the south african coal ash association...

THE SOUTH AFRICAN COAL ASH ASSOCIATION (SACAA)

11 September 2019

Industrial Efficiency Conference

BY: MARK HUNTER SACAA General Manager


THE BRIEF HISTORY OF ASH IN SOUTH AFRICA

• SACAA integrated with and participated in

world ash associations and conferences. This currently still continues

• Identify characteristics of ash market USA, Australia, EU, India and South Africa • Critical examinations of utilisation data

• Discussions of increased ash utilisation and

beneficiation and new applications

• Market opportunities in South Africa

THE SOUTH AFRICAN COAL ASH

ASSOCIATION (SACAA) EST. 1987

OBJECTIVES:

To be the umbrella association for the

“ASH” Producers, Marketers, Users,

Universities, Research Organisations

and Individuals playing an active role in

the promotion of responsible ash

utilization. This is for growth and

business development by our members

for the benefit of the South African

economy in compliance with the

environmental legislation.


THE USE OF ASH IS NOT NEW IN SOUTH AFRICA

Major projects specified the use of fly ash as a critical success factor for the construction of these infrastructure projects (mainly in the cementitious applications)

Katse Dam Burj Khalifa

Ash House


The Elbphilharmonie concert hall

• This concert hall in Hamburg Germany, the Elbphilharmonie, uses 10,000 unique and specially designed panels to perfectly balance the acoustics within the venue! ... the auditorium, using special .

• Perforated acoustic partition walls and ceiling finishes is most commonly found to be used in commercial offices, multi-purpose hall, auditorium and much more. The use of perforated gypsum board as an acoustic finish eliminates the maintenance of conventional acoustic finishes, whereby it can be painted to any colour of choice.


USE OF FLY ASH FOR THE MAPUTO-CATEMBE LONGEST SUSPENSION BRIDGE IN AFRICA

Commissioned in 2018

The 3Km Maputo-Catembe Bridge consists of a 1230m precast concrete element on the south approach,

a 1100m cantilever bridge on the north approach and a 680m suspension bridge, built 60m above the

Maputo Bay to ensure that ships can pass underneath it on their way in and out of the International Port of

Maputo. The main cables are anchored into two massive “anchor” blocks on the North and South side of

the bay at a distance of 260m and 284m from the pylons respectively. Two circular shafts 50m deep with a

diameter of 50m each have been constructed to house the concrete and sand filled anchor blocks which

will in fact hold up the entire main span of the bridge, for perspective the South Bank anchor block weights

177000tons.

40% of South African Ash specified to be used in the concrete


Broad Ash Definitions

Siliceous Fly Ash - • Classified Fly Ash - • Unclassified Fly Ash - Clinker Ash - Bottom (Course) Ash - Dump Ash (run of station) - Economiser Ash - Gasified Ash (Sasol) -

All South African ash (Class F) Classifier erected to a source Fine ash that is not classified Old Chain grate boilers Course ash that falls to the bottom of the boiler Ash that has been dumped on the ash dump Course ash from limited stations that have economisers Available for Sasol as a result of the boiler process


THE ASH ESSENTIALS

• The appetite by producers to make ash delivery/handling infrastructure available, particularly for emerging businesses and youth.

• New products and applications are required by innovation and acceptance testing.

• Life cycle costing for projects, exceeds the power plant lifetime. ROI border line.

• Ash utilisation should form part of the civil engineering specification.


THE ASH PITFALLS!!!

Most of the producers require a large percentage of ash to construct the ash dump walls, as part of the operational requirements Only certain producers of ash are capable of commercialising ash, for both economical and quality reasons The lack of a proper diversified and knowledgeable contracting staff are in place to speedily resolve commercial contracts


TRANSPORTATION OF FLY ASH PRODUCTS • Transportation costs are very high in relation to

product price.

• Pneumatic conveying used for dry bulk transport over relatively short distances.

• Belt conveyors and Pipe Conveyors

• Dry bulk transport in rail or road tankers

• Conditioned ash in road tipper trucks

• Bulk Bags & Paper Sacks

•For special applications it is possible to slurry and pump ash in pipelines over long distances


TO ENSURE ENVIRONMENTAL COMPLIANCE

Environmental legislation of ash – Must be resolved Targets set for producers and monitored by SACAA on behalf of DEA. Volumes utilised should be increased from about 10 % to 20 % CO² emissions saved by using ash: Producers/off –takers must report the volumes Norms and standards to be set by industry to ensure compliance. Audits should be instituted


THE ASH OPPORTUNITIES

• All research that is complete should be scrutinised for commercialisation opportunities.

• Ash utilization rules need to be developed to ensure that no natural resource is used within 100 km’s from a producer.

• Youth development courses need to be developed and training provided.

• The support of the Governments Phakisa Initiative for waste utilisation in creating jobs must be workshopped and tracked.

ENTERPRISE DEVELOPMENT PERSPECTIVE


• Create at least 1 million jobs within five years

• Prioritise growth and investment

• Contain state debt and spending

• Give the black majority a bigger state in the economy

• Reduce the cost of doing business

• Improve the education system

• Clamp down on graft

Ramaphosa plans to fix SA’s beleaguered economy

Ash can play a part in all of these initiatives


WHAT IS THE STATE OF SOUTH AFRICA’S WASTE?

South African State of Waste Reporting (SoWR) Waste workshops conducted by CSIR throughout South Africa in 2014 • to look at the various streams • to determine volumes • to identify the critical waste streams for action plans

New State of Waste Report targeted for completion in 2018 • Bulk organic waste 39.7% • Ash (fly and bottom ash) 36.47% • Non-recycling waste 8.5% • Slag 5.9% • Construction and demolition 5.2%

16 categories in total but one can see the impact of Ash

118 million tons per annum


Governments Phakisa Initiative on waste minimisation

• DEA See SACAA as the driver of the initiative? • Ash takes up nearly 40 % of the entire waste stream • Used the baseline waste data of 2012

WHAT ARE THE EXPECTATIONS • Grow the GDP of the economy (?) • Create 28 000 new jobs • Target 19% utilation of all ash produced as an impact on the environment

ALL ROLL PLAYERS TO PLAY THEIR PART


WHAT OTHER COUNTRIES HAVE DONE?

Tax incentives

Producers to fund ash utilisation by free delivery

Specifications adopted

Emissions funding

Policy for using ash within a 100km radius


Background: Roles, responsibilities and information required to enable the ash value chain

Provide enabling legal

framework:

• Detailed legal

requirements for

ash beneficiation

e.g.:

Date when

Exclusions

regulation will be

implemented

Clarify legal

requirements for

exporting ash

Increase ash availability to small and big off-takers and users: • Awareness and compliance

with applicable legal requirements

• Knowledge and experience with ash management and sales

• Locations, quantity, types and quality of ash available

• Access to ash (access model, type of contracts, infrastructure)

• Contractual obligations • Logistic options specific to

site • List of all off-takers/ users • Record of all quantities

sold • Ash beneficiation job

creation onsite

Increase quantities of ash prepared for specific uses: • Awareness and compliance


• Knowledge and experience with ash off-taking

• Locations, quantity, types

and quality of ash required • What materials will be

substituted by ash (type, quality, cost and availability)?

• Quality specifications for standardized ash fractions

• Transformation and inclusion

• List of all ash users • Record of quantities sold • Ash beneficiation job

creation related to activities

Increase ash transport options from generation to reuse locations: • Awareness and compliance


• Knowledge and experience with ash transportation

• Routes, quantity, types and

quality of ash transported/ transportable

• Transport cost per origin and

destination • Loading and off-loading

capabilities per origin and destination

• Transport type: pipe, rail, truck, airplane, boat, etc.


• Manifest system in place • Ash beneficiation job creation

related to activities

Increase demand for ash: • Awareness and compliance


• Knowledge and experience with ash use

• Locations, quantity, types and quality of ash required

• Final application of standardised ash fractions

• Environmental considerations of ash products and end use

• End product certification • Access to funds • Research and development

capabilities


• Record of quantities used • Ash beneficiation job creation

related to activities

Ash Regulator Ash

Generators Ash Off-takers

Ash

transporters Ash Users


Brick manufacturing and housing alternatives

Mine backfilling

Road and embankment construction

Agriculture, sludge and soil reclamation

Treatment of acid mine drainage and water


THE WORK MUST START TODAY Acid Mine Drainage(AMD) Alternative Building Materials Lightweight Aggregate/concrete Mine Backfilling and embankments Road building and fill material Agriculture and soil amelioration

Premamix: • mixture of two grades of

ash with a portion of fly ash • quality guaranteed product • use in the base layer of

roads • medium strength concrete • capital intensive process

While shown to be uneconomical against existing ash screening and utilisation practices, a further study

showed that Premamix is the only

road material with which labour

intensive construction can be done

economically


• Clear proper plans must be in place for producers to capatalise on infrastructure at new power plants. (Kusile and Medupi)

• This is critical to limit the dumping from day one. The contracting and build process will take at least 3 to 5 years

• This should be one of the Governments Strategic Infrastructure Projects (SIPS)

• Create an innovation hub for industry or basic technical training courses on ash

• Funding must be easily accessible for start up enterprises

THE WORK MUST START TODAY


THE NEXT STEPS Roadshows and awareness campaigns Unpack “ALL” research papers and assess readiness of commercialisation Write up information and norms and standards documents Innovation center’s and training workshops Have clear access to ash roadmaps and infrastructure development Set and measure targets against the government objectives Drive to project and clear out any obstacles

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