1. Beneficial Uses & Disposal of Coal Combustion Residues (CCRs)
Tarunjit Singh Butalia, Ph.D., Research Associate Professor
Department of Civil, Environmental, & Geodetic Engineering
The Ohio State University
Shiv Kumar Dube, Ph.D., Senior Fellow
Centre for Resource Security & Development Policy
Green Growth & Resource Security Division
The Energy and Resources Institute (TERI)
ccp.osu.edu

2. What are Coal Combustion Residues (CCRs)?
CCRs are solid minerals that remain after coal is burned to generate electricity or steam
Types:
Fly Ash
Bottom Ash
Boiler Slag
Flue Gas Desulfurization (FGD) Materials
Wet FGD Materials (sulfite & sulfate)
Dry FGD Materials (FBC, CFBC, SD, etc.)

3. Beneficial Uses of CCRs
Concrete & concrete products
Cement production
Structural & flowable fills
Road base
Mineral fillers
Gypsum wallboard
Soil & waste stabilization
Snow & ice control
Blasting grit & roofing granules
Aggregate
Agricultural
Mining

4. Existing OSU CCR Program
Established 20 years ago by industry and
government agencies at OSU College of Engineering
Objective: To continue to promote the technically sound, environmentally benign, and commercially competitive uses of CCRs as raw materials in commercial and industrial activity instead of landfilling and pond disposal
Implemented about 20 research projects (lab testing, bench-scale, and full-scale demo projects) totaling over $20 million external funding with multiple private (utilities, marketers, trade sponsors), federal and state agencies.
Model CCR University Program for US – American Coal Ash Association
USEPA C2P2 Award Winner for Research & Technology Transfer
Voice of Trust among national CCR stakeholders (particularly regulatory agencies)

5. US CCR Production & Use

7. India: Fly Ash Use & Pathways Forward
Fundamental challenge: Indian coal is of low grade, ash content = 30-45%

8. Source: Central Electric Authority

10. High volume, high value High volume, low value Low volume, high value
Market Segments
High volume, high value High volume, low value Low volume, high value

11. Cement Industry & Concrete
Use of fly ash as pozzolan in cement manufacturing and concrete production
High volume (about 40Mt/year), high value use
Accounts for 40% of fly ash use in India
Requires good quality fly ash
Future increases in cement industry will be incremental as technologies are developed for beneficiation / modification of poorer quality fly ashes.
Use of good quality fly ash in concrete to replace cement is a promising area of volume increase

12. Structural Fills (Roads, Embankments, Ash Dykes)
Designed structural fills for highways, embankments, and dykes for ash ponds
High volume (about 15Mt/year), low value use
Accounts for about 15% of fly ash use in India
Many fly ashes (good / poor quality) can be used for this application
Project specific and increases will be minimal

13. Mine Filling Backfilling open cast as well as underground mines
Cradle to grave approach
High volume (about 10Mt/year), low value use
Accounts for about 10% of fly ash use in India
All types of fly ashes (good / poor quality) can be used for this application
Transportation of ash to the mine is the critical issue
Large potential volume increases at mine mouth (pit head) power plants

14. Fly ash from Singrauli power plant under consideration for reclamation of Gorbi Mine

15. Building Products (Bricks, Blocks, Tiles)
Use of fly ash in manufacture of bricks, blocks, and tiles
High volume (about 15Mt/year), high value use
Accounts for 15% of fly ash use in India
Good potential for volume increases for power plants located near urban areas

16. Reclamation of Low Lying Areas
Use of fly ash as fill for low lying areas
High volume (about 12Mt/year), low value use
Accounts for about 10% of fly ash use in India
Contact of fly ash with groundwater is primary concern due to potential of leaching of trace elements
Market for this use has stabilized and future increases will be incremental

17. Agricultural Uses Soil amendment applications
Low volume (about 2Mt/year), low value use
Accounts for about 2% of fly ash use in India
More suitable for horticulture applications and food/feed applications due to concern for accumulation of trace elements in edible plants and meat.
Not a significant market for future volume increases

18. India: Pathways Forward
Target of 100% utilization of fly ash by December 2017
50/150 = 100% utilization achieved
40/150 = 75% to 100% utilization
15/150 = 60% to 75% utilization
45/150 = Less than 60% utilization
Plant modifications: Wet to dry ash handling, silos for storage of ash
In-house use by power plants for infrastructure development
Transportation is the key issue
Subsidy by power plant (100km to 300km)
Rail transportation
Use of ponded / landfilled ash – fly ash recovery
Use of good quality fly ash in concrete to replace cement is a promising area of volume increase
Building products use potential for power plants located near urban areas
Large potential volume increases at mine mouth (pit head) power plants

19. Closing Remarks
India power plants should aggressively promote the technically sound, environmentally benign, and commercially competitive uses of CCRs as raw materials in commercial and industrial activity instead of landfilling and pond disposal
“In today’s world, the coal industry cannot be complacent and simply state that all practices regarding management of coal combustion residuals and products are in compliance with all related applicable laws. There is a need for more due diligence planning to confirm that scenarios do not occur that result in system failures and environment releases when handling these materials.”

20. Lectures, workshops & site visits, factsheets, & website.
The goal of this work is to increase the annual utilization tonnage of Ohio Coal Combustion Products (CCPs) from 3 million tons per year in 2008 to about 5.6 million tons by 2012, i.e. increase Ohio utilization rates from current 30% rate to 35% by 2012 despite a projected 60% increase in the annual production of CCPs

21. Lectures, workshops & site visits, factsheets, & website.
The goal of this work is to increase the annual utilization tonnage of Ohio Coal Combustion Products (CCPs) from 3 million tons per year in 2008 to about 5.6 million tons by 2012, i.e. increase Ohio utilization rates from current 30% rate to 35% by 2012 despite a projected 60% increase in the annual production of CCPs

22. Program Focus Expand use in proven areas
Increase use of low carbon fly ash for air entrained concrete
Promote use of high carbon fly ash for non-air entrained concrete
Full depth reclamation, pervious concrete
Driver: CO2 emission reductions, sustainability, “green” construction
Sulfite FGD use in mine reclamation
Remove or reduce regulatory & perceptual barriers to use
Impact of TVA’s December 2008 ash spill and recent Duke fly ash release
Work with USEPA and state EPAs
Educating general public
Emphasize different types of CCPs (not all of them are fly ash)
Develop new or under-used large-volume market applications
Fly ash and FGD use in mine reclamation and structural fills
FGD gypsum as soil amendment
Infrastructure rehabilitation
Evaluate .Green Construction Certification Frameworks
Explore current USGBC LEED (Leadership in Energy & Environmental Design) certifications