Coal Ash Matters - November 2023

23

November

THIS ISSUE - NOVEMBER 23 2

Editorial

3

Carbon Abatement Fund Update

4

Euro Coal Ash : Shifting Global Paradigm for CCP’s : Harvesting For The Circular Economy – ADAA CEO Craig Heidrich Presentation

5

Driving the Green Revolution in Construction: Calcined Clay as a Sustainable Substitute for Concrete

6

Emerging Trends in the Recovery of Ferrospheres and Plerospheres from Coal Fly Ash Waste

7

Latrobe Magnesium Progress With Three-Phase Development Plant

8

Ivan Skidmore Recaps ASHTRANS 2023

9

Concrete 2023 Recap

10

Mt Piper Power Station – Ash Repository Management

11

Dewatering Product for Coal Ash Waste

12

World Of Coal Ash Conference

14

Profile Piece: Joel Rickuss, Millmerran Operating Company

15

Concrete Institute of Australia Roadshow

16

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CCPs - a valuable resource

Views expressed in Coal Ash Matters newsletter do not

ADAA COAL ASH EDITORIAL TEAM

necessarily reflect the opinion of the Ash Development

Chief Executive Officer: Craig Heidrich

Association of Australia. All contributions are welcomed,

Contributors: Samuel Patane, Benjamin Grant

though the publisher reserves the right to decline or edit

Craig Heidrich, Deb O’Regan, Ivan Skidmore

for style grammar, length and legal reasons. ©2005-23.

Ben Eastwood Coal Ash Matters is a bi-annual publication

Editor: Benjamin Grant Design: 101 Design Circulation: 2000 ADAA | NOVEMBER 23

01

MEMBERSHIP COMPANY MEMBERS A primary role of the ADAA is to bring together producers and marketers of coal combustion products (CCPs).

Our activities cover research and development into CCP usage, advocacy and technical assistance to CCP producers and users, as well as a forum for the exchange and publication of CCP information.

For more information visit us at www.adaa.asn.au CURRENT MEMBERS • Adbri Limited www.adbri.com.au • BG&E Materials Technology www.bgeeng.com • Bilmar Solutions www.bilmarsolutions.com.au • Boral Quarries & Recycling www.boral.com.au • Cement Australia www.cementaustralia.com.au • CS Energy www.csenergy.com.au • Daracon Constructions www.daracon.com.au • Delta Electricity www.de.com.au • Dr. Jane T Aiken Consulting & Environmental Services www.cessoils.com.au • Energy Australia www.energyaustralia.com.au • Hills Barker Blower www.barkblower.com.au • Independent Fly Ash Brokers mflyash.com.au • Independent Cement & Lime www.independentcement.com.au • Intergen (Millmerran) www.intergen.com • Latrobe Magnesium www.latrobemagnesium.com • NRG Gladstone Power Station www.nrggos.com.au • Origin Energy Eraring Power Station www.eraring-energy.com.au • SA Premium Cement sapremium.com.au • Stanwell Corporation www.stanwell.com • Vecor Australia www.vecor.com.au RECIPROCAL MEMBERSHIPS • CSIRO www.cmit.csiro.au • European Coal Combustion Products Association (ECOBA) www.ecoba.org • UK Quality Ash Association www.ukqaa.org.uk • American Coal Ash Association www.acaa-usa.org • World Wide Coal Combustion Products Network (WWCCPN) www.wwccpn.org

EDITORIAL Welcome back to the second and final issue of Coal Ash Matters for 2023!

Since our previous edition, the Ash Development Association of Australia has seen lots of activity! In this issue, we begin with a Carbon Abatement Fund Update, and the recent signing of a Memorandum of Understanding between the NSW EPA and ADAA, forming the basis of the Partnership over the next 3 years.

Our ADAA CEO Craig Heidrich attended the 2023 EuroCoalAsh International conference in Warsaw, Poland, and presented a joint paper on behalf of the World Wide Coal Combustion Products Network to experts in the Coal Combustion Products industry from all over the globe.

We then focus on University of Melbourne’s Senior Lecturer, Engineer, and Academic Leader of the Geopolymer and Minerals Processing Group - Dr Rackel San, who is influencing investigations into maintainable, low-carbon alternatives to conventional concrete.

A pioneering study has revealed new opportunities to successfully recapture valuable materials from coal fly ash. This cutting-edge report suggests encouraging solutions for managing fly ash and provides great chances for the environment.

We look at two of our latest members: Independent Fly Ash Brokers and AGL, who are both contributing to the success of the industry. Independent Fly Ash Brokers continue to produce quality ash products from their South East Queensland facility, and AGL have committed to a ‘Climate Transition Action Plan’ which will see the lowering of carbon emissions in the years to come.

Latrobe Magnesium (LMG) are making great developments with their flagship Magnesium Demonstration Plant in Latrobe Valley, Victoria. After a recent capital raising, LMG are preparing to use the Company’s patented extraction process using industrial fly ash from Energy Australia’s Yallourn W brown coal generation Power Station.

Ivan Skidmore, with his role as Sales & Technical Director at Power Minerals in the United Kingdom and the ASHTRANS 2023 Organiser attended the conference in Rome, Italy, in September 2023.

ASHTRANS brings together over 100 people from businesses around the globe for two days of business networking, discussion, and debate. Ivan heard from many industry leaders about the international trade in low carbon materials, new technologies and supply chain developments, as well as natural pozzolans and the availability of modern day pozzolans, such as fly ash and he has provided us with a summary of what occurred over the two days.

This September the ADAA Team attended the Concrete Institute of Australia 31st Biennial National Conference in Perth. The theme this year was based around ‘Resilient and Sustainable Concrete: Breaking Down Barriers’, and covered all aspects of concrete materials, design, construction, repair, and maintenance that are relevant to our changing world.

Furthermore, we introduce a new dewatering product which is an environmentally neutral dewatering system for coal ash slurry from CRC, providng rapid safe removal to storage, disposal, or recycling sites.

The Ash Development Association of Australia would like to express their gratitude to all members for their ongoing support and contributions over the past 12 months, your achievements are nothing short of incredible! We cannot wait to report on your 2024 triumphs and look forward to working together again in the future.

ADAA | NOVEMBER 2023

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CARBON ABATEMENT FUND UPDATE

Following on from the NSW Government allocation $3.25 million, under the Carbon Abatement Fund, to support construction material industry efforts earlier this year, the Ash Development Association of Australia (ADAA) can report that progress is underway.

Following the outcome of the March election and change in NSW Government leadership the CEO of ADAA, Craig Heidrich continued to work closely with the NSW EPA and Penny Sharp, incoming Minister of Environment. In the month following NSW EPA underwent a restructure, moving responsibility of the funding into another programs portfolio.

Coincident with these ongoing changes, we [ADAA] continued our work with NSW EPA and conducted three (3) internal workshops with NSW EPA Industry Engagement & Programs Team members. In October, the Association signed a Memorandum of Understanding (MOU) between the NSW Government [EPA] and ADAA formalising the Partnership agreement prior to commencing mapping the milestones and deliverables for the Phase 1 project contract.

Phase 1 will involve a series of staged investigations working with our NSW based members and specialist service providers to validate and characterise resources [CCPs]. A series of industry stakeholder workshops are planned with key NSW Government agencies. CEO Craig Heidrich stated that, “the Association will be the key organisation responsible for coordinating, managing key deliverables. These include the potential opportunities along with side investigations such as harvesting protocols and pathways to enable utilisation.”

Phase 2 of this plan will become clearer once the Phase 1 report is complete, where opportunities will be evident. Members in NSW will be able to access the $2 million funding based on demonstration projects and job creation opportunities found in Phase 1.

The Carbon Recycling and Abatement Fund initiatives targeting coal combustion products opportunities are outlined below. Carbon Abatement Opportunities for Circular Economy study identified several remanufacturing and recycling opportunities based on carbon abatement potential. The Carbon Recycling and Abatement Fund will support the following opportunities concerning coal combustion products: 1. Coal Ash Pathways Research Partnership: The Environment Protection Authority (EPA) will partner with Ash Development Association of Australia to map and characterise ash repositories in NSW, gaining a better understanding of resource supply and applications to inform industry investment. $950,000 2.

Coal Ash Harvesting Infrastructure Fund: The EPA will provide funding to support feasibility trials targeting infrastructure and technology that improve access to stored coal ash repositories, informed by the findings of the Coal Ash Pathways Research Partnership with the Ash Development Association of Australia. $2 million

3.

New and Updated Government Material Specifications for Geopolymer and Portland Cement: The EPA will partner with NSW Government agencies to fast-track new and updated material specifications to build demand for geopolymer cement applications and coal combustion products in Portland cement. $200,000

4.

Publishing Coal Ash Supply Chain Information: The EPA will partner with NSW Government agencies to publish coal ash supply chain information and anticipate future demand. $100,000

For more information about these initiatives, visit the EPA website or contact the Ash Development Association of Australia to learn more and get involved.

ADAA | NOVEMBER 2023

03

EURO COAL ASH SHIFTING GLOBAL PARADIGM FOR CCP’S: HARVESTING FOR THE CIRCULAR ECONOMY

Euro Coal Ash 2023: An international conference that surrounds promoting the use of Coal Combustion Products (CCPs) in the construction industry within Europe and the entire world. This conference shares the experiences of specialists from business, industry, research, and government departments on the use of CCPs in the circular economy and construction industry in Europe.

In May, ADAA CEO Craig Heidrich attended and presented a joint paper on behalf of the Worldwide Coal Combustion Products Network at the 2023 EuroCoalAsh international conference in Warsaw, Poland.

Mr Heidrich presented his joint paper, ‘Shifting global paradigm for CCPs: Harvesting for the circular economy’ with Joachim Feuerborn from ECOBA, Europe.

Highlights from the presentation include the following: WHY THE WORLDWIDE COAL COMBUSTION PRODUCTS NETWORK EXISTS: 1. To stimulate the sharing and transfer of technical information.

2. To co-operate internationally for harmonisation of appropriate codes, specifications, and guidelines.

3. Promote internationally consistent and appropriate regulations, standards, and guidelines.

4. Facilitate the awareness and understanding of the environmental, economic, engineering, manufacturing and societal benefits derived from the use of CCPs.

Image: ACAA Executive Director Thomas H. Adams with ADAA CEO Craig Heidrich at Euro Coal Ash 2023 in Warsaw, Poland.

GLOBAL TRADE CHANGES 1.

2.

3.

4.

More than four million tonnes of CCPs traded globally or across borders, as opposed to three and a half million in 2010.

It has generated over US $115 million, an increase from US $101 million in 2010.

Eight countries are reporting trade of CCPs across 9 different HS codes, as opposed to six countries in 2010.

Long-term trends indicate that trade is expected to further increase.

STATE GOVERNMENT & INDUSTRY RESPONSE IN AUSTRALIA This included the NSW Government’s establishment of a +$37 million Carbon Recycling and Abatement fund, of which $3.25 million was allocated from the fund to support innovative circular economy approaches that manage CCPs more efficiently and reduce industry emissions.

This year’s conference themes revolved around the sustainability opportunities from CCPs. In particular, the increasing trend of harvesting from existing repositories to support low carbon applications, which is increasingly included in the new construction product regulations and is part of the considerations – for example, coal ash uses in all types of construction and engineering works.

ADAA | NOVEMBER 2023 04

DRIVING THE GREEN REVOLUTION IN CONSTRUCTION:

GALCINED CLAY AS A SUSTAINABLE SUBSTITUE FOR CONCRETE

Engineer, Senior Lecturer and Academic Leader of the Geopolymer and Minerals Processing Group at the University of Melbourne, Dr Rackel San Nicolas is driving research into sustainable, low-carbon alternatives to traditional concrete.

Australia will potentially find itself blessed with over 500 years of raw materials if calcined clay becomes a successful substitute for concrete. Dr San Nicolas believes that “shortly, both Australia and the rest of the world will extensively adopt calcined clay as a substitute for cement”.

Dr San Nicolas is currently driving research into what she believes to be the “greening of the concrete jungle” through developing better concrete knowing that the majority of the carbon footprint of concrete stems from limestone-based cement.

“This emerging calcined clay trend is not limited to developed regions such as Europe and the United States as developing countries such India and Africa are eager for a locally available alternative to cement” Dr San Nicolas states.

“The widespread support from numerous researchers further reinforces the potential of calcined clay. And considering that clay is found abundantly worldwide and can be calcined with minimal CO2 impact, it presents a remarkable opportunity to create concrete.”

We may be soon able to achieve zero emissions within the concrete production process as we phase out limestone-based cement.

The transition to what is known as geopolymer concrete would be relatively simple in Australia as there are already existing stockpiles of over 400 million tonnes of fly ash from the Australian coal industry, with around 30% of the stockpile being appropriate for use in concrete. However, as the coal industry is wound down and many cleaner energy generation methods are introduced, the supply of fly ash will not be constant, however, within many repositories, there is over 500 years’ worth of supply of clay that can be calcined.

At the current time, concrete with 50% cement is available, however, it may be only used for retaining walls and other less structurally important projects as confidence is yet to be built in products that engineers can design with.

Dr San Nicolas states that this may be a large hurdle for project designers and engineers to build confidence in these materials.

Additionally, many more suppliers are stating that by the end of 2023, there will be concrete that they can design with and will additionally have full-scale trials and data surrounding durability.

Dr San Nicolas states that excavated foundation clay being used to create cement concrete for the building that then sits on that foundation will be the ultimate goal, potentially revolutionising construction and engineering.

Coal industry waste can be utilised as a vital ingredient in the production of concrete similar to the likes of how spent brewers’ yeast is recycled into another product of value in vegemite!

Dr San Nicolas has been conducting research into how fly ash can not only be recycled into concrete as a cement alternative but can also replace concrete most environmentally dangerous ingredient as cement represents approximately 8% of global carbon emissions.

San Nicolas states that “you can make sustainable concrete in many different ways, but at the core, it is mainly about reducing the amount of Portland cement used.

The main approach that is being used is to utilise different waste materials such as fly ash, slag or different processed material such as calcined clay that have a much lower CO2 footprint.

ADAA | NOVEMBER 2023 05

EMERGING TRENDS IN THE RECOVERY OF FERROSPHERES AND PLEROSPHERES FROM COAL FLY ASH WASTE In a ground-breaking study, titled “Emerging Trends in the Recovery of Ferrospheres and Plerospheres from Coal Fly Ash Waste and Their Emerging Applications in Environmental Clean-up,” researchers have uncovered new avenues for the effective recovery of valuable materials from coal fly ash waste. This innovative research not only offers promising solutions for managing coal fly ash waste but also presents opportunities for environmental clean-up.

Coal fly ash, a by-product of coal combustion, has long been regarded as a significant environmental concern due to its potential for releasing harmful substances into the environment. However, this study, conducted by a team of experts from renowned institutions, highlights the potential of recovering ferrospheres and plerospheres from coal fly ash waste, opening new possibilities for environmental remediation.

dual benefit of waste reduction and resource utilisation underscores the importance of innovative research in waste management.

The findings of this study present a breakthrough in the field of coal fly ash waste management and environmental clean-up. By recovering valuable particles from this waste stream, researchers have not only addressed a pressing environmental concern but also uncovered new opportunities for sustainable resource utilisation.

The implications of this research extend beyond academia, as governments, industries, and environmental organisations can leverage these findings to develop effective strategies for waste management and pollution control. The potential commercialisation of the recovery process holds promise for creating a circular economy that maximises the value of waste materials.

IMAGE: Generalized scheme of the transformation of coal mineral matter during combustion. Adapted and modified from Kutchko and Kim (2006).

Ferrospheres and plerospheres are spherical particles found in coal fly ash waste, known for their unique chemical and physical properties. They have garnered considerable interest due to their potential applications in various industries, including construction, ceramics, and environmental remediation.

As the world continues to grapple with environmental challenges, innovative studies like this provide hope for a more sustainable future. The recovery of ferrospheres and plerospheres from coal fly ash waste and their subsequent applications in environmental cleanup mark significant progress in addressing waste management and pollution concerns. By harnessing the potential of these valuable materials, we can pave the way for a cleaner, greener planet.

The research team explored innovative methods to extract and recover these valuable particles from coal fly ash waste, emphasising the importance of sustainable waste management practices. By employing techniques such as magnetic separation and centrifugation, they were able to isolate and collect the ferrospheres and plerospheres efficiently.

The study also shed light on the emerging applications of these recovered particles in environmental clean-up. Ferrospheres and plerospheres possess adsorbent properties, making them effective in the removal of heavy metals, organic pollutants, and other contaminants from soil and water. This discovery could significantly impact the field of environmental remediation, offering a costeffective and sustainable solution for addressing pollution and contamination issues.

Furthermore, the recovered ferrospheres and plerospheres exhibit potential in the construction industry. These particles can be utilised as lightweight aggregates in concrete production, enhancing the material’s properties and reducing its environmental footprint. This

IMAGE_4: SEM micrographs of nonmagnetic 1 and magnetic particles (2–8) (A,B) collected from Uong Bi and Pha Lai fly ash. Adapted from Vu et al. (2019).

ADAA | NOVEMBER 2023 06

LATROBE MAGNESIUM MAKING PROGESS WITH THREE STAGE DEVELOPMENT PLANT PLANS Latrobe Magnesium (LMG) continues to make great progress on their flagship Magnesium Demonstration Plant in Latrobe Valley, Victoria, Australia. There has been no health, safety, or environmental incidents to date.

Project activities remain on budget and all equipment packages fully awarded, with a total of $17.5M committed to over 35 suppliers around the world.

Boosted by a recent $4.2 million capital raising, LMG is preparing to use the Company’s patented extraction process, which involves producing Magnesium Metal and Supplementary Cementitious Material (SCM) from industrial fly ash, a waste resource from Energy Australia’s Yallourn W brown coal generation Power Station.

All HAZOP’s have been completed for the Demonstration Plant, with engineering nearing completion and focusing on managing vendors and suppliers during fabrication and equipment close-out.

103 Twenty-foot Equivalent Units (TEU) of equipment and 138 tonnes of freight have been delivered to Site, including components related to critical long lead equipment, achieving the targeted delivery schedule.

External issues, such as recent changes in construction strategy and contractor negotiations have created risks in delivering the targeted outcomes in the given time. LMG is continuously undertaking project schedule reviews and optimisations, considering factors such as vendors, suppliers, and contractor timelines. Despite these difficulties, LMG is confident that the 1,000 tonne per annum Demonstration Plant will start operating by the end of the year.

The next phase of the development involves constructing a Commercial Magnesium Plant in the Latrobe Valley with a capacity of more than 10,000 tonnes per annum, to operate for over 20 years with current fly ash supply, if the Demonstration Plant is proven successful.

Stage 3, a Malaysian-based Mega Plant, in LMG’s development plan, is aiming to produce 100,000 tonnes of Magnesium metal using renewable energy to generate net-zero CO2 emissions.

LMG anticipates the signing of non-binding memorandums of understanding (MoUs) with various potential international equity partners in Q4 2023. The MoUs will assist in obtaining commitments to help contribute funding in proportion to any new partners equity holdings in the project.

Currently, Australia imports 100% of the 8,000 tonnes of magnesium annually disbursed by the industry. With the global magnesium market expected to grow at a Compounded Annual Growth Rate (CAGR) by 5.3% by 2028, these are encouraging signs for Latrobe Magnesium.

ADAA | NOVEMBER 2023 07

IVAN SKIDMORE RECAPS

ASHTRANS 2023

Delegates from across the globe attended the recent ASHTRANS conference in Rome. Set against a breath-taking cultural backdrop, over two days delegates discussed industry, innovation and business surrounded by the historic grandeur of the Italian capital where, 2000 years ago, the Romans perfected the use of natural pozzolans to create the first cement.

Fittingly for such an historic setting, the legacy of coal ash stockpiles was high on the agenda, with delegates hearing from Atritor and STET about their Trans-Atlantic collaboration to dry and size coal ash for beneficial use, and from UK-based Hive Aggregates on sourcing and securing value.

The availability of stocks in Europe, shipping insights from the EU area and the Med, and innovations in logistic handling reflected the global nature of the ash sector.

Finally, delegates heard how multi-industry net zero roadmaps are changing the course for SCMs. ASHTRANS organiser Ivan Skidmore, publisher of ASHES Magazine, said: “We’ve been overwhelmed by the positive feedback this year.

How are we going to top this? Being in the heart of Rome, falling out into the streets around the Spanish Steps and Peoples’ Square, just a few minutes’ walk from the Pantheon, the Colosseum and Vatican City, was amazing in itself.

“We had delegates from all over the world, with the prize for longest distance travelled going to David Howard, Senior Manager for Ash Management from AGL in Australia.

“Delegates were all talking about Lawrie Evans – a leading independent consultant from EmCem. His talk ‘Clinker: The Last Thing the Cement Industry need Right Now’ was purposefully provocative but straightforward and honest. It highlighted the practical challenges going forward to achieve net zero targets.

“Holcim’s Stefan Dietz was also the talk of the conference, demonstrating the wide scope of mineral components and technological innovation levers being deployed across the global business.

“As organisers, it was great to see people coming together and having deep interactions. During the networking breaks delegates used the quiet corners and meeting rooms to connect and do business, enjoyed breaking bread at the gala dinner, and built relationships while taking a refreshment during after dinner drinks in the courtyard of the palazzo ripetta.

“Into the second day, the conversation was driven on by ECOBA, Atritor, STET and Hive, with the talks covering a range of ways to unleash the availability of fly ash from legacy landfill.

“Finally, logistics and trade were discussed with Sylvie Doutres and Thomas Duve, chaired by Charlie Zeynal.

“It was clear that the future presented opportunities and challenges for the industry and the solutions were being sought by the people in the room.

Image: Ivan Skidmore's opening address at ASHTRANS conference in Rome, Italy.

“Roma Eventi - Piazza di Spagna conference venue was outstanding – from the stage where Federico Fellini previewed movies such as La Dolce Vita, we kicked of the conference with speakers giving perspectives from Europe, Turkey, Asia and North America.

“A combination of global trade and local sources from fresh generation and from legacy stockpiles will drive up the availability to meet demand – we are in the middle of some very exciting times – an era of rapid change. The industry is investing in the future and does have the tools needed to achieve our climate change targets.”

ADAA | NOVEMBER 2023

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The 31st Biennial National Conference, Concrete 2023, organised by the Concrete Institute of Australia (CIA) and its dedicated Committee, was a resounding success. Held at the Perth Convention & Exhibition Centre from September 10th to 13th, 2023, the event brought together members of the CIA, Ash Development Association of Australia (ADAA) and concrete industry professionals from across the globe.

The overarching theme of the conference, “Resilient and Sustainable Concrete: Breaking Down Barriers,” comprehensively addressed various facets of concrete, including materials, design, construction, repair, and maintenance, all of which are increasingly relevant in our ever-changing world. The primary objective was to convene global leaders in the concrete industry, fostering discussions on the present and future of resilient and sustainable concrete while identifying obstacles that may hinder progress.

The conference was expertly co-chaired by Rodney Paull and Shan Kumar, featuring a robust 3-day technical program that encompassed over 200 papers and presentations spanning more than 20 concrete related topics. Among the distinguished presenters, ADAA CEO Craig Heidrich made noteworthy contributions with his papers titled “Opportunities and challenges for coal combustion products with a Circular Economy” and “Low Carbon Concrete Pavement Innovation: Coal Combustion Products, Rigid and Flexible Pavement Application” exploring innovative approaches to utilise coal combustion products in concrete applications, shedding light on opportunities and challenges in the context of a circular economy and low carbon concrete pavement solutions.

Attendees were treated to special workshops delving into durability and innovative concrete practices, along with insightful keynote and invited speakers. The program culminated in a contractors’ forum, providing valuable insights into industry trends and challenges. Amidst the global challenges experienced in recent times, Concrete 2023 provided a platform for colleagues worldwide to reconnect face-to-face.

The conference facilitated the exchange of research findings, innovative ideas, and practical knowledge among industry experts.

Concrete 2023 in Perth, not only expanded our understanding of resilient and sustainable concrete but also reinforced the importance of collaboration in advancing the concrete industry. We Thank the Concrete Institute of Australia for making this conference a memorable and enriching experience. We eagerly look forward to future gatherings that continue to drive innovation and excellence in our select industries.

ADAA | NOVEMBER 2023 09

ENERGY AUSTRALIA WINS ENVIRONMENTAL AWARD FOR ASH REPOSITORY MANAGEMENT The team at Mt Piper Power Station have won an Environmental award for the design and installation of a leachate barrier management system to prevent the contamination of surface water and groundwater.

The contamination of water resources from ash repositories and dams associated with coal fired power plants is a global issue. Brine water, salts and ash are waste products from coal fired power plants and are known to leach contaminates (chlorides and metals) into surrounding surface and groundwater. This impacts the environment, communities and often breaches operating licences and approvals, exposing business to possible prosecution by local authorities.

The design, development, and installation of an integrated leachate barrier management system to prevent contaminated water entering the environment was carried out by Mt Piper Asset engineers, the environment and procurement teams, along with specialist consultants and contractors.

This process involved modifying existing practices and gaining relevant state approvals to install a new technology and method to prevent contamination. Several internal stakeholders across multiple teams were involved in the successful planning, engineering design, procurement, supply, and installation of the leachate barrier management system.

Figure 1: The multiple stages during the installation and use of the leachate barrier management system at the Mt Piper Power Station

The leachate barrier management system represents an engineered environmental control measure that eliminates the risk of contamination to water resources.

The benefits and results that were achieved were immediate. These included: • • • • •

The successful installation & operation of the first stage of the Leachate Barrier Management System in April 2022 Providing local authorities, regulators, community and special interest groups with greater confidence that water contamination will not occur Allowing for higher concentrated waste materials including brine wastewater and solid salts to be disposed Extending the life of the ash repository through the disposal of higher concentrated waste materials with less volume Supporting the transition of sourcing water from local river catchments to using saltier groundwater from underground mines at the Mt Piper Power Station

This is one of the first leachate barrier management systems installed at an Australia coal fired power station and demonstrates EnergyAustralia’s commitment to proactive and preventative environmental management.

ADAA | NOVEMBER 2023

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DEWATERING PRODUCT

FOR COAL ASH CRC is a solutions-based manufacturer and distributor, delivering sustainable products and solutions to industry, for dewatering, waterproofing and stabilisation.

Coal Combustion Products (CCPs) – often referred to as “coal ash” and including “fly ash” and “bottom ash” – are solid materials produced when coal is burned to generate electricity. There are many good reasons why the 12 million tonnes of CCPs generated annually are viewed as resources. Quickly dewatering these residuals from storage ponds delivers significant critical path savings.

Dewatering coal ash is critical to transforming holding ponds that are hazardous to the environment and surrounding communities into safer and sustainable disposal storages by dry stacking and other disposal methods. Coal Ash disposal and storage methods have attracted the attention of mining operators and research communities worldwide due to the increasing mining practices and environmental protection regulations.

Solid-liquid phase separation as applied to dewatering of fine coal tailings poses a major technological and environmental challenge to the coal industry effort to advance ash disposal and recycle water while capturing fine mineral particles that negatively affect the performance of coal processing. Current solid-water separation technologies have been aimed at achieving better solutions that can produce an end-product with lower moisture content, together with increased solids recovery to significantly improve the quantity and quality of process water for recycling, while reducing the transportation cost and environmental effect during the disposal process.

Super absorbent polymer, also referred to as ‘SAP’ or ‘super absorbent material’ (SAM), is used in a broad range of applications for both consumer and industrial markets due to their incredible affinity for water and water-based solutions, typically absorbing up to 300 - 500 times their own weight of liquid. SAPs were first developed in the 1960’s by the US Department of Agriculture as part of a project to improve water conservation in soil. This initial polymer was based on acrylonitrile polymer attached to starch molecules.

However, over time the chemistry advanced and the use of starch-

based polymers diminished and more modern SAP technology were developed based on crosslinked acrylic polymers.

CRC’s 950 Coal Ash Dewatering Product is part of the SAP family more specifically containing Carbon Chemistry (neutral carbon compounds).

CRC’s 950 Dewatering Product is an environmentally neutral, dewatering system for coal ash slurry. This granular powder made from 100% pure uncut material, Consolidates & Dewaters the coal ash slurry making it easily portable by any mechanical means, providing rapid safe removal to storage, disposal, or recycling sites.

Our key solutions-based deliverables: • • • • • • • •

Solidification mitigates negative effect of coal ash in ground water (encapsulating most heavy metals) Requires a very small amount, absorbing 300 - 500 times its own weight High early reaction time Environmentally friendly, non-toxic, VOC free Continues to absorb moisture (rain & wicking ground water) Reduces or eliminates the need for cement or LKD EPA compliant material Highly compactable

If your corporation needs to deliver coal ash solutions and significant critical path savings, please contact our local distributors: Darren and Deborah O’Regan Representatives in Australia for The Specialty Products Group & CRC Coatings DOR Trading Pty Limited Trading as IMCO Australasia PO Box 112, Albury NSW 2640 Phone: 1300 038 855 Mobile: 0422 084 581 Email: deb.oregan@imcoaust.com.au

FOOTNOTE 1.

Significant Labs testing has proven CRC 950 encapsulates most coal ash hazardous chemicals including Arsenic, Lead, Mercury and some Hydrocarbons (Detailed Reports Available).

2.

Detailed isotope testing to determine the long-term stability of 950 in the environment has yielded 76% stability over a100 year period.

ADAA | NOVEMBER 2023 11

10 WORLD OF COAL ASH CONFERENCE TH

World of Coal Ash (WOCA) is an international conference organised by the American Coal Ash Association (ACAA) and the University of Kentucky Centre for Applied Energy Research (UK CAER).

In May 2024, ACAA and the University of Kentucky Centre for Applied Energy Research UK CAER will be jointly hosting the 10th World of Coal Ash Conference in Grand Rapids, Michigan. While planning has already begun for WOCA 2024, the technical program is still in its early stages of being organised, and the Call for Papers is officially open.

The 2024 conference is the 10th joint biennial meeting with a focus on the science, applications, and sustainability of worldwide coal combustion products (CCPs) as well as gasification products.

The previous World Coal Ash Conference was in 2022, which set a record for presentations, and had over 1,000 attendees at the Northern Kentucky Convention Centre.

The conference will be held on 13-16th May, with call for abstracts closing December 18th, 2023.

Previous attendees, such as Lisa Bradley from Haley & Aldrich stated, “if you want to know about coal ash, and you want to know the companies that work in the field of coal ash, and the people that work in the field of coal ash, you need to be at WOCA. that’s the place to be.”

John Seymour, Senior Principal at Geosyntec Consultants also said, “it’s one of the most valuable events I go to because I meet a lot of clients and learn a lot about what other people are doing.”

ADAA | NOVEMBER 2023

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WOAH!! THE WOCA ABSTRACT DEADLINE IS NEARING! Been waiting for the last-minute to submit an abstract to the World of Coal Ash 2024 in Grand Rapids, Michigan? Well, the last-minute is here! The WOCA 2024 abstract deadline is December 18th.

Submitting an abstract for WOCA 2024 is quick and easy!

Log on to the official WOCA website and ensure you and your team will be heard at WOCA 2024.

Learn more here: www.worldofcoalash.org/speakers/

Unveiling the New Coal Ash Library

Since the very beginning of WOCA, The World of Coal Ash have kept a repository of all of the talks on the Coal Ash Library. The ash library received a much-needed facelift this summer and early fall. Please check it out at: www.coalashlibrary.com. It is a great resource for anyone in the coal ash industry. And with that historical information, it is the best source for seeing how far technology has come since WOCA 2005.

Become a WOCA Exhibitor or Sponsor

If you are looking to have an exhibit booth or be a WOCA sponsor, this is the time to act. Opportunities are still available but are going fast. Contact ACAA’s Alyssa Barto to figure out how best to market your company to the best coal ash audience in the world.

WOCA 2024 to Feature Two Short Course Options

What’s better than the WOCA Short Course? Two WOCA Short Courses! For the first time in WOCA history, The World of Coal Ash will be offering two separate short course options. WOCA 2024 will feature Short Course 101 and Short Course 301.

Short Course 101 is designed for those new to the industry or for those who are looking to brush up on the coal ash knowledge.

Short Course 301 is recommended for attendees with a basic understanding of groundwater and CCR chemistry. This option is for participants who are veterans in the field and looking into a more technical education on the latest CCR rules.

As in past years, WOCA Short Course will be held on Monday prior to the beginning of the full WOCA meeting (Monday, May 13, 2024). Attendees must register for the Short Course AND the full WOCA conference if you wish to attend both activities.

WOCA Registration Easier than Ever Before The WOCA team has streamlined and simplified the registration process. Register here: www.woca2024.exordo.com/login Should you have any questions about registrations, you can learn more on the WOCA website. The website provides complete pricing information, early-bird deadlines and other pertinent information.

Book Your Stay at WOCA’s Host Hotel

Get the most out of your WOCA experience by staying at the WOCA host hotel, the historic Amway Grand Plaza. Located in the heart of downtown Grand Rapids – and just steps away from where WOCA will take place – you will fall in love with the grandeur and ambience of Grand Rapids’ finest hotel. Book your room today!

ADAA | NOVEMBER 2023 13

PROFILE PIECE:

JOEL RICKUS MILLMERRAN OPERATING COMPANY

Joel Rickuss has been involved in the mining and power generation industry for roughly 15 years, holding a wide range of roles. For the last 10 years, Joel has worked as an External Resources Manager, controlling site management teams who look after mining and coal handling operations, including ash management.

Recently, Joel has undertaken the role of Production Manager at the Millmerran Power Station. This encompasses the management of day-to-day maintenance and operations.

Working from the Millmerran Power Plant in Queensland, this is one of the most reliable base load power stations in Australia and has been operating for over 20 years.

Coming from an environmental management background, Joel believes that the power generation and mining industry has changed significantly, and is developing valuable ways to contribute to environmental management.

His previous role as External Resources Manager was focused on external contractors and major contracts associated with mining, coal and ash handling, water supply, environmental management and community issues.

“The mining and power generation industry is constantly active, and with the current transition phase that is occurring in most companies, there is a real once in a generation challenge for the industry to be part of and being in a management role at this time is exciting!”

Joel believes there has been an important shift in awareness of Coal Combustible Products (CCP) and how to recycle and reuse them since he first began his career. He also considers technology as being one of the key revolutions in maintenance and operations monitoring with remote equipment. Additionally, Joel states that enhancements in IoT remote plant monitoring are improving the ability to efficiently undertake their roles.

The Ash Development Association of Australia would like to thank Joel for his contributions to this edition’s Coal Ash Matters magazine and wish him all the best with his new role.

Image: Joel Rickus & Millmerran Power Plant ADAA | NOVEMBER 2023

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CONCRETE INSTITUTE OF AUSTRALIA

ROADSHOW LOWER CARBON ALTERNATIVE BINDER CONCRETE

With the current focus on sustainable concrete construction solutions, the use of alternative binders in concrete has been an area of research, development, testing and discussion for some time.

However, with the recent release of the Australian Standard document TS199 “Design of geopolymer and alkali-activated binder concrete” there is now a specific guideline for the industry to design and specify Lower Carbon Alternative Binder Concrete in a practical way to respond to some of the challenges posed by traditional cement and concrete, and to help reduce the carbon footprint of the construction industry.

The Concrete Institute of Australia has stated that they are thrilled to announce the National Roadshow on Lower Carbon Alternative Binder Concrete. Two highly regarded industry experts in Professor Stephen Foster and Dr James Aldred will be presenting on this highly topical subject, with specific reference to the new Standards Australia TS 199 document, and to discuss further developments that are taking place in this sector.

Join the CIA from the 27th November to the 7th of December in 5 different states to gain valuable insights and learn how to implement this exciting technology:

SYDNEY: Monday 27th, November BRISBANE: Tuesday 28th, November MELBOURNE: Monday 4th, December ADELAIDE: Tuesday 5th, December PERTH: Thursday 7th, December

The invited speakers - Professor Stephen Foster (UNSW) and Dr James Aldred (Future Concrete) will present on the following topics: Design procedures and structural considerations when using geopolymer or alkali activated binder concrete in accordance with AS TS 199 - Presented by Professor Stephen Foster Synopsis: The recently released SA TS 199:2023 “Design of geopolymer and alkali activated binder concrete (GPC and AABC) structures” provides requirements and guidance for the design and construction of alternative binder concrete building structures and members that contain reinforcing steel or tendons, or both.

This presentation looks at how GPC and AABC structures can be designed for ultimate strength and serviceability limit states as set out in AS/NZS 1170.0 and AS 3600. The models developed AS TS 199 for predicting deformation due to shrinkage and creep of GPC and AABC will also be discussed.

Material properties of geopolymer or alkali activated binder concrete. Presented by Dr James Aldred Synopsis: There are many different geopolymer and alkali activated binder concrete (GPC and AABC) systems available with a wide range of material properties. AS TS 199:2023 provides guidance on both systems that achieve their hardened properties at ambient temperature and systems that are heat cured. GPC and AABC have been the subject of much research and offer alternatives to ordinary Portland cement (OPC) based concrete in a variety of applications.

Potential benefits of concrete may include improved chemical resistance and reduced CO2 impact. This presentation discusses the mechanical and durability properties of GPC and AABC and the recommended performance requirements for their use in building structures and members designed to AS/NZS 1170.0 and AS 3600.

Some practical considerations when using these alternative binders are presented as well as examples of structures and members constructed with GPC and AABC. We hope that you can join us for this valuable seminar that will assist all designers, specifiers, constructors, researchers, and suppliers in working towards a consistent pathway towards carbon neutral concrete.

FOOTNOTE 1.

Significant Labs testing has proven CRC 950 encapsulates most coal ash hazardous chemicals including Arsenic, Lead, Mercury and some Hydrocarbons (Detailed Reports Available).

2.

Detailed isotope testing to determine the long-term stability of 950 in the environment has yielded 76% stability over a100 year period.

ADAA | NOVEMBER 2023 15