ECOBA environmental requirements.pdf

NCAB_workshop_Nov. 23/24, 2005 1

Regulations regarding

Coal Ash Utilisation in Europe

Hans-Joachim Feuerborn

EuropeanCoal CombustionProducts Association


Content

1. Introduction

2. Regulations for use of coal ash in

- cement production

- concrete

- road construction

3. Environmental regulations

4. Concluding remarks


Production of CCPs in Europe (EU-15) in 2003

Fly Ash

Bottom AshBoiler Slag, 3.2 %

FBC Ash 1.7 %FGD GypsumSDA Product, 0.8%

67.8 %

9.3 %17.2 %

Introduction

total amount 65 million tonnes


Utilisation of CCPs in Europe (EU-15) in 2003

total amount 65 million tonnes

52.4% 35.9%

Utilization in construction Industry and Underground Mining Restoration of Open Cast Mines, Quarries

and Pits

Disposal, 3.7%Temporary stockpile, 8.0%

Introduction


Demands of the construction market

availability of huge amounts of material

constant quality (continuous process)

sufficient product properties (grain sizedistribution, surface,reactivity, ...)

long term availability

meeting of technical requirements

environmental compatibility

Introduction


25.9%

11.3%

27.8% 5.8%

23.4%

CementRaw Material

BlendedCement

ConcreteAddition Concrete Blocks

Road Construction,Filling Application

Infill, 3.3%Others, 2.5%

Utilisation of fly ash in the construction industry and in underground mining in Europe (EU 15) in 2003

(total utilisation 21.1 million tonnes)

Introduction


48.2%

33.1%

ConcreteBlocks

Cement

Others

Road Construction, Filling Application

10.4%

3.7%

Concrete

4.6%

(total utilisation 2.7 million tonnes)

Utilisation of Bottom Ash in the Construction Industryand Underground Mining in Europe (EU 15) in 2003

Introduction


Utilisation of Fly Ash in the cement and concreteindustry in Europe (EU 15) from 1993 to 2003

0

2

4

6

8

10

12

14

16

1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003

utili

zatio

n in

mill

ion

tonn

es

clinker raw material blended cement concrete

Introduction


Chemical parameters of fly ashes from coal and ligniteParameter Fly ash from Coal Fly Ash from Lignite

SiO2 36 60 18 80Al2O3 23 35 1 19FeO3 3 17 1 22CaO 0,3 8,5 2 52CaOfrei 0,1 25MgO 0,5 5,4 0,5 11K2O 0,5 6 0,1 2Na2O 0,1 3,5 0,01 2SO3 0,1 2,1 1 15

Regulations for use of coal ash for cement


Parameter siliceous fly ash calcareous fly ash

V W 1 W 2

Loss on ignition 5 % by mass

Reactive calcium oxide1) 10 % by mass 10 15 % bymass

15 % by mass

Free calcium oxide 1 % by mass 2)

Reactive silicon dioxide3) 25 % by mass -

Compressive strength at 28d4) - - 10 N/mm

Expansion5) - - 10 mm

1) CaOreactiv = total CaO reduced by fraction calculated as CaCO3 and CaSO42) CaOfree-= amount up to 2,5 % by mass accepted when soundness is given (see 5))3) SiO2reactiv = fraction of SiO2 which is soluble after treatment with HCl and boiling KOH-solution4) mortars with ground fly ash as binder, amount < 40m between 10 and 30 % by mass5) mixture of 30 % by mass ground fly ash, 70 % by mass cement

Requirements for Siliceous and CalcareousFly Ash by DIN EN 197-1

Regulations for use of coal ash for cement


Utilisation of fly ash as an addition to concrete has a long history in several countries.

In 1994, the first European Standard EN 450"Fly Ash for Concrete" was published.

About 6 million tonnes of fly ash are usedas concrete addition every year in Europe.

In May 2005, the harmonized standard EN 450 part 1 and part 2 was published. This standard has to beintroduced to national law in 2006.

Regulations for use of coal ash in concrete


Parameter Requirements Test Frequency

Loss On Ignition max. 5.0 w.-% d

SO3 max. 3.0 w.-% m

Cl max. 0.01 w.-% m

CaOfree max. 2.5 w.-%1) w

d : daily 1) fly ash with CaOfree higher than 1 w.-% but less w: once per week than 2.5 w.-% must comply with the requirements m: once per month for soundness

Chemical Requirements for Fly Ash for Concrete by EN 450



Parameter Requirements Test Frequency

Soundness 1) max. 10 mm w

Fineness 2) max. 40 w.-% d

Fineness variation 3) 10 w.-% d

Activity index

after 28 days

after 90 days

min 75 %

min 85 %

2 m

2 m

Density variation 3) 150 kg/m3 m

d : daily 1) required only if CaOfrei > 1,0 w.-%w: once per week 2) mass proportion in % of the ash retained when wet sievedm: once per month on a 0,045 mm mesh sieve2 m: twice per month 3) average value as declared by the producer

Physical Requirements for Fly Ash for Concrete by EN 450



EN 450-1Fly ash for concrete - Part 1:

Definition, specifications and conformity criteria

EN 450-2Fly ash for concrete - Part 2:

Conformity evaluation



Definition of fly ash

fine powder of mainly spherical particles, derived fromburning of pulverized coal, with or without co-combustionmaterials, which has pozzolanic properties and consistsessentially of SiO2 and Al2O3,...

Reactive SiO2 min 25 % by mass

Reactive CaO max 10 % by mass

EN 450-1: Fly ash for concrete



Introduction of three categories of loss on ignition

Introduction of two categories of fineness

Acceptance of fly ash obtained from co-combustion

Consideration of processing plants as production plants

New items of EN 450




Category LOI in % by mass min max

A - 5.0 B 2.0 7.0 C 4.0 9.0

LOI Categories of EN 450-1




Fineness Categories of EN 450-1

Category Amount retained on a 0.045 mm mesh sieve

in% by mass

Fineness variation from declared value

in percentage points

N 40 10

S 12 no requirement




Types of Co-combustion Materials

1 Vegetable material like wood chips, straw, oliveshells and other vegetable fibres

2 Green wood and cultivated biomass3 Animal meal4 Municipal sewage sludge5 Paper sludge6 Petroleum coke7 Virtually ash free liquid and gaseous fuels




Minimum percentage of coal (Kc) shall not be less than 80 % by mass of the fuelMaximum proportion of ash from co-combustionmaterials (M) shall not be greater than 10 % by mass of thefly ash

)AK....AKAK(AKAK....AKAKM

nnccnn ++++

+++= 10 %100

2211

2211

Ki and Kc are the proportions of co-combustion materialsand coal being fired

Ai and Ac are the ash contents of the co-combustionmaterials and the coal

Limitation of Co-combustion Materials



The new standard covers also fly ashproduced by:

classification

selection

sieving

drying

blending

grinding

carbonreduction




United Kingdom classification (BS 3892) carbon reduction (ST I - process)

Processing Plants in Europe


STI separation unitinstalled at:- Longannet PowerStation (Scotland)

- Didcot Power Station (England)


The Netherlands silo, mixing and sieving installation(SMZ centre, Rotterdam)

(source: Vliegasunie)



SMZ Center in Maasflakte nearRotterdamconstruction in 1995capacity250.000 tpa


France re-drying facilities (Carling, Hornaing)

(source: Surschiste)



Hornaing; capacity 50 tphCarling; capacity 80 tph


Germany re-drying facility (Lnen)

(source: SEG)



capacity60.000 tpa


1) if CaOfree-amount is > 1.0 % by mass soundness has to be proven 2) requirement to be fulfilled for fly ash obtained from co-combustion

EN 450:1994-09 DIN EN 450-1:2005-05

Comparison of the chemical requirements of EN 450: 1994 / 2005

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)



Comparison of the chemical requirements of EN 450: 1994 / 2005

EN 450:1994-09 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

5.0 % by mass (as Na2Oeq)1)

MgO - 4.0 % by mass (as Na2Oeq)1)

P2O5soluble - 100 mg/kg1)

1) requirement to be fulfilled for fly ash obtained from co-combustion



Comparison of the physical requirements of EN 450: 1994 / 2005

1) average value as declared by the producer

requirement EN 450:1994-09 DIN EN 450-1:2005-05

fineness (residue on 45 m mesh sieve) fineness variations 1) (deviation from declared value)

40 % by mass 10 % by mass

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)

density variation 1) 150 kg/m 1) 200 kg/m



Comparison of the physical requirements of EN 450: 1994 / 2005requirement EN 450:1994-09 DIN EN 450-1:2005-05

soundness1) max. 10 mm (50/50)2) max. 10 mm (30/70)3)

activity index after 28 days after 90 days

75 % 85 %

75 % 85 %

initial setting time - 120 min more than cement paste with test cement 4)5)

water demand - category N: not valid category S: 95 % of that for test cement alone

1) required only if amount of free calciumoxide is > 1 % by mass2) paste made from 50 % by mass of fly ash and 50 % by mass of cement3) paste made from 30 % by mass of fly ash and 70 % by mass of cement4) paste made from 25 % by mass of fly ash and 75 % by mass of cement5) requirement is assumed to be met for fly ash produced by combustion of pure coal



DIN 18990Fly ash for concrete

Attestation of conformity

EN 450-2 Fly ash for concrete - Part 2:

Conformity evaluation


EN 450-2 "Conformity evaluation"


Producer

Factory production control Internal quality control Autocontrol testing of fly ash samples

Certification body

Initial inspectionEvaluation of results of autocontrol testingAudit testing of fly ash samples




Producer

operator of a production plant

or

a person (natural or legal) authorisedby the production plant

The producer is named in the certificateof conformity !




... The producers documentation and procedures for theproduction control shall be described in a works qualitymanual. The manual has to contain:

statement on aims and organisation structure, responsibilities and powers of responsible staff

production and quality control techniques, processes and systematic actions that will be used

inspections and tests during and after production, and test frequency




responsibilitypower plant operator

responsibility producer

scope of the production control according to EN 450-2 = responsility of the producer / owner of certificate

boilerl

DENOXKAT

ESP

silo 1Q I

EN450

fly ash

FGD

stack

silo 2Q II

nonEN450

final productfly ash

internalquality control- fineness- LOI

auto-controltesting

productioncontrol

internalqualitycontrol

auto-controltesting

+

=



EN 450-1 Fly ash for concrete

Part 1: Definitions, specifications and conformity criterea

EN 450-2Fly ash for concrete

Part 2: Conformity evaluation

01234

AnyCo Ltd, PO Box 21, B-105005

01234-CPD-00234

EN 450-1

Fly ash for concrete

Fineness Category: NDeclared value of fineness in case of category N: 25 %Loss on ignition Category : AParticle density: 2300 kg/m3Dangerous Substance: NL, F



EN 12620 Aggregates for Concrete

EN 13055 Lightweight Aggregates for Concrete

These standards contain characteristics of aggregates and conformity criteria. As harmonizedstandards categories are defined which allowrestriction based on national experience!

National application documents in Germany!

DIN 20000-104: Aggregates for concrete

DIN 20000-105: Lightweight aggregates forconcrete.

Regulations for use of coal ash

Use of fly ash as aggregate (harmonized)


Use of fly ash in road construction

Soil stabilisation

Landscaping

Dams and embankments

Hydraulically bound bearing layers

Asphalt filler

Additions to concrete



Principal use of CCPs in road construction

Soil beneficiation

Base layer

Hydraulic bound layers

Filler in asphalt / concrete addition



prEN 14227 Hydraulically Bound Mixtures

part 3: Fly ash bound mixturesdefinitions of mixtures for roads,airfields and other trafficked areas

part 4: Fly ash for hydraulicallybound mixturesdefinitions of specification on physicaland chemical properties of fly ash

part 13: Soil beneficiation with fly ash


Use of fly ash in road construction


EN 14227- 4 Hydraulically bound mixtures- Specifications -Part 4: Fly ash for hydraulically mixtures

Siliceous Fly AshParticle size

Loss on Ignition

Free calcium oxide/soundness

water content

pozzolanic activity

Calcereous Fly AshParticle size

Soundness

reactive calcium oxide

water content

hydraulic activity

DIN V ENV 13282 Hydraulic Road Binders - Composition,specifications and conformity criteria



European Construction Products Directive (1988) requires activities of the authorities regarding emissionsof dangerous substances from construction products

Emissions to air, surface water and ground water

CEN is mandated to develop harmonised assessmentmethods and harmonized approaches regardingdangerous substances

Environmental Regulations


Limiting values on leaching of heavy metals and organics are set nationally in several EU member states

Leaching limit values restrict the utilisation of CCPsin certain applications like unbound use in roadconstruction (e.g. embankments, grouting, filling)

Tightening up of limiting values by some EU memberstates is threatening further applications of CCPs




Requirements for bound and unbound use of CCPs by Dutch BMD

The Building Materials Decree of the Netherlands (Boustoff-Besluiten) 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 clearconditions 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..


Unbounded utilisation

Bounded utilisation

Percolation (column) test according NEN7343

Diffusion test (standtest) according NEN 7345

percolation at L/S=10 in mg/kg Immission in mg/m2

Element > 10 m Element max Antimoon Sb 0,03 Antimoon Sb 39 Arseen As 0,83 Arseen As 435 Barium Ba 2,20 Barium Ba 6300 Cadmium Cd 0,02 Cadmium Cd 12 Chroom Cr 0,36 Chroom Cr 1500 Cobalt Co 0,23 Cobalt Co 300 Koper Cu 0,33 Koper Cu 540 Kwik Hg 0,02 Kwik Hg 4,5 Lood Pb 0,99 Lood Pb 1275 Molybdeen Mo 0,17 Molybdeen Mo 150 Nikkel Ni 0,70 Nikkel Ni 525 Seleen Se 0,03 Seleen Se 15 Tin Sn 0,08 Tin Sn 300 Vanadium V 1,10 Vanadium V 2400 Zink Zn 2,30 Zink Zn 2100

Fluoride F 3,80 Fluoride F 14000 Chloride Cl 560 Chloride Cl 30000 Sulfaat SO4 1090 Sulfaat SO4 45000 Bromide Br 3,40 Bromide Br 90

Requirements for bound and unbound use of CCPs by Dutch BMD




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 useClass Z1.1: restricted open use and Class Z1.2: restricted open use with defined technical

safety measurementsClass Z2: restricted use with defined technical safety

measurements


CCP Boiler Slag

source/process

dry

botto

m

boile

r

fluid

.bed

co

mbu

stio

n

wet

bot

tom

bo

iler

class Z 2 Z 2 Z 2 Z O Z 1.1 Z 1.2 Z 2 Z O Z 1.1 Z 1.2/ Z2

ZO

parametercolour x1) x1) x1) x1) x1) x1) x1) x1) x1) x1) x1)

clouding x1) x1) x1) x1) x1) x1) x1) x1) x1) x1) x1)

smell x1) x1) x1) x1) x1) x1) x1) x1) x1) x1) x1)

pH-value 8-13 10-13 8-13 10-12 10-12 10-12 10-12 7-12 7-12 7-12 6-9conductivity S/cm 5000 10000 5000 500 1000 1000 1000 500 1000 1000 200As 100 40 100 10 10 40 100 10 10 40Pb 20 40 20 40Cd 10 10 10 2 2 2 2Crtot 350 300 350 15 30 15 30Cu g/l 50 50 50 50Ni 40 50 40 50Hg 0.2 0.2 1 2 0.2 0.2 1Zn 100 100 100 100Cl mg/l 50 100 50 10 20 50 50 10 20 20SO3 mg/l 1000 2000 1000 50 75 200 200 50 75 200

Fly Ash Bottom Ash Grate Ash

Environmental Regulations Requirements for selected CCPs for use in earthworks and road construction by

German LAGA (leaching criteria)


Requirements for selected CCPs for use in earthworks and road construction by German LAGA (content of trace element)

CCP

source/processclass Z O Z 1.1

parametercolour x1) x1)

clouding x1) x1)

smell x1) x1)

As 20 30Pb 100 200Cd 0.6 1Crtot 50 100Cu mg/kg 40 100Ni 40 100Hg 0.3 1Zn 120 300

1) = to be declared

Bottom Ash /Grate Ash



unit insignificancethreshold values

Antimon Sb 10

Arsen As 10

Blei Pb 25

Cadmium Cd 5

Chrom gesamt Cr 50

Chromat CrVI 8

Kobalt Co 50

Kupfer Cu 50

Molybdn Mo 50

Nickel Ni 50

Quecksilber Hg 1

Selen Se 10

Zink Zn 500

Zinn Sn 40

Cyanid gesamt CN- 50

Cyanid leicht freisetzbar CN- 10

Fluorid F- 750

g/l


DIBt-insignificance threshhold values for evaluation of building products


unit insignificancethreshold values

PAK, gesamtNaphthalin

0,22

LHKW, gesamt 10

Aldrin 0,1

DDT 0,1

PCB, gesamt 0,05

Minerallkohlenwasserstoffe 200

BTX- Benzol als Einzelstoff

201

Phenole 20

g/l


DIBt-insignificance threshhold values for evaluation of building products


Building Material

Determination of trace element content

Criteria met?yes

no

information on environmental compatibility

comparison withsimilar products

yes

requirementmet

requirementnot met

step 1


DIBt-evaluation procedure for building products(for technical approval with use of industrial by-products in concrete, only!

Restriction Dangerous substancesToxic substances (R-crierias) LAGA criterias Z2


production of leachate/realistic situation!

determination of general parameters

harmful changes bygeneral characteristics

determination of trace element content

threshhold insignificancevalues, TOC met

determination of biological parameters

ecotoxicological

step 2

2.1

2.2

2.3

yesrequirementnot met

no

yes requirementmet

param. ecotox.concerned

requirementnot met

yesrequirementnot met

no requirementmet

ecotox.harmlessness not proven


no


test: +, no test: -1)test to be performed only when fly ash is used2)test to be performed only when organic additives are used3)test only for mortar

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)



UK: Water supply regulations:

This regulation has requirements for materials, such as cementitious materials, foruse in contact with public drinking water supply. Specifications of testing is coveredby BS 6920, which gives limiting values for certain metals leachates from such material.

BS 6920 max. allowable concentration

[g/l]Aluminium Al 200Antimony Sb 10Arsenic As 50Barium Ba 1000Cadmium Ca 5Chromium Cr 50Iron Fe 200Lead Pb 50Manganese Mn 50Mercury Hg 1Nickel Ni 50Selenium Se 10Silver Ag 10



Provisional limit values for table 1 and table 2 of the

BUWAL recommendation

(BUWAL = Ministry for

Environment, Forestry and Agriculture)

parameter Limit values regarding table

1[mg/kg]

Limit values regarding

table 2[mg/kg]

Limit values for fly ash

[mg/kg]

antimony Sb 5 20 40arsen As 30 80 10lead Pb 100 500 300cadmium Cd 1 2 2chrome total Cr 200 500 300copper Cu 200 500 200nickel Ni 200 500 200mercury Hg 0.5 1 1thallium Th 0.5 1 3Zinc Zn 400 1000 1000tin Sn 30 80 30barium Ba 1500beryllium Be 10cobalt Co 100selen Se 5vanadium V 300Cr VI 2



Concluding Remarks

52.4 % of the total CCPs produced in Europe is producedto meet technical requirements to replace natural materialsin construction.

CCPs are accepted as raw materials due to their chemical, mineralogical and physical properties. The acceptance isbased on more than thirty years of experience.

For nearly every field of application technical regulations orrequirements have to considered.


Concluding Remarks

The new standard for fly ash for concrete introduces a quality control system including internal quality control by the producer audit testing by a certification body notified by the

building authorities.

In order to avoid any negative impact on the environmentand on human health environmental regulations have beendeveloped in some European countries for raw materials (trace elements, leaching behaviour) products (prediction models for bound applications).

As a result of the environmental regulations no negative impact on the environment or on human health by the utilisation of CCPs has been reported so far.


Thank you for your attention!

Hans-Joachim Feuerborn

European Coal Combustion Products Associationwww.ecoba.org

Documents

ECOBA environmental requirements.pdf