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Ash and Slag Materials Market of Russia: Problems and Solutions
www.ksfenix.com
c o n s o r t i u m
integratedash & slag materialutilization system
Ash & slag materials (ASM) in Russia
Annual production of ASM:
≈30 000 000tons
172 of them produce>100 000 tons of ASMannually
Coal power plants andthermal power stations
350
c o n s o r t i u m
Tomsk
MoscowOrel
Saint Petersburg
Samara
Yekaterinburg
Nizhnevartovsk
Noyabrsk
Krasnodar
Tomsk
MoscowOrel
Saint Petersburg
Samara
Yekaterinburg
Nizhnevartovsk
Noyabrsk
Krasnodar
Tomsk
MoscowOrel
Saint Petersburg
Samara
Yekaterinburg
Nizhnevartovsk
Noyabrsk
Krasnodar
Major sales volumes of ASM in 2013:
Utilization volumeof produced ASM
(30 mln. tons)
≈ 0,63 mln. tonsper year
≈ 3,27 mln. tonsper year
ASM sales in Russia
Geography of deliveries:
Irkutskzoloprodukt
≈ 4,0TGK-11
Ekozoloprodukt
Refinskaya Power Plant
ProfCement-Vector
Siberian GK
Others
Dry ash Sent to ash dumpsHydrated ash
0 0,5 mln. tons 1 mln. tons
mln. tons
1,02
0,67
0,36
0,17
0,15
0,12
Uncontrolled ≈ 1,00
0,06 0,06
0,10 0,26
0,08 0,94
0,15
0,17
≈ 0,35
0,07 0,60
2% 11%≈ 26 mln. tons
per year
87%
c o n s o r t i u m
Every ash dumpis a localecologicalcatastrophe
Every ash dump is a local ecological catastrophe
Coal power plants andthermal power stations
172
110 power plantalmost exhausted theirash dump capacities
Reftinskaya power plant
ASM production:
Cost of thesystem:
≈ 6 mln. tons per year
until 2040
10,2 billion rubles
The old water-based ash removal systemallows the plant to run only until 2016
Energetics industry problems
A new system of dry ash removal is being made which will allowthe plant to operate
c o n s o r t i u mCauses of weak ASM marketing
Power industry officials mustturn waste into goods
Stableproductparameters
Stabilepresenceon the market
1
2
Required conditions for theexistence of goods:
c o n s o r t i u m
Характеристики некоторых зол уноса Европейской части РФ
Химический состав и физико-механические характеристики зол уноса Новочеркасской, Каширской, Рязанской, Черепецкой, Подмосковной ТЭЦ-22.
Specific surface area, cm2/g
Novocherkasskaya Kashirskaya TPS-22 Ryazanskaya
SiO2 35,0-56,0 46,0-55,0 35,0-56,0 46,0-55,0 53,0-62,0 46,0-55,0Аl2О3 12,0-28,0 22,0-39,0 12,0-28,0 22,0-39,0 22,0-25,0 22,0-39,0Fe2О3 9,0-18,0 5,0-17,0 9,0-18,0 5,0-17,0 7,0-14,0 5,0-17,0СаО 1,0-5,0 2,0-5,0 1,0-5,0 2,0-5,0 3,0-5,0 2,0-5,0MgO 0,2-3,0 0,2-2,4 0,2-3,0 0,2-2,4 0,2-2,5 0,2-2,4K2O 2,5-5,0 0,2-1,0 2,5-5,0 0,2-1,0 0,1-0,2 0,2-1,0
Na2O 0,6-2,0 0,1-0,7 0,6-2,0 0,1-0,7 0,1-0,3 0,1-0,7SО3 0,2-3,0 0,2-1,6 0,2-3,0 0,2-1,6 0,3-0,8 0,2-1,6СаО 1,5 1 1,5 1 1 1
Underburn 8,0-22,0 0,2-1,3 8,0-22,0 0,2-1,3 ок. 15 0,2-1,3
Cyclone ash - 2300-2400 - 2300-2400 880-2040 880-2040
Electrofilter ash 3000-5000 1500-5200 3000-5000 1500-5200 1530-4000 1530-4000
Characteristicsof fly ash
Type 2BR & type T Type 2BR
Name of fly ash
Cherepetskaya
Chemicalcomposition(oxides), %
Type of coal
Type A Type T Type A Type T
c o n s o r t i u m
Of 172 power plants in Russia 110 have almost exaustedthe capacity of ash dumps.
Environmental charges are very low and still make 5-16 rubles per ton. However, later this year 2014 Ministry of En-vironment plans to triple the fee. The idea of a quarterly payment is being discussed.
On September 12, 2013 the Russian government made a decision according to which in the year 2014 the tariffs of natural monopolies will not grow.
Incentives for power industry officials
12
3
c o n s o r t i u m
Incentives for power industry officials:fines in Europe and Russia
Fine amount,€ per ton
Supplement to the client for ASM disposal
ItalyFinland Russia
Utilization leveltends to 100%
Utilization levelnot more than 13%
100
50
0
0,3
0,3
60
20
90
20
Penalty for storage in the dumps
Germany
120
15
c o n s o r t i u mRussian ASM market potential
Cement market
Recultivation market
Road construction market
Market of soil deoxidation
mln. tons≈17
mln. tons≈5
mln. tons≈10
mln. tons≈3
1
2
3
4
Totals to about tons of ASM per year35 000 000Сurrent consumption: not more than 4 million tons of ASM per year
Cement consumption:68,5 mln. tons
Produced: Productioncapabilities:
65,2 mln. tons 85 mln. tons
Imported:5,1 mln. tons
Exported:1,8 mln. tons
Russian cement market in 2013
Average percentage of fly ash inputin concrete systems in Europe
25%of cement
volume
The potential market in Russia only in the fields where cement is usedcan consume about 17.1 million tons of ASM per year
c o n s o r t i u m
c o n s o r t i u mNeeds of the Russian marketPresident and Government program:
100 mln. m2 of housing per year
≈ 20 mln tons of cement
6 billion € 3 billion €
At least 100 million tons of cement per year is needed1 m2 of housing = 1 ton of cement
Defecit:
Investments in cement: Investments in ASM:
minimum 300 € per ton maximum 130-150 € per ton
20 000 000 tons 20 000 000 tons
c o n s o r t i u m
Active mineral additivesfor cement
Raw materialsfor the production oflarge artificial fillers
for concertes
Activemineral additives for concretes and mortars
Lightconcrete
Heavyconcrete
MortarsFoam & gasconcrete
Active mineral additivesfor the production of
dry mortars
Manufacture of ceramic products
Fly ash use capabilitiesin the construction industry
The main effects of ASM usage in concrete systems:
Reduction ofwater requirementof the concrete system
Structure compaction due to:• spherical particle shape• small particle size (< 40 μm)• chemical structure
1 2
In these conditions was born the idea of creating an international consortium, which would bring together professionals from the energy, cement and construction industries.
The solution
Strategic financial partner
c o n s o r t i u m
Integrated ash & slag materialutilization system Fenix offers:
Investigation of physical, mechanical and chemical properties of all types of the power plants ashes and slags, identification of factors affecting their stability. Definition of usage di-rections for these materials in industry, con-struction and agriculture. Formation of the market within 500-1500 km from the station. Development of technical conditions and ob-taining certificates of conformity on ash and slag materials, produced by the power plant.
Development of technical concepts of dry ash re-moval system oriented at 100% selling of ASM to the consumers and not its storage in the dumps, using the most modern technologies and equipment. Feasibility study of construction of a dry ash removal system for newly construct-ed or reconstructed power plant.
Making the project of dry ash removal system with binding and adaptation of the Dry Ash Re-moval System 100™ technological scheme to the power plant, based on the existing condi-tions and customer requirements.
Research Pre-project work
Engineering design
1: 2:
3:Assistance & organization of loan financing from Russia’s largest bak — Sberbank — for the construction of the Dry Ash Removal System 100™.
Funding4:
Construction of the Dry Ash Removal System 100™ by most modern and quick ways on a working power plant.
Construction5:Organization of ash and slag marketing to the consumers.
Sales6:
c o n s o r t i u m
Dry Ash Removal System 100™focused at 100% utilization of ASM
Екатеринбург
Екатеринбург
™
Coal preparation system:• averaging of parameters and providing a certain level of coal grinding.
Stabilization of coal burning modes:• providing the level of underburn not higher than 5%;• power unit certification for production of quality ash and slag materials.
Separate selection of fly ash from different fields of electrostatic filters (and cyclones) and slag from power units.
Monitoring system of ash and slag production in the power plants own laboratories capable of analyzing up to 4,5 thousand samples per year from one power unit and providing the necessary consumer properties of ash.
Multi-comparetment concrete silo (or multiple silos) for ash from different fields of electrostatic filters with the possibility of their controlled mixing and a volume of one-time storage not less than 10-day-production of ASM.
Slag grinding system and its separate storage.
Shipping system with cement trucks, railway hopper wagons and big bag packers.
Backup ash removal system with 30% moistening of ash waste (water-to-ash ratio 3:10) and storage into small ash dumps.
Principles of theDry Ash Removal System 100™
1
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5
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c o n s o r t i u m
M
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Силос некондиции
Система увлажнения
MM
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м
Силос
мммм
м
M
MM
MM
M
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M M
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Секция №2 Секция №3 Секция №4 Секция №5Секция №1
Отвал
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MOTOR-ALLG
Вертикальная мельница
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Котёл
MOTOR-ALLG
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№ п
/п
Наименование, обозначение Позиция
Кол-
во Производитель-ность
Основное оборудование1 Электрофильтр 2
2 Рукавный фильтр 1
3 Рукавный фильтр 12
4 Дробилка валковая 1 5 т/час
5 Мельница вертикальная 1 5 т/час
6 Система аэрожелобов выгрузки из секции 1 1
7 Система аэрожелобов выгрузки из секции 2 1
8 Система аэрожелобов выгрузки из секции 3 1
9 Система аэрожелобов выгрузки из секции 4 1
10 Система аэрожелобов выгрузки из секции 5 1
11 Элеватор 1
12 Пневмокамерный насос 9
13 Делитель потока 5
14 Система увлажнения 1
15 Ленточный конвейер 4
16 Виброгрохот 3
17 Скребковый транспортер 1
18 Виброжелоб 1
19 Система отгрузки в ж.д. транспорт 1 до 250 т/час
20 Система отгрузки в автотранспорт 1 до 150 т/час
21 Весы для ж.д транспорта 1
22 Весы для автотранспорта 2
23 Компрессор 3
24 Воздуходувки для системы аэрации компл.
25 Пробоотборник 9
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Перечень оборудования
АвтодорогаАвтодорога
Зола Зола ЗолаЗолаШлак
1920 20
2222 21
Сж.воздух Сж.
воздух Сж.воздух
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MOTOR-ALLGMDWALZENSCHÜSSELMÜHLE - HAUPTANTRIEBROLLER MILL - MAIN DRIVEMOLINO VERTICAL - MOTOR
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MOTOR-ALLGMDWALZENSCHÜSSELMÜHLE - HAUPTANTRIEBROLLER MILL - MAIN DRIVEMOLINO VERTICAL - MOTOR
M
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B MB M
B MB M
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Mшлак в
отвал
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MM25 Сж.
воздух
12
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воздух Сж.воздух
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Технологическая схема
c o n s o r t i u m
Principle technological scheme of theDry Ash Removal System 100™
Dry Ash Removal System 100™ project implementation stagesby the participants of the Consortium Fenix
Stages and worksExecutors t.(months) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30+
Stage I: Research 15 m.
Feasibility study,technical requirements for project realization
Design specificationsdevelopment 4 m.
5 m.
Sampling, researchesof the applicability
of ash and slag12 m.
Processing of theresearch results 3 m.
Stage II:Stage II: Engineering 16 m.
Elaboration of designdocumentation 6 m.
Design documentationagreement 3 m.
Design documentationstate examination 2 m.
Elaboration ofworking documentation 9 m.
Stage III: Design specification
and contract preparationТехн. консультант
Техн. консультант
2 m.
Construction, productionand equipment delivery,
commissioning
Stage IV:15 m.
Stage V: Marketing
Credit funding
c o n s o r t i u m
c o n s o r t i u m
The main components of the system: electrostatic filters and IBAU multicompartment silos
© IB
AU
Ham
bur
g
IBAU Two-Way ValveElectrostatic Filter
IBAURotary Air Lock
IBAU FluidslideIBAU Screw Pump
IBAU MulticompartmentSilo
IBAU Flow Control Gate
IBAU Loading
Main components of theDry Ash Removal System 100™
c o n s o r t i u m
List of necessary laboratory teststhat should be conducted by the power plant during output control of ash
№ Test name Testing methodology
1Chemical composition(oxide composition, harmful impurities including Cl-, SO3, Р2О5)
ГОСТ* 8269.1-97
2 СаОfree content ГОСТ 23227-78
3 Underburn content ГОСТ 11022-95
4 Specific surface area & fineness (sieve 008 residue) ГОСТ 310.2-76
5 Bulk density of ash in natural state ГОСТ 8735-88
* ГОСТ (Государственный Стандарт) — Russian state standard
Initial data for the financial model
c o n s o r t i u m
Pricing policy
of Dry Ash Removal System 100™ usageon Khabarovsk Thermal power plant-4
1
Savings factorswhen using dry ash removal2
Ash typeOutput of ash Year I II III IV V
Field I 300 400 400 500 500
Field II 400 500 500 600 600
Field III 500 600 600 700 700
Field IV 700 800 800 900 900
Price, rub./ton
Slag 100 100 200 200 200
53%
22%9%
4%11%
Operating expensesfor ash removalare reduced
Environmental charges for ash dumping increase forecast:
3 times increasein the coming year
30% increaseevery next year
2–2,5 times
These price levels will provide quick entry to the ASM market with attainment of 100% utilization in the course of the 5th year.
SakhalinskayaGRES-2
х
40
95
190
55
0%
Mayskaya GRES
55
879
105
9
2024
51%
Komsomolskayathermal plant 2
Amurskayathermal plant
Komsomolsk-na-Amure
23
44
7364
140
51
2055
89%
2022
90%
Schem e L EGENDPrimorskaya GRES
2029 y.
89%
1250thousands
of tonsper year
107
1010
127Concrete and mortar market
(radius: 1000–1500 kmfrom site)
Road constructionmarket
(R = 150–200 km)
ASM production
— total
Estimated timeof ash dump filling
with current level ofconsumption
Recultivation market(R = 100–200 km)
Percentage of ash dump filling
thous.tons/year
ASM market potential analysisof RAO ES Vostoka enterprises
Blagoveshenskthermal plant
224
51
80
202
71
2033
43%
Artemovskayathermal plant
PartizanskayaGRES
Vladivostok
101227
226
448
554
129
2015
90%
2015
97%
Thermal plant 1 Thermal plant 2Khabarovsk
24
105
174220
303
133
2017
93%
2017
41%
NeryungrinskayaGRES
334
4383
2020
2034
63%
≈1000 km
(conservative estimate)
(ash + slag)Road construction
• Mounds and earth bed construction
• Soil strengthening• Road base strengthening• As an additive in pavement
manufacturing
thousand tonsper year588
Far East markets of ash and slag
Concretes & mortars(ash)
radius: 1000–1500 km from power plant radius: 100–200 km from power plant radius: 150–200 km from power plant
1 2 3
• Active mineral additives for cements and mortars
• Raw material for the production of large artificial concrete fillers
• Active mineral additives for concretes and mixes
thousand tonsper year476
(ash + slag)Soil recultivation
• Restoration of soil fertility• Filling of depleted quarries
and mines• Landscaping
thousand tonsper year638
mln. tonsper year1,7
c o n s o r t i u m
(conservative estimate)
Marketpotential:
Payback periodsince launching the system 5½ years
mln. rubles1950Investment in constructionof Dry Ash Removal System 100™:
Target technical and economic indicatorsof Dry Ash Removal System 100™ operation on Khabarovsk Thermal plant 4 c o n s o r t i u m
Dry Ash Removal System 100™ operation:
Year I III V VII X
ASM sales volume 225 360 450 450 450 thousand tonsper year
Additional income from ASM sales 75,5 156,8 236 236 236 mln. rublesper year
Reduction of operating costs for the maintenance and expansion of ash dumps 67,5 108 135 135 135 mln. rubles
per yearReduction of environmental charges
for ash & slag waste removal 24,2 65,5 138,4 233,9 513,8 mln. rublesper year
Simulation periodsince launching the system
NPV during simulation period IRR 15,6 %
10 years
151,1
Expenses:Incomes:
14 %Discount rate
millionrubles
Thank youfor your attention
www.ksfenix.com8 (812) 363-01-43
c o n s o r t i u m