200,000

CCP USE(Ton)

22,975,45023,205,204

6,082,4075,474,167

1,374,7161,437,556

11,807,77012,102,964

IndividualUse

38.3%44.54%

36.8%38.82%

68.64%83.53%

47.23%50.01%

TOTAL: A+B+C+D= (2011) 103,402,764 t; (2012) 81,120,945 ton

USE: = 42240343 ton; 42,219,881 ton

% Use:= 40.85% 52.04%

Ash Haulback Sites Visited

• Lauritta Mine – Fort Martin haulback

• Chaplin Hill mine – MEA haulback

• Metikki Mine – Mount Storm haulback

• Solomon Mine – Fort Martin Haulback

• On site landfills of:• Mount Storm Power Station

• Harrison Power Station

Acid Mine Drainage

Eastern U.S. bituminous coals can contain pyrite

When oxidized and exposed to water, pyrite creates sulfuric acid and Fe++

Major Environmental problem in Appalachian coal fields.

Alkaline CCBs are used in the abatement and prevention of AMD

Ash haulback

Coal Combustion Byproducts are hauled back to mines to:– Be used as alkaline amendments and bulk fill

materials in surface mining– Fill mine voids in deep mines to prevent acid mine

drainage and subsidenceAsh haulback arrangements are becoming

common practice with Appalachian Coal and Utilities.

Examples from Power Plants:

Harrison Power Station, Allegheny Energy, WVFort Martin, Allegheny Energy, WVMount Storm, VEPCO, WV-Heated Scuba DivingMorgantown Energy Associates, Dominion, WVBull Run Power Station, TVA TennesseeBeechurst Power Station, Morgantown, WV

Fort Martin Summary Ash backhauled three miles to

open pit mine Ash used to:

return landscape to approximate original contour

Provide an alkaline amendment to soil

Cap potentially toxic materials

Chaplin Hill MinesAn Example of Ash Haulback and

Coal Mining TogetherThese are the mines located in the West

Virginia Area.These are the mines where Coal Mining and

Ash filling in the mines is taking simultaneously.

To fill the Power plant coal ash in the mines in mandatory in the West Virginia to continue the mining of coal.

Chaplin Hill Mine-1

Coal Mining in Progress

Chaplin Hill Mine-2Mandatory FBC ( Fluidized Bed Combustion) Fly Ash being placed in the mined out area.

Chaplin Hill Mine-3

Mine Overview

Chaplin Hill Mine-4

Coal Mining in Progress

Chaplin Hill Mine-5

Reclamation after coal mining

Chaplin Hill Mine-10

FBC ash and bottom ash being dumped

Chaplin Hill Mine-11

Patriot Mining Company

Chaplin Hill Mine-15

Grass bed laid on the reclaimed mine

Mined area brought to natural contour

Chaplin Hill Mine-18

Mined area brought to natural contour

Chaplin Hill Mine-19

Another view of the area

Chaplin Hill Mine-20

Photography of the site in progress

Chaplin Hill Mine-21

Chaplin Hill Mine-22

1. Reclaimed mine area here seen in two stages

2. Collection of water in a Pond3. Water percolated from the

reclaimed area.

Chaplin Hill Mine-23

Another view of the area

Chaplin Hill Mine-24

Construction of drainage for the collection of percolated and run off water in the pond.

Chaplin Hill Mine-25

Close up view of the water collection channel

Chaplin Hill Mine-26

Coal being mined from mine, processed and placed for dispatch to customers.

Reclaimed area

Chaplin Hill Mine-27: OSAGE Surface Mine

A

sign

placed

before

the

mine

entry

Chaplin Hill Mine-28

Coal Mining AreaMined out area

Mandatory placement of FBC (Fluidized Bed Combustion) Fly Ash in the coal mined out zones.

Harrison Power StationLargest power station in Allegheny Power System~ 2000 MW (It’s three identical units, rated at 684

MWe each, were launched into service in 1972, 1973, and 1974): Super Critical Units; ~35 Years before India ushered into)

Lime ScrubberIt has one of the tallest chimneys (Stack) in the

world (305 m), built in 1994.Got the best Power station Award of US EPASome activity recently on ownership

Harrison Power Station (2000 MW), Haywood, West Virginia, USA

Harrison Power Station

Ash Reclamation Site at Harrison Power

Reclaimed and Vegetated Locations.

Lime and Ash Mixed placed for disposal.

Land Site Reclaimed with the Ash Ash and Lime Mix dumped for Land Reclamation

Another View of the Land Reclamation Site

Land Reclaimed to the Natural Contour

Ash Brought in Trucks and dumped for Land Development near the Power Station

Bottom Ash Dumped for Land Development

Ash and Lime Mixture Dumped for Land Development

Deeper View of Dumped Ash Mix for Land Development

Water Collection Channels from Ash Disposal Sites

Close-Up View of Water Collection Channels from Ash Disposal Sites

Close-Up View of Water Collection Channels from Ash Disposal Sites made up of Fibro Foam Material

Close-Up View of Water Collection System from Ash Disposal Sites

Water Collection and Treatment facility for the water released from Ash Disposal sites.

Section of Water Collection from Ash Disposal sites.

Summary of Ash Hual back

Ash haulback is common practice in Appalachian Coal fields

Used for acid mine drainage abatementBulk fill material in reclamationCoal companies work ash haulback costs

into price of coalFull measure are taken for the

Environmental protection.

Let us join hands to march ahead!!!

May Like to Contact:

Dr. S. K. Dube(1) Email:

(a) Shivkumar.dube@teri.res.in(b) skdube@yahoo.com

(2) Phone:(O) +91 (11) 2468 2100(M) +91 (965) 099 2260