THEME: COMPLEX PROCESSING OF ASH-SLAG OF EKIBASTUZ COAL TO ALUMINA, ALUMINUM SALTS, FERROSILICIUM AND CEMENT

Almaty 2014

Reporter: academician, doctor of technical sciences, professor Nurkeyev Samat Sagievich

STRUCTURE OF PRESENTATION

1. Coal in Kazakhstan’s power industry: current state and perspectives.

2. Characterisitics of Thermal Power Plant (RK) .3. Volumes of ash-slag materials on TPP of

Kazakhstan.4. Main directions of ASM use.5. Analysis of ASM technology in RK.6. Barriers of coal energy use in Kazakhstan.7. Recommendations.

COAL IN KAZAKHSTAN POWER INDUSTRY: CURRENT STATE AND PERSPECTIVES

Coal industry in Kazakhstan is one of the largest sectors of the economy. Reserves of coal Kazakhstan is among the top-ranked countries, behind China, the USA, Russia, Australia, India, South Africa and Ukraine.

Рисунок 1 - Мировые запасы угля, млрд. тонн Рисунок 2 - Размещение балансовых запасов угля Республики Казахстан по регионам

State balance includes stocks from 49 fields and up to 33.6 billion tons, including stone - 21.5 billion tons, lignite - 12.1 billion tons. Most of the coal deposits are concentrated in central (Karaganda and Ekibastuz coal basins and deposits Shubarkol) and Northern Kazakhstan (Turgay coal basin).

COAL IN KAZAKHSTAN POWER INDUSTRY: CURRENT STATE AND PERSPECTIVES

Today the coal industry provides 80% of electricity production

In the republic there are 33 coal mining coal companies , the largest of which "Bogatyr Coal " cuts "East" and JSC " Shubarkol " Eurasian Energy Corporation , Coal Department of JSC " Arselor Mittal Temirtau " Coal Department "Borly" corporation " Kazakhmys ".

Currently, the major coal basins of Kazakhstan are:

Karaganda coal basin .

Ekibastuz coal basin .

Shubarkol coal deposit .

Karazhirinskoe coal deposit .

Thermal power plants are the largest consumers of energy coal , supply. Ekibastuz coal for thermal power plants in Kazakhstan will increase by 2010-2015 to 39-40 million tonnes from 22.5 million tonnes in 2000

TPP CHARACTERISTICS IN RK

around 1 bln. tonnes

20 mln. t/year

2 mln. t/year

accumulated

Year issue

1 2 3

development and use

Ash-slag materials (ASM) volume on TPP of Kazakhstan

Main aim: coal TPP – free of ash-slagMain aim: coal TPP – free of ash-slag

Ways of achievement:• Change of laws and norms of

RK (ash – mineral resource; ASM – construction material);

• Use cement and concrete, containing ASM;

• Use of ASM for road construction

• Development of small and medium business in the sphere of ASM utilization (is the most effective in case if Ash-Slag is considered not waste but ASM or Side-products of coal burning);

• Inculcation of exisiting and development of new technologies to use ASM.

MAIN DIRECTIONS OF ASM USE (ASH-SLAG MATERIALS)

Main directions of ASM (ППСУ) use

Production of construction

materials (cement, fillers

– ash and agloporit gravel,

expanded clay alumina, silica brick, concrete walling – ash-

ceramic

Construction materials

production of the new

generation (semi-porous wood, sulfur

nanocomposite materials)

Ferrosilicon production, rare metals

To isolate different

waste and packing material

generated for mining space

Agricultutre

Firefighting

Production of alumina

Production of coagulants, sorbents for wastewater

preparation and use

ANALYSIS OF TECHNOLOGICAL DEVELOPMENT OF ASM IN RK

In Kazakhstan, the production of electric energy is made on 14 powerful TPP , which burns mostly Ekibastuz coal. Further development of the power system of Kazakhstan is based on the combustion of Ekibastuz coal . Recently, the Senate of the Parliament of Kazakhstan ratified an intergovernmental agreement between Kazakhstan and the Republic of Korea, "On the construction and operation of the Balkhash thermal power stations .“ Start of exploitation of the first unit of the first module ( 660 MW ) is scheduled for October 2017 , but all the first module ( 1320 MW ) - in April 2018.

The Act was very important from the point of view of energy security of the Republic of Kazakhstan as power plant construction creates the necessary reserve power capacity in southern Kazakhstan .

Ekibastuz Basin coal have reserves of more than 11 billion tons containing up to 50 % or more of ash. Meanwhile two Ekibastuz TPP annually thrown more than 15 million tons of ash , and the launch of the Balkhash thermal power plant will emit about 2 million tons. In Ekibastuz coal ash contains SiO2 (~ 50 %) and Al2O3 (~ 30 %). Additionally, it consists of a chemically resistant components in the form of mullite and quartz. This ash is abrasive , which leads to high abrasion boiler heating surfaces . This ash is highly dispersed , moreover it is still a high-resistance , hence inefficiency of electrostatic precipitators. The consequence of all this is pollution by untrapped silicosis ash. Due to lack of binding components in the ash a solid crust is not formed on the ash dumps and they raise dust in the wind , re- polluting the environment by captured ash. At the same time, the mineral part of the fuel contains valuable components such as aluminum, iron and other metals , as well as rare earth , rare and trace elements on which production , delivery and grinding in the metallurgical industry , industry spent a lot of money .

In the Kazakh National Technical University named after KISatpayev over the years the scientific basis and technology of complex processing of aluminum Ekibastuz coal ash developed, which can be a source of providing the national economy salts of aluminum, alumina, ferrosilicon, rare metals and other products.

Our research on the scientific basis and technology of alkaline and acid methods allowed to propose new technical solutions and methods of complex processing of alkali-free aluminum materials. Economic efficiency of these methods was determined by comparing the existing or previously used technology. In this case we used the results of research and development, production tests, as well as data of non-ferrous metallurgy and chemical industry.

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Barriers on the way of coal based power industry development

угольной энергетикиCoal generation:

- share in energy production – 80%;-Quantity of waste – 250 mln.tones.

In ash disposals more than 1 bln. Tonn of ASM accumulated.

Low level of ASM utilization – barrier on the way of functioning and development of coal generation in Kaakhstan

In Kazakhstan, the annual output of ash and slag materials in coal combustion is about 20 million tons

Annually recycled and used not more than 10% (2 million tonnes) output ASW.

. In Germany and Denmark 100% of Asm is used in construction. No one is permitted to have ash-slag deposits in Germany

In the USA, China, Poland 50-70% of year ASM stock is used. Change in the Indian laws led to increase in the volume of utilized

ash from 30 to 53 which is 70 mln. Tonne /year.

RECOMMENDATIONS1. Necessary to create a holistic set of legal and regulatory documents of direct

action and continuous improvement of it, based on the system of public funding of research on the treatment of ash and slag from thermal power plants.

2. Policy formulation , enabling maximum processing of ash instead of natural raw materials in order to increase economic stability and environmental security of the state as a whole.

3. Active cooperation with international and national associations of the world community on the issue of the treatment of ash and slag.

4. Working out of an effective strategy for the development of coal-fired generation in Kazakhstan on the basis of modern "clean" coal technology and energy technology complexes with the possibility of increasing the capacity of the joint cooperation with the CIS countries and the world community in the energy industry

5. Pilot projects of modern "clean" coal technologies under public-private partnership with subsequent replication in TPP Kazakhstan.

6. Preparing skilled personnel for handling problem with ash and slag.

THANK YOU FOR ATTENTION

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