OSU Coal Combustion Products (CCP) Program:

Past, Present, & Future

Tarunjit Butalia, Ph.D., P.E.Associate Professor - Research

Department of Civil, Environmental, & Geodetic Engineering

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Objective & Focus

• Objective: To promote technically sound, environmentally benign, and commercially competitive uses of Ohio CCPs (FGDmaterial, fly ash, bottom ash, etc.) as raw materials in commercial and industrial activity instead of landfill and impoundment disposal

• Focus: Sustainable, high-volume beneficial uses of CCPs, primarily from sulfur dioxide scrubbing processes, in construction, reclamation, infrastructure rehabilitation, manufacturing and agricultural applications

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About 35 years ago!(Ash at Work, 1982)

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Beneficial Uses of CCPs(investigated by OSU researchers)

• 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

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Establishment & Developments• Established at OSU College of Engineering in 1997

• Objective: To promote technically sound, environmentally benign, and commercially competitive uses of Ohio CCPs (FGD material, fly ash, bottom ash, etc.) as raw materials in commercial and industrial activity instead of landfill and impoundment disposal

• Program duration of nearly 2 decades:• Phase I : 1997 – 2000 (Pilot project established by OCDO, First CCP Summit in 1999)• Phase II : 2000 – 2005 (FGD feeding pads)• Phase III: 2005 – 2009 (CCP use is highway construction and rehabilitation)• Phase IV: 2009 – 2014 (FGD in mine reclamation)• Phase V: 2014 - 2017 (Current, Second CCP Summit in 2016)

• Program today is better and stronger than ever before – continues to gain national recognition for our work in Ohio

• Successful long-term funding mechanism: Multiple state, federal, utilities, & trade sponsors

• Demonstrates leadership of university in working with regulatory agencies regarding evolving CCP regulatory framework

• Liaisons with OSU Office of Energy and Environment (fossil fuels) and Office of Outreach and Engagement

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Educate & Disseminate

Examples of what we have done?

• Established statewide CCP research online repository (ccp.osu.edu)

• Compiled Ohio and national technical information

• Worked with regulatory agencies (USEPA, OEPA, ODNR, ODOT, OSM, ODA, etc.)

• Published several Fact Sheets in collaboration with OSU Extension Service and distributed over 15,000 copies

• Regular meetings and briefings with CCP stakeholders

• Conducted over 20 CCP utilization training workshops and open houses

• Over 200 publications & presentations at Ohio & national conferences / meetings

• Over 250 publicity articles published

“An excellent job in getting the program to its present stateof providing technical information to end users and regulatorsin Ohio and nationally” – 2009 Independent Program Reviewer

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Recognition of OSU CCP Program

• Model CCP University Outreach Program for the nation – American Coal Ash Association

• USEPA C2P2 Award Winner for 2008 - Research & Technology Transfer

• Voice of Trust among Ohio and national CCP stakeholders (particularly regulatory agencies) - USEPA C2P2 Award Citation

• Secured about 40 research projects totaling over $20 million since 1997 (about $1 million per year for nearly 20 years) – 30 Ph.D. dissertations & Masters theses

• Program is member of: American Coal Ash Association (ACAA)Midwest Coal Ash Association (MCAA)

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Target Program Goals

Goal Status for 2012

Increase CCP utilization rate CCP utilization rate was from 21% (1997) to 35% (by 2012) 36% (4.4 Mt / 12 Mt)

2000 Ohio CCP Market Study: 1997 – 8% FGD utilization rate– 21% CCP utilization rate

(2.1Mt / 10 Mt)

CCP: Fly ash, bottom ash, boiler slag, and FGD material

Target goal of program was achieved in 2012 by working with CCP stakeholders in state

Goal of current program: Increase utilization rate to 40% or more by 2017 (with increased regulatory scrutiny)

15 years

5 years

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Major CCP Market Segments in Ohio (2012)

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Current CCP Program

• Continues collaborative technology transfer (outreach) & research effort between OSU, state agencies, and private sector (including Ohio utilities, trade associations, and other stakeholders)

• Identify new areas for economic use of CCPs in the marketplace and assist commercial activity by developing, assessing and transferring to all stakeholders the necessary technology.

• Objective: To develop, assess, and technology transfer promising CCP use technologies for commercial and end-use sectors

• Goal: Continue to increase utilization of CCPs in Ohio at a pace comparable with past performance

• Increase Ohio CCP annual utilization to 40% or more by 2017

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Program Focus Areas• 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 for elimination of highwall safety hazard

• Remove or reduce perceptual barriers to use• Impact of TVA’s December 2008 ash spill and Duke fly ash release• Work with USEPA, OSMRE, Ohio EPA, ODNR, ODOT, etc.• Educating general public - Publish OSU factsheets on environmental benefits and safety of CCPs for

beneficial use applications of public concern• Emphasize different types of CCPs (not all of them are fly ash)

• Develop new or under-used large-volume market applications• Sulfite FGD use in remediating acid mine drainage• FGD gypsum use in mine reclamation and structural fills• FGD gypsum as soil amendment• Infrastructure rehabilitation

• Evaluate Alternative Green Construction Certification Frameworks• Explore alternatives to current USGBC LEED (Leadership in Energy & Environmental Design)

certifications

• Statewide Coal Ash Pond Study• Study stability of coal ash ponds• Track progress of closure of coal ash ponds• Investigate post-closure uses (such as landfill extension, solar panels, etc.)

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Funding Mechanism

• Two decades of partnership between state, university, utilities, & trade sponsors

• OCDO 50% • OSU 25%• Private Sector 25%

• OSU overhead rate to OCDO is reduced to 15% (normal is >50%)

• Private sector funders• Ohio Utilities• CCP Marketers• CCP Industry Trade Groups• Other Private Sector Stakeholders

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Current CCP Program Co-Funders• Ohio Coal Development Office• The Ohio State University• 18 Private Sector Partners

• Utilities• AES• American Electric Power• First Energy• LG&E

• Marketers• Beneficial Reuse• Headwater Resources• Waste Management - FlyAshDirect

• Industry Trade Groups• American Coal Ash Association• Midwest Coal Ash Association• Ohio Coal Association• Ohio Mineland Partnership

• Other Private Sector Stakeholders• Carmuese NA• CH2MHill• Energy Industries of Ohio• Graymont Lime• GSE• Hull• Resource International

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OSU Office of Outreach and Engagement

• “Outreach and Engagement is defined as a meaningful and mutually beneficial collaborationwith partners in education, business, public and social service.”

• As a land grant university, OSU promotes: • that aspect of teaching that enables

learning beyond the campus walls• that aspect of research that makes

what we discover useful beyond the academic community

• that aspect of service that directly benefits the public

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A word of optimism & caution“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 state and federal 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.” - 2013 Independent Program Reviewer

The OSU CCP Program has been “very effective leader in promotion of usage of coal combustion products and in responding to existing and proposed regulations regarding usage of coal combustion products... respected as one who will present an honest and objective analysis of issues regarding usage of coal combustion products.”– 2013 Independent Program Reviewer

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2016 OSU CCR Summit

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