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FGD) and OTHER COAL COMBUSTION PRODUCTS (Ccps)

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FGD) and OTHER COAL COMBUSTION PRODUCTS (Ccps) MARKET OPPORTUNITIES FOR UTILIZATION OF OHIO FLUE GAS DESULFURIZATION (FGD) AND OTHER COAL COMBUSTION PRODUCTS (CCPs) Volume 1 – Executive Summary Tarunjit S. Butalia, Ph.D., P.E. William E. Wolfe, Ph.D., P.E. Originally Issued: May, 2000 Department of Civil and Environmental Engineering and Geodetic Science The Ohio State University Market Opportunities for Utilization of Ohio FGD and Other CCPs – Volume 1 May 2000. Complete electronic versions of Volumes 1 and 2 of this report may be downloaded from the following internet web sites: http://ccpohio.eng.ohio-state.edu/ccpohio/ http://www.odod.state.oh.us/tech/coal/ ii Market Opportunities for Utilization of Ohio FGD and Other CCPs – Volume 1 May 2000. ACKNOWLEDGEMENTS This report was compiled as a part of a research project entitled Bringing Coal Combustion Products into the Marketplace (OCDO Grant CDO/R-96-26) and was performed at The Ohio State University. The principal sponsors of this research project are the Ohio Department of Development’s Coal Development Office and The Ohio State University. Industrial co-sponsors are American Electric Power, Cinergy, FirstEnergy and Dravo Lime Company (now Carmeuse NA). The US Department of Energy’s Federal Energy Technology Center (now National Energy Technology Laboratory) and American Coal Ash Association – national and Ohio chapter both provide support. Sponsoring trade organizations include the Ohio Farm Bureau Federation, Ohio Cattlemen’s Association, and Ohio Dairy Farmer’s Association. The authors express their appreciation to all the respondents of the Ohio CCP survey. The data provided by them on the production and use of CCPs in the state has been invaluable and is included in this study. The help and guidance provided by the national American Coal Ash Association in compiling and providing CCP data relevant to Ohio is valued. Ms. Debra Pflughoeft-Hassett of University of North Dakota provided the authors with several topical reports on barriers to CCP use. These reports were helpful in identifying many of the barriers to CCP utilization. The assistance of Ms. Michelle Tinnel of the Ohio Department of Natural Resources- Division of Mines and Reclamation is appreciated. The resources of The Ohio State University Library, particularly the interlibrary loan division, and the Ohio Department of Transportation Library were helpful in the compilation of this report. The authors express their thanks to the staff of these libraries for their assistance. The input provided by the reviewers of the report contributed significantly towards an enhancement of the technical and economic issues associated with CCP utilization that are presented in this report. The comments received from the reviewers are appreciated. iii Market Opportunities for Utilization of Ohio FGD and Other CCPs – Volume 1 May 2000. iv Market Opportunities for Utilization of Ohio FGD and Other CCPs – Volume 1 May 2000. TABLE OF CONTENTS Page ACKNOWLEDGEMENTS iii LIST OF FIGURES vi LIST OF TABLES vii 1 INTRODUCTION 1 1.1 Background and Objectives 1 1.2 Information Sources 1 2 STATUS OF CCP INDUSTRY IN OHIO 3 2.1 Regulation of CCPs 3 2.2 Advantages and Limitations of Utilization 4 2.3 CCP Production and Utilization 4 2.4 CCP Producer Economics 5 3 FUTURE OF CCP INDUSTRY 13 3.1 Overview of Existing and Potential Uses 13 3.2 Highway / Road Applications 13 3.3 Mine Reclamation Uses 14 3.4 Agricultural Applications 15 3.5 Other Civil Engineering and Miscellaneous Uses 16 3.6 Social Costs and Benefits 16 3.7 Effect of Landfilling Costs on Potential FGD Utilization and Disposal 17 3.8 Future Projections and Estimates 18 4 RECOMMENDATIONS 27 5 CONCLUSIONS 29 6 REFERENCES 30 7 LIST OF ACRONYMS AND ABBREVIATIONS 31 v Market Opportunities for Utilization of Ohio FGD and Other CCPs – Volume 1 May 2000. LIST OF FIGURES Page Figure 2-1 Surveyed Coal-Fired Facilities in Ohio 8 Figure 3-1 Funded and Unfunded AML Problems in Ohio (1998 dollars) with Potential for FGD Utilization 22 Figure 3-2 Effect of Landfilling Cost on Amount of FGD Potentially Used and Landfilled 24 vi Market Opportunities for Utilization of Ohio FGD and Other CCPs – Volume 1 May 2000. LIST OF TABLES Page Table 2-1 Types of Coal Combustion Products (CCPs) and Their Characteristics 6 Table 2-2 Annual Production of Selected Non-Fuel Mineral Commodities for Ohio 6 Table 2-3 Ohio Coal-Fired Facilities Surveyed 7 Table 2-4 CCP Production and Use – 1997 9 Table 2-5 FGD Material Production – 1997 10 Table 2-6 Estimated CCP Utilization by Type of Use – 1997 10 Table 2-7 Comparison of CCP Production and Use for Ohio, Regional States, and the United States – 1997 11 Table 3-1 Existing and Potential Uses of CCPs in Ohio 19 Table 3-2 Existing and Potential Uses of CCPs for Highway Applications 20 Table 3-3 Recommended Changes to ODOT Specifications 21 Table 3-4 Potential FGD Tonnage for Uncompleted AML Projects 23 Table 3-5 Effect of Landfilling Cost on Amount of FGD Potentially Used and Landfilled 25 vii Market Opportunities for Utilization of Ohio FGD and Other CCPs – Volume 1 May 2000. viii Market Opportunities for Utilization of Ohio FGD and Other CCPs – Volume 1 May 2000. 1 INTRODUCTION 1.1 Background and Objectives The combustion of over 50 million tons of coal annually in the state generates enormous quantities (approximately 10 million tons annually) of solid by-products, referred to as Coal Combustion Products (CCPs). CCPs can be used, or disposed in landfills and surface impoundments. Developing economic and environmentally sound alternatives to expensive and non-productive landfilling of coal combustion products (CCPs) is of vital importance to the state of Ohio. This report has been prepared as a part of the Coal Combustion Products Pilot Extension Program established at The Ohio State University in January of 1998. The extension program promotes the responsible uses of coal combustion products, including fly ash, bottom ash, boiler slag, and flue gas desulfurization (FGD) material. The study presented in this report focuses on the existing and potential uses of all CCPs, particularly FGD and fly ash, generated in the state of Ohio. The report was compiled with the primary objective of understanding the opportunities that exist for innovative uses of these materials as alternatives to conventional materials, the advantages and disadvantages of utilizing CCPs, and to identify barriers to utilization. Opportunities for high-volume and high-value applications receive particular attention. 1.2 Information Sources The compilation of this report involved reviewing information from a wide range of print and online publications. The primary information sources used by the authors in finalizing this report were: · American Coal Ash Association; · American Concrete Institute; · American Electric Power; · Cinergy; · County Engineers Association of Ohio; · Dayton Power and Light; · Dravo Lime Company (now Carmeuse NA) · Electric Power Research Institute; · Federal Highway Administration; · FirstEnergy; · Ohio Department of Agriculture; · Ohio Department of Development – Coal Development Office, Office of Strategic Research; 1 Market Opportunities for Utilization of Ohio FGD and Other CCPs – Volume 1 May 2000. · Ohio Department of Natural Resources – Division of Geological Survey, Division of Mines and Reclamation; · Ohio Department of Transportation; · Ohio Environmental Protection Agency; · The Ohio State University; · Organization for Economic Co-Operation and Development; · Public Utilities Commission of Ohio; · Transportation Research Board; · United States Department of Agriculture; · United States Department of Energy – Federal Energy Technology Center (now National Energy Technology Laboratory), Energy Information Administration, Office of Fossil Energy; · United Stated Department of Interior - Office of Surface Mining; · United States Environmental Protection Agency; and · United States Geological Survey. 2 Market Opportunities for Utilization of Ohio FGD and Other CCPs – Volume 1 May 2000. 2 STATUS OF CCP INDUSTRY IN OHIO Current coal consumption for Ohio exceeds 50 million tons annually, with almost half of this coal being mined in the state. Coal-fired electric utilities account for 90% of the coal consumed and supply nearly 90% of the state’s electricity. The combustion of such a large quantity of coal leads to enormous amounts of coal combustion products (CCPs). CCPs include fly ash, bottom ash, boiler slag, and flue gas desulfurization (FGD) material (refer to Table 2-1). CCPs can be utilized, or disposed in landfills and surface impoundments. The annual production of CCPs for the state is nearly 10 million tons. Total annual tonnage of CCPs generated in Ohio equals that of portland cement and ranks behind only crushed stone, sand, and gravel among all non-fuel mineral commodities (refer to Table 2-2). If all CCPs generated annually in Ohio were placed on top a football field, the height of CCP material would be about one mile. 2.1 Regulation of CCPs Currently, CCPs are exempt from Subtitle C of the Resource Conservation and Recovery Act (RCRA), and are regulated by most states as solid wastes. A recently published final regulatory determination for all CCPs by USEPA (Federal Register of May 22, 2000, Part III, EPA, 40 CFR Part 261) concluded that CCPs do not warrant regulation under Subtitle C of RCRA and that USEPA is retaining the hazardous waste exemption for CCPs under RCRA Section 3001(b)(3)(C). However, EPA determined that voluntary Subtitle D (non-hazardous) national standards need to be developed for CCPs disposed in landfills or surface impoundments, and used in filling surface or underground mines. USEPA also determined that no additional regulations were warranted for CCPs that are used beneficially (other than for minefilling). In the regulatory determination, USEPA supported increases in beneficial uses of CCPs, such as additions to cement and concrete products, waste stabilization, and use in construction products such as wallboard. More detailed background information and updated documents on USEPA’s determination can be obtained from http://www.epa.gov/epaoswer/other/fossil/index.htm.
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