Potential export of fly ash from India - Logistical challenges and quality issues

Thomas Duve & Peter Brennan 18. February 2013

STEAG Power Minerals Group Development and geographic coverage of activities

2002
Quantity (million metric tons) 3 68 148

2011
4.7

2016
>6 136 151

Power plants under contract

Sales (million ) Staff (FTE)
Germany

> 50 power plants

116 144

Felix Hltken

Benelux

United Kingdom

Eastern Europe

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Why using fly ash in concrete and cement?

In concrete Fly Ash (FA) improves the workability and lowers water demand In concrete FA generally exhibit less bleeding and segregation FA improves the Sulfate and Alkali Aggregate Resistance Lower heat of hydration, No or little need for cooling. FA reduces the permeability and absorption of concrete Utilization of FA in concrete/ cement is friendly to our environment

Avoids landfilling of Coal-Combustion-Byproducts (CCPs)

Every ton of ash reused in cement products equates to nearly a ton of CO2 savings

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Logistic supply chain for exports of FA

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Actual situation Big Bag handling

No investment required High operational costs due to frequently packaging Easier palletized transport Dust formation during packaging

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Challenges for bulk handling

Identify an efficient way to handle all challenges occuring during transport of bulk fly ash. Discharge equipment
Mechanical or pneumatical For lorry, train or ship

Storage
Depot Silo Floating terminal

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Discharge equipment

mechanical
Crane Conveyor Able to load up to 3.000 t/h Higher operational costs Environmental issues (e.g. dust blow) conventional ships can be used

pneumatical
Loading with compressed air Unloading using vacuum device or screw conveyor Able to load up to 1.500 t/h Higher investment costs Specialised ships required

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Storing / Transshipping

Depot Silo

Storage dome Floating terminal

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Quality and reliability issues

Significant variations in quality within India

Fly ash quality in India often comparatively poor:

- Variation in loss of ignition, inconsistent fineness, contamination with bottom ash etc. Large proportion of production volume is not certifiable and therefore not usable in high value applications (for example cement or concrete) Reliable production (consistent production, availability of silo facilities) Lower quality Fly Ash can be utilised in other applications (for example road construction, embankments, manufacture of building blocks)

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Quality control measures

Regular monitoring of Fly Ash

Segregation of lower quality material

Quality Assurance of higher quality material Certification to recognized industry Standards: For example

EN450: The European standard for using Fly Ash in concrete

ASTM618: The equivalent American standard Establishment of laboratory facilities: Regular testing and analysis

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Summary I

Big Bags Investment costs Operational costs Handling Enviromental friendly

Bulk

Big Bag requires no investment, but is expensive at operational costs

Bulk handling needs higher investment, but isnt expensive at operational

When dealing with high volumes for a longer term bulk handling is preferable

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Summary II

Bulk handling needs to be established There is a need for storage and transshipping facilities

Quality issues will become increasingly important in the future.

MOEF-regulation will increase pressure on power station operators

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