Intercem – Enel ash

management

Istanbul, 14th - 15th September 2015

1
 What are CCPs
The Clean Coal Technologies

Coal  combus+on  products  (CCP)  are  the  materials  produced  in  modern  coal  power  plants  
adop2ng  Clean  Coal  Technologies.  
These  by-­‐products  have  a  wide  range  of  uses:  construc+on,  manufacturing,  environmental  
remedia+on,  and  other  industries.  

Lay-­‐out  of  a  typical  clean  coal  power  plant  unit  

Produc2on  Unit   Clean  Coal  Environmental  Unit  

Stack

Steam De-­‐SOx  
Generator De-­‐NOx  

Alternator
ESP / FF

BoJom  ash Fly  ash FGD  Gypsum

2
Enel ash management
Fly ashes production and logistics

Electrostatic or
Bag filters

Stocking silos Trucks Vessels

3
 What are CCPs
The Clean Coal Technologies

CCPs  and  their  rela+ve  produc+on  

(in  %,  data  ECOBA,  year  2013)     Each  year,  more  than  52  million  tons  (data  
year  2013)  of  coal  and  lignite  ashes  and  
desulphuriza2on  products  are  produced  by  
FGD  Gypsum   power  sta2ons  throughout  the  European  
Fly  ash   (11,4  Mt)   Union  (EU  15)  in  addi2on  to  the  main  
(33,7  Mt)   product  electricity.    
21,9%  
64,7%   These  solid  materials,  collec2vely  described  
as  Coal  Combus+on  Products  (CCPs),  are  
BoJom  ash   produced  as  a  result  of  requirements  to  
9,0%   (4,7  Mt)   meet  air  emission  standards.    
Boiler  Slag  1,7%  (0,9Mt)  
FBC  Ash  1,7%  (0,9  Mt)  
SDA  Product  0,9%  (0,5  Mt)  

4
 What are Fly Ash
Physical properties

Chemical  composi+on  
With  par2cle  diameters  mainly  between  1  and  100  µm,  fly  
ash  appears  like  a  fine  grey  powder,  its  fineness  is   Element  
Coal  Fly   Pozzolana  
ash     naturale    
comparable  to  the  cement  one  
Si  (%)   16÷22   21÷31  
Its  chemical  composi2on  is  characterized  by  the  presence  
Al  (%)   12÷18   8,0÷16  
of  high  contents  of  silica,  alumina  and  ferrous  oxides  in  an  
amorphous  phase,  and  can  be  considered  equivalent  to   Fe  (%)   1,5÷8,7   3,0÷8,0  

that  of  a  volcanic  pozzolana.   Ca  (%)   0,7÷6,5   2,0÷7,0  

MgO%)   0,1÷1,1   0,5÷2,0  
Spherical  shape,  vitreous   K  (%)   0,4÷0,9   1,0÷7,0  
structure   Fineness  
Na  (%)   0,1÷0,4   0,6÷3,2  
C  (%)   3,0÷9,0   -­‐  

5
 What are Fly ashes
Beneficial use of Fly Ashes (1/2)

Cement  and  concrete  produc+on  diagram   Fly  ashes  uses  in  cement  and  concrete  produc+on  
Raw materials (Ca, Si, Al, Fe, Mg)
•  BoJom  ashes  and  wet  fly  ashes  (lower  value  
Bottom ashes, Fly ashes)  can  be  used  as  raw  material  for  the  
ashes (dry or wet) supply  of  the  necessary  minerals  (SiO2,  Al2O3,  
Mixing unit Lower economic Fe2O3)  for  the  cement  produc2on.  
value
Cement Raw material

Cement kilns

Clinker •  Dry  fly  ashes  classified  UNI  EN  450  class  A,  B  
Dry fly ashes
or  C  (high  value  ashes)  can  be  mixed  
Lime, Gypsum,
(pozzolan) Mills (generally  up  to  30%)  with  :    
High economic value
•  Milled  clinker  to  obtain  blended  cement  
(CEM  II  or  IV)  as  pozzolan;  
Cement
Dry fly ashes
•  CEM  I  to  obtain  concrete  (type  II  
addi2on).  
High economic value

Water and Ready Mix Lower quality

Aggregates Plant Dry Fly Ashes
Lower economic •  Dry  fly  ashes  classified  UNI  EN  12620  (lower  
value value  ashes)  can  be  added  as  filler  in  concrete  
Concrete
produc2on  (type  I  addi2on).    

6
 What are Fly ashes
Beneficial use of Fly Ashes (2/2)

Fly  ashes  give  great  benefit  when  used  in  the  cement  and  
U+lisa+on  of  Fly  Ash  in  the  Construc+on   concrete  industry  :    
Industry  and  Underground  Mining    in  Europe  
!  Admixture  of  fly  ashes  could  be  performed  either  
(EU  15)  in  2013   directly  in  the  concrete  mix  design  or  by  using  a  mixed-­‐
ash  cement  
Concrete  &  Blended  Cement  
(52,7  %  -­‐  7,2  Mt)   !  Fly  ashes  reduce  the  Water/Cement  ra+o,  keeping  the  
same  workability  and  pumpability  of  the  fresh  mix  
Concrete  
Addi+on   40,3%   Concrete  Blocks   !  Pozzolanic  reac2on  induced  by  fly  ashes  reduce  free  
(5,5  Mt)   (0,9  Mt)   Lime  content  (CaO  free)  in  the  hardened  concrete  
6,6%   matrix  "  less  permeability  
!  The  lower  heat  of  hydra2on  of  ash-­‐concrete  leads  to  
lower  thermal  gradients  within  the  massive  pour  "  less  
Road    
cracks  
21,4%   Construc+on,  
12,4%   !  Admixture  of  fly  ashes  effec2vely  prevents  the  
Blended   Filling  
Cement   Applica+on   occurrence  of  alkali-­‐aggregate  reac+on  (chemical  
(1,7  Mt)   16,4%   (2,9  Mt)   degrada2on)  
Cement  
Raw  Material  
!  Addi+on  of  fly  ash  increases  the  durability  of  the  
Others,  2,9%  (0,4  Mt)   concrete  and  extends  the  useful  life  of  the  work    
(2,2  Mt)  
!  Adding  fly  ashes  increases  sustainability  of  the  
product:  1,25  ton  of  CO2  saved  per  each  ton  of  fly  
Total  u+lisa+on  :  13,6  Mt ashes  used  
7
 What are Fly ashes
Examples of innovative uses based on unique characteristics

30%  ash   0%  ash  

Commercial   Ash  based  ceramic  

Coal   ash   can   be   used   as   a   stable   raw   product     foam  
material   for   the   produc+on   of   bricks  
in   place   of   the   natural   clay,   with   Cellular  geopolymeric  brick  (low  density,  
low  Thermal  conduc2vity,  low  cost)  
posi2ve  effects  (i.e.  less  weight)  

Enel  Research  Center  can  rely  on  more  than  20  years  of  R&D  experience  on  fly  ashes  in  
suppor+ng  our  clients,  in  tradi+onal  as  well  as  in  innova+ve  applica+ons
Beneficial use of Fly Ashes
Regulatory framework

Coal  Fly  Ashes  in  Europe  are  classified  as  Not-­‐

Hazardous  wastes  (GG030  code)  
According  to  Regula2on  EU  1013/06,  export  is  
permiced  towards  other  OECD  countries  with  a  
Simplified  Procedure  
Export  is  permiced  towards  non-­‐OECD  countries  with:  
−  No2fica2on  procedure;  
−  Simplified  procedure  if  the  impor2ng  country  
gives  its  approval  to  EU  Commission.    

In  any  case,  impor+ng  sites/plants  must  be  

authorized  by  local  authori+es  for  using  fly  
ashes  

9
 Beneficial use of Fly Ashes
Technical framework

Fly  ash  harmonized  EU  quality  control  standards  are:   Fly  ash  to  cement  equivalence  k-­‐factor  
−  EN  450-­‐1  for  the  use  of  fly  ash  as  an  addi2on  of   for  concrete  mix  design  (EN  206)  
type  II  (pozzolanic)  in  the  produc2on  of  concrete   FA/cem  ≤  0,33  
conforming  to  EN  206  and  for  the  produc2on  of  
blended  cements  conform  to  EN  197-­‐1   cemeq  =  cem  +  k  FA        (fa  =  fly  ash)  

−   EN  12620  for  the  use  of  ash  as  an  addi2on  type  I   Dcmax  ≤  k  (cmin  -­‐  200)  [kg/m3]  
(inert  filler)  in  the  produc2on  of  concrete  according   (k  values  define  on  a  na+onal  basis:  
to  EN  206   In  Italy  (UNI  11104)  
k=0,4  for  concrete  with  CEM  I  
Fly  ash  content  in  composite  cements  (EN  197-­‐1)   42,5/52,5  N/R;      
k=0,2  for  CEM  I  32,5  N/R,  CEM  II-­‐III-­‐IV-­‐
TYPE   DESCRIPTION   FLY  ASH  CONTENT  
V  /  A  )  
CEM   II/A(/ Portland   fly   ash      6÷20  %  (/A);  21÷35  %  (/B)  
B)-­‐V   cement   (Approx.:  100-­‐150  kg  of  FA  per  m3  of  
CEM   II/A(/ Portland   concrete  can  be  introduced  as  
B)-­‐M   composite  cem.      6÷20  %  (/A);  21÷35  %  (/B)  
pozzolanic  addi@on)  
CEM   IV/A(/ Pozzolanic  cement   11÷35  %  (/A);  36÷55  %  (/B)  
B)  
CEM   V/A(/ Composite   18÷30  %  (/A);  31÷50  %  (/B)  
B)   cement  
10
 Beneficial use of Fly Ashes
Technical framework

Example  of  Factory  Produc+on  Control1)  (Brindisi  PP)   EN  450  requirements  for  Fly  Ash  
DeNOx   PE   DeSOx   Stack  
Coal  

Furnace  

SiloSilo
Silo Gr3 Gr
Silo Gr 3 (EN
Unit  
3 Gr 3 s
(EN
ilos  
(EN(EN 12620) 12620
Final  
12620
Quality  Control   12620 ) Silo  B  
EN  12620  (1sample/ ) )
Final  
week)   Silo  A  

+
Internal  Control  EN   Auto-­‐Control    
450   EN  450  
 (4x3samples/day)   (1+1samples/day)  

The  Internal  Control  system  ensures  that  only  

the  ashes  with  acceptable  stable  and  constant    
quality  are  collected  in  the  silo  
1)  All  ENEL  GEM  Coal  Power  Plants  in  Italy  have  been  cer2fied  during  2007  according  to  the  standards  EN  450  and/or  EN  12620    
11
 Beneficial use of Fly Ashes
Economic valorization

Local  Market  value   Economic  valoriza+on  comparable  to  the  

one  of  subs+tuted  products.  Some  of  the  
typical  2013  price  ranges  across  the  US  
markets    for  various  CCPs  are  1)  :  
Unloading,  transport  
and  storage −  Concrete  quality  fly  ash  :  20-­‐45  $/mt  
−  Bocom  ash  and/or  fly  ash  for  road  base  :  
4-­‐8  $/mt  
Costs Shipping

Storage  transport  
and  loading
Aim:  maximising  the  Ex-­‐works  economic  
value,  gejng    and  matching  the  right  
Ex-­‐works  economic  value Local  market  value,  in  order  to  fit  in  Enel  
porkolio  
1)  American  Coal  Ash  Associa2on  
12
 Enel ash management
Market trend

Star2ng   from   2008,   the   cement   market  

Cement  consump+on  (2009  basis)  1)   dropped  drama2cally  in  Italy    
150   The   cement   demand   in   Western   Europe  
Italy   decreased   at   a   lower   pace   as   a  
140  
Western  Europe   consequence   of   the   combina2on   of   a  
130   United  States   stable   demand   in   Northern   Europe   and  
120   the   crisis   in   the   construc2on   industry   in  
110  
European  MED  

100   Aler   the   crisis   of   2007,   US   is   showing   a  

strong  recovery  of  the  construc2on  sector  
90  
80  
70   The  collapse  of  the  construc2on  market  in  
60   Italy  and  southern  Europe  aler  2008,  led  
to  an  increase  in  Enel’s  Italian  ashes  export  
50  
to  Northern  Europe  and  US
2009   2010   2011   2012   2013E   2014E   2015E  

1)  Morgan  Stanley,  Global  Cement  Markets  -­‐  CemTech  conference  (June  2014)  

13
 Ashes production in Enel Group
Worldwide annual production in Enel Group’s Coal Power Plant

Italy  =  1,3  Mt/y  

Spain  =  1,5  Mt/y  

Russia  =  5,2  Mt/y  

Colombia  =  50  kt/y  
Chile  =  130  kt/y  

Total  Enel’s  ashes  :  8,2  Mt  

14
 Enel ash management
Export of the Italian model in other Enel’s countries

production recovery
1300 1300 production recovery production recovery

85% 1500
5200
66%
96% 600
3%
250
40%

Spain Russia

100%
production recovery production recovery

130
50
50
51% 15
28% 38% 30%
Italy
Chile Colombia

15
 Enel ash management
Ashes flows

Russia  :  recovery  in  local  

market  (250  kt)  

Colombia  :  recovery  in   Italy  :    

local  market  (15  kt)   # recovery  in  local  market  (700  kt)  
# export  (600kt)  to  MED,  USA,  NE  

Chile  :  recovery  in  local   Spain  :  recovery  in  local  

market  (50  kt)   market  (600  kt)  

16
 Beneficial use of Fly Ashes
Italian Coal Power Plant

Ash  Produc+on  [total  1,3  Mt  @  2014]   Ash  Quality  and  Quan+ty  [kt]  

Local  mkt   Export  

EN  450  -­‐  Class  A   270
140
EN  450  -­‐  Class  B  
46% co-­‐combus2on   180
54%
wet  
GENOVA 7 kt FUSINA 200 kt EN12620   540 50
bocom   90
SPEZIA 90 kt
FUSINA
BASTARDO 5 kt
200 kt
SPEZIA
90 kt BRINDISI Local  Market  vs  Export1)  (TVN  &  BS)  
530 kt
TORRE NORD
TORRE400 kt 40  
NORD 400 BRIND %  Export  
kt
85  
ISI MERCURE 10 kt %  Italy  
530 kt 60  
SULCIS 3 15  
SULCIS 3 30 kt
30 kt
Torre  Nord   Brindisi  
1) Export to MED,  USA,  NE

17
 Enel ash business development
Enel Qualification process

Star+ng  from  01/01/2015,  all  new  contracts  must  be  with  counterpar+es  qualified  in  
Enel  Qualifica+on  System    (assessment  of  the  recovery  capability  of  the  counterparty)

Authorized    Recovery  
facility    Recovery  
Authorized  
Enel   Qualified  trader1)   facility  
Authorized    Recovery  
Enrolled  in  :     facility  
−  Italian  Albo  
−  Enel  Qualifica2on  system       Authorisa2on  for  recovery  
of  CER  10.01.01,  10.01.02  
+    regista2on  in  Enel  
qualifica2on  system  (in  
SRTS18)  
Enel   Qualified  Recovery  
Facility  1)  
Enrolled  in  Enel  Qualifica2on  system  
Authorisa2on  for  recovery  of  CER  
10.01.01,  10.01.02    (R5  or  equivalent)    

1)  The  qualified  counterparty  is  the  only  environmental  and  contractual  counterparty  of  Enel.

18