An Update on Combustion

Products Utilization in Wisconsin

Presented at Session 1 of Fly Ash in Concrete

Tribute to Tarun R. Naik

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

 4.4 million customers

 1.6 million electric customers
 2.8 million gas customers

 60% ownership of ATC

 70,000 miles of electric distribution
 44,000 miles of gas distribution
 9,400 MW of power plant capacity

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

Natural gas – 3,753 megawatts

 Port Washington Generating Station among the
lowest cost combined-cycle plants in country

Coal – 5,044 megawatts

 Oak Creek heat rate is top 5% in country

Renewables – 483 megawatts

 Wisconsin’s two largest wind farms and biomass plant

Hydro – 169 megawatts

*Owned nameplate capacity 9

Positioned for the Future
Supporting a Clean Energy Future

Over the past decade, WEC Energy Group has

implemented a multi-emission strategy to achieve
greater environmental benefit for lower cost
 Retired older, less-efficient coal-fired generation
 Added two combined cycle natural gas units
 Added state-of-the-art, coal-fired generation with
performance that ranks among the most thermally
efficient coal-fired units in the nation
 Invested more than $1 billion in renewable energy –
including the state’s two largest wind energy sites
 Invested more than $1.5 billion in air quality
systems

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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

Milwaukee Art Museum

High Rise Buildings

Miller Park - 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.

Ash Fuel Reburn is a key component of our program

Technologies are patented, and produce high quality fly
ash for concrete with numerous environmental benefits.
Uses remaining fuel value in currently produced and
recovered ash.
P4 and OCXP power plants have advanced Air Quality
Control Systems, and comply with air permits.

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Ash Reburn
Ash Recovery Process
(US Patent # 6,637,354)

Construction
Materials
Coal

Pleasant Prairie Energy

Power Plant

Stored Ash
Environmental
Benefits

Fly Ash Reburn

U.S. Patent
5,992,336

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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

Displaced more than 2,900 railcars

of coal since 2000!
335,000 Tons coal equivalent
Fly Ash Storage Facilities

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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

Energy Use and Materials

Full-Depth Reclamation vs. New Base
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trucks needed 12

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)

New Base Full-Depth Reclamation

Based on 1 mile (1.6 km) of 24 foot (7.3 m) – wide

2-lane road, 6-inch (150 mm) base

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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

Fly Ash, Portland Cement, Recycled Concrete

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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

Manufactured Composite Lumber

Fly Ash for Durable Building Products

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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 ?

Pleasant Prairie Power Plant

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