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Title: Advanced Multi-Product Coal Utilization By-Product Processing Plant

Abstract

The objective of the project is to build a multi-product ash beneficiation plant at Kentucky Utilities 2,200-MW Ghent Generating Station, located in Carroll County, Kentucky. Phase 1 was completed successfully, but the project did not continue on to Phase 2 due to withdrawal of CEMEX from the project. Attempts at replacing CEMEX were not successful. Problematic to the continuation of the project was its location in the Ohio Valley which is oversupplied and has low prices for fly ash and the change in CEMEX priorities due to merger and acquisitions. Thus, CAER concurred with the DOE to conclude the project at the end of Budget Period 1, March 31, 2007.

Authors:
;
Publication Date:
Research Org.:
University Of Kentucky
Sponsoring Org.:
USDOE
OSTI Identifier:
908592
DOE Contract Number:
FC26-05NT41781
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
01 COAL, LIGNITE, AND PEAT; BY-PRODUCTS; COAL; FLY ASH; KENTUCKY; OHIO; PRICES; PROCESSING; VALLEYS

Citation Formats

Thomas Robl, and John Groppo. Advanced Multi-Product Coal Utilization By-Product Processing Plant. United States: N. p., 2007. Web. doi:10.2172/908592.
Thomas Robl, & John Groppo. Advanced Multi-Product Coal Utilization By-Product Processing Plant. United States. doi:10.2172/908592.
Thomas Robl, and John Groppo. Sat . "Advanced Multi-Product Coal Utilization By-Product Processing Plant". United States. doi:10.2172/908592. https://www.osti.gov/servlets/purl/908592.
@article{osti_908592,
title = {Advanced Multi-Product Coal Utilization By-Product Processing Plant},
author = {Thomas Robl and John Groppo},
abstractNote = {The objective of the project is to build a multi-product ash beneficiation plant at Kentucky Utilities 2,200-MW Ghent Generating Station, located in Carroll County, Kentucky. Phase 1 was completed successfully, but the project did not continue on to Phase 2 due to withdrawal of CEMEX from the project. Attempts at replacing CEMEX were not successful. Problematic to the continuation of the project was its location in the Ohio Valley which is oversupplied and has low prices for fly ash and the change in CEMEX priorities due to merger and acquisitions. Thus, CAER concurred with the DOE to conclude the project at the end of Budget Period 1, March 31, 2007.},
doi = {10.2172/908592},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Sat Mar 31 00:00:00 EDT 2007},
month = {Sat Mar 31 00:00:00 EDT 2007}
}

Technical Report:

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  • The objective of the project is to build a multi-product ash beneficiation plant at Kentucky Utilities 2,200-MW Ghent Generating Station, located in Carroll County, Kentucky. This part of the study includes the examination of the feedstocks for the beneficiation plant. The ash, as produced by the plant, and that stored in the lower pond were examined. The ash produced by the plant was found to be highly variable as the plant consumes high and low sulfur bituminous coal, in Units 1 and 2 and a mixture of subbituminous and bituminous coal in Units 3 and 4. The ash produced reflectedmore » this consisting of an iron-rich ({approx}24%, Fe{sub 2}O{sub 3}), aluminum rich ({approx}29% Al{sub 2}O{sub 3}) and high calcium (6%-7%, CaO) ash, respectively. The LOI of the ash typically was in the range of 5.5% to 6.5%, but individual samples ranged from 1% to almost 9%. The lower pond at Ghent is a substantial body, covering more than 100 acres, with a volume that exceeds 200 million cubic feet. The sedimentation, stratigraphy and resource assessment of the in place ash was investigated with vibracoring and three-dimensional, computer-modeling techniques. Thirteen cores to depths reaching nearly 40 feet, were retrieved, logged in the field and transported to the lab for a series of analyses for particle size, loss on ignition, petrography, x-ray diffraction, and x-ray fluorescence. Collected data were processed using ArcViewGIS, Rockware, and Microsoft Excel to create three-dimensional, layered iso-grade maps, as well as stratigraphic columns and profiles, and reserve estimations. The ash in the pond was projected to exceed 7 million tons and contain over 1.5 million tons of coarse carbon, and 1.8 million tons of fine (<10 {micro}m) glassy pozzolanic material. The size, quality and consistency of the ponded material suggests that it is the better feedstock for the beneficiation plant.« less
  • The objective of the project is to build a multi-product ash beneficiation plant at Kentucky Utilities 2,200-MW Ghent Generating Station, located in Carroll County, Kentucky. This part of the study includes the examination of the feedstocks for the beneficiation plant. The ash, as produced by the plant, and that stored in the lower pond were examined. Filter media candidates were evaluated for dewatering the ultrafine ash (UFA) product. Media candidates were selected based on manufacturer recommendations and evaluated using standard batch filtration techniques. A final media was selected; 901F, a multifilament polypropylene. While this media would provide adequate solids capturemore » and cake moisture, the use of flocculants would be necessary to enable adequate filter throughput. Several flocculant chemistries were also evaluated and it was determined that polyethylene oxide (PEO) at a dosage of 5 ppm (slurry basis) would be the most suitable in terms of both settling rate and clarity. PEO was evaluated on a continuous vacuum filter using 901F media. The optimum cycle time was found to be 1.25 minutes which provided a 305% moisture cake, 85% solids capture with a throughput of 115 lbs dry solids per hour and a dry cake rate of 25 lb/ft2/hr. Increasing cycle time not did not reduce cake moisture or increase throughput. A mobile demonstration unit has been designed and constructed for field demonstration. The continuous test unit will be operated at the Ghent site and will evaluate three processing configurations while producing sufficient products to facilitate thorough product testing. The test unit incorporates all of the unit processes that will be used in the commercial design and is self sufficient with respect to water, electricity and processing capabilities.« less
  • The objective of the project is to build a multi-product ash beneficiation plant at Kentucky Utilities 2,200-MW Ghent Generating Station, located in Carroll County, Kentucky. This part of the study includes the examination of the feedstocks for the beneficiation plant. The ash, as produced by the plant, and that stored in the lower pond were examined. A mobile demonstration unit has been designed and constructed for field demonstration. The demonstration unit was hauled to the test site on trailers that were place on a test pad located adjacent to the ash pond and re-assembled. The continuous test unit will bemore » operated at the Ghent site and will evaluate three processing configurations while producing sufficient products to facilitate thorough product testing. The test unit incorporates all of the unit processes that will be used in the commercial design and is self sufficient with respect to water, electricity and processing capabilities. Representative feed ash for the operation of the filed testing unit was excavated from a location within the lower ash pond determined from coring activities. Approximately 150 tons of ash was excavated and pre-screened to remove +3/8 inch material that could cause plugging problems during operation of the demonstration unit.« less
  • The objective of the project is to build a multi-product ash beneficiation plant at Kentucky Utilities 2,200-MW Ghent Generating Station, located in Carroll County, Kentucky. This part of the study includes an investigation of the secondary classification characteristics of the ash feedstock excavated from the lower ash pond at Ghent Station. The secondary classification testing was concluded using a continuous demonstration-scale lamella classifier that was operated at a feed rate of 0.3 to 1.5 tons/hr. Feed to the secondary classifier was generated by operating the primary classifier at the conditions shown to be effective previously. Samples were taken while themore » secondary classifier was operated under a variety of conditions in order to determine the range of conditions where the unit could be efficiently operated. Secondary classification was effective for producing an ultra-fine ash (UFA) product. Inclined lamella plates provided an effective settling surface for coarser ash particles and plate spacing was shown to be an important variable. Results showed that the closer the plate spacing, the finer the size distribution of the UFA product. Flotation of the secondary classifier feed provided a lower LOI UFA product (2.5% LOI vs. 4.5% LOI) and a dispersant dosage of 2 to 2.5 g/kg was adequate to provide UFA grade (3.8 to 4.4 {micro}m) and recovery (53 to 68% 5{micro}m recovery). The UFA yield without flotation was {approx}33% and lower ({approx}20%) with flotation. Demonstration plant product evaluations showed that water requirements in mortar were reduced and 100% of control strength was achieved in 28 days for the coarser products followed by further strength gain of up to 130% in 56 days. The highest strengths of 110% of control in 7 days and 140% in 56 days were achieved with the finer products. Mortar air requirements for processed products were essentially the same as those for standard mortar, suggesting that the unburned carbon remaining does not have an affinity for air entraining admixture (AEA), a consideration that is a significant benefit. In concrete, substitution of 20% showed that the UFA product outperformed a typical ash by achieving 105 to 107% of control strength after 28 days and 109.5 to 112% after 56 days. Higher substitution levels were shown to delay early strength development, but surpass control strength after 28 days while lower substitution levels provide both early and longer term strength. One of the most significant benefits provided by using UFA in concrete mix designs is the improved resistance to chloride permeability while some improvements is flexural strength were realized and tensile strength was essentially unchanged. Potentially significant benefits may also be offered by using UFA as a process addition in the manufacture of cement clinker.« less