Bruce W. Ramme
April 19, 2016
ACI Spring Convention - Milwaukee
Fly Ash in Concrete Session
Tribute to Tarun R. Naik
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A Family of Companies
Electric
Generation and Natural Gas Distribution Electric
Transmission
Distribution
60% ownership
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Serving the region’s energy needs
Service Territory Company Statistics
We Energies
Michigan Gas Utilities Corporation
Minnesota Energy Resources Corporation
North Shore Gas Company
The Peoples Gas Light and Coke Company
Wisconsin Public Service Corporation
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Positioned for the Future
State-of-the-Art Generation Fleet
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Combustion Products (Tons)
400,000
600,000
200,000
800,000
0
1,200,000
1,000,000
1980
1981
1982
1983
1984
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
We Energies Combustion Products
2010
2011
Production & Utilization (1980 - 2015)
CP Utilized (Tons)
CP Produced (Tons)
2012
2013
2014
2015
99%
Benefits from Combustion Products Utilization
Avoids new landfills …… Over 11 million cubic
yards NOT landfilled since 1980 – (i.e. two new
landfills avoided).
Reduces O&M costs & provides customer savings.
Revenue from sales.
Lower cost construction with better performance.
Reduced greenhouse gas emissions
Reduced quarry and mining needs.
Promotes resource conservation & reduces energy.
Conserves natural resources for future use.
Sustainability benefits - improved durability &
longer life. 12
Fly Ash In Concrete Calatrava - Milwaukee
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Green Concrete
Northwestern Mutual Building
Paving for Silver Spring & Port Road Project
Paving for Silver Spring & Port Rd Project
Paving for N. 27 th Street Projects
Paving for N. 27 th Street Project
I-94 in Dane County Project
I-94 in Dane County Project
I-94 in Dane County Project
Quality of CCP’s – Fly Ash
• Regular/routine sampling of fly ash
• Importance of Consistency – routine tests
–Loss on Ignition (LOI – carbon content)
–Foam Index (impact of carbon)
–Fineness (particle size - reactivity)
–Ammonia content (if necessary)
–On Site Labs at our Power Plants
• Performance testing of fly ash to meet
specifications and standards of end users
(ASTM C618)
Oak Creek Expansion Units
• 130,000 cubic yards of concrete
• Up to 50% fly ash concrete in 25 different mixtures
• 0.45 or less - water/cementitious materials ratio
• 5 years to permit
• 17 miles of railroad track
• 33,000 tons of structural steel
• 6 million cu yds excavated
• 550 ft tall chimney
• 27 ft diameter intake tunnel
• Over 5 years to construct
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Fly Ash for Construction
Stronger, more durable concrete
in roads and structures
100 Year Concrete, sustainable
with lower carbon footprint
Road Base Stabilization -
longer life paving, lower cost
roads
CLSM Flowable fills, for efficient
cost effective backfill and pipe
bedding
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CLSM Flowable Backfill (ACI 229)
Products – Bricks, Blocks, & Pavers
High Value Building Products, using Fly Ash
Low CO2 Impact, Non-Fired Brick
Sustainable Building Material & Technology
Jobs in Green Building Industry
Scalable
Superior
U.S./Global
economics
Huge
sustainability Same / better performance
advantage 30
Bottom Ash for Construction
Fine Aggregate “Sand” & “Stone”
Foundation & Road Base
Local Source
Lower Cost
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Bottom Ash Loading for
Cement Raw Feed Use
Ash Recovery from Monofill Landfill
Same uses as bottom ash
Helps meet customer demand
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Ash Recovery
FGD Gypsum
Calcium Sulfate (CaSO4)
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FGD Gypsum Uses
Floors
Wallboard
Agriculture
Cement Ingredient
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FGD Gypsum Benefits for Agriculture
Improves soil properties and increases crop production by
increasing soil permeability and water retention (drought
resistance)
Promotes deeper rooting and growth, provides plant
access to nutrients
Reduces silt loading in runoff from fields; Reduces
fertilizer runoff into rivers and lakes
Lower cost gypsum for region’s agricultural producers
Lower fuel usage and emissions with shorter haul
distance for “locally produced” commodity
Reduces natural gypsum mining and associated impacts
Preserves natural gypsum supplies for use by future
generations.
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Gypsum to Agriculture
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Ash Fuel Reburn and Recovery
Legacy Ash Sites: No use for ash from the past?
Solution: Ash Recovery and Reburn changes ash from
the past to construction materials in demand for use.
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Ash Reburn
Ash Recovery Process
(US Patent # 6,637,354)
Construction
Materials
Coal
Stored Ash
Environmental
Benefits
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Ash Fuel Influence ( Example)
• Coal typically has 5% Ash Content
• High Carbon Supplemental Fuel has 80%
Ash Content
• For 2% Ash Fuel Addition:
Resulting Coal Ash Influence =
(.98 X .05) + (.02 X .80)
.049 + .016 = .065
So for .016/.065 we have 25% influence in
total ash by adding 2% Ash Fuel.
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Ash Recovery from
Former Landfill Site
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Reburn and Displaced Coal
Annual Totals
140,000
120,000
Ash
100,000
Reburned
80,000
Coal
60,000
Displaced
40,000
20,000
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Fly Ash Placement into Storage Building
Fly Ash Utilization:
Cold In-Place Recycled Pavement
(Full Depth Reclamation)
Using fly ash as binder
for in-place stabilization
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Environmental Benefits
Cold In-Place Recycled Pavement
with Self Cementing Fly Ash
4,500
(5,000)
New Roadway Materials tons
(metric tons) 300 (330)
2,700 (2,100)
Metrial Landfilled cubic yards
(m3) 0
3,000 (11,400)
Diesel Fuel Consumed gallon
(liters) 500(1,900)
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CCP Utilization: Eco-Pad Stockyard Paving
Heavy Point Loads & Truck Traffic at Utility Service Center
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CCP Utilization:
Biofuel Storage Building Eco-Pad
Low cost, fast paving installation
Mixed in-place concrete
Using 93% recycled materials
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Biomass Co-Generation Plant
Rothschild, Wisconsin
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Combustion Products Utilization: Wood Ash
Annual Production
40,000 tons Btm Ash
15,000 tons Fly Ash
CCP Patented Technologies
Ash Fuel Reburn & Ash Recovery
Electrically Conductive Concrete & CLSM
Ammonia Removal from Fly Ash
Mercury Removal from Fly Ash
Carbon Sequestration -Fly Ash, Slag, CKD and LKD
Ash Alloy – Composite Metals
Dry Cenospheres Separation
Use of Ash Landfill Leachate for Production of
Concrete and Concrete Products
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Conductive Concrete
Imagine structures that are not harmed by lightning
Imagine bridges and overpasses that
never get icy.
CO2 Mineralization
Carbonated LW Aggregate
Cenospheres – Dry Separation
Ash Alloy Metal Matrix Composites
(a) (b)
(c)
(d)
CCPs - New Beneficial Uses
Ashphalt Research
Spray Dryer Ash for improved asphalt
paving with longer life and durability
Gypsum Research
Phosphorus Runoff Control on Agricultural Land,
Reducing Algae in Rivers and Lakes.
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New Beneficial Uses
Cenospheres Research
High Value Fly Ash Particles
for Manufacturing
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Sustainability Benefits
Benefits – Environmental, Economic, and Social
Use of combustion products benefits:
• Reduced CO2 emissions
• Reduced energy use
• Reduced water consumption
• Reduced demand for portland cement
• Conserves virgin materials
• Conserves landfill capacity
• Conserves land
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Concrete Benefits
Use of fly ash in concrete can enhance:
• Ultimate compressive strength
• Decrease permeability
• Improve long term durability
• Extend service life (the single most important factor
in reducing impact of embodied energy).
• Extended service life also decreases need for
demolition, removal and recycling of building
materials which reduces fugitive dust, greenhouse
gases and other potential environmental issues
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Conclusions
“Right thing to do”
Environment
Cement Industry
Construction Industry
Utility Customers
Utility Stockholders
Global Community
A Sustainable Future
Thank You – Questions ?