Coal Ash Destruction Report Sept. 2000

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CONFIDENTIAL

TREATMENT OF A VR FLY ASHBY CEMENT-LOCKsM TECHNOLOGY

Prepared by:ENDESCO Services. Inc.1700 S.Mt Prospect Road

Des Plaines, Illinois 60018

Submitted to:

C O N F I D E N T I A LSeptember 2000


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TREATMENT OF AVRFLY ASHBY CEMENT -LOCJ(SMTECHNOLOGY

SUMMARYThe AVR fly ash was analyzed for its major and minor oxides by XRF method. The analysisshowed that the fly ash contains 42.5% Si02, 23.1 % CaO, 11.1% A1203, and 4.0% F~03'The fly ash was mixed with naturally occurring modifiers (90% fly ash + 10% modifiers wtratio) and processed in a laboratory-scale equipment to produce Ecomelt'" utilizing theCement-Lockf" Technology.The Ecomelt was analyzed for total metals and their leaching behavior (for eight RCRAmetals + Antimony, Molybdenum, and Vanadium). All of the metals are present in the flyash, however, none of the metals was detected in the leachate except Barium. Theconcentration of Barium in the leachate was 0.065 mg/1; the regulatory limit for Barium is100. Therefore, all heavy metals are immobilized within the Ecomelt matrix in its silicatenetwork, rendering it environmentally stable. The Ecomelt easily passes the US EPA TCLP.The Ecomelt was also examined by the Construction Technology Laboratories, Inc. (CTL;research arm of the Portland Cement Association) using microscopic and XRD techniques.The samples were examined under an optical microscope using both the plane-polarized andcross-polarized light. The amount of amorphous phase was visually estimated to be more that98 percent. A broad hump in the XRD pattern also confirmed the amorphous (non-crystalline) nature of the Ecomelt. Based on the amorphosity of the Ecomelt, the material issuitable for producing construction-grade cement.

FLY ASH CHARACTERIZATIONThe AVR fly ash received from. was analyzed by the Construction TechnologyLaboratories, Inc. (CTL; researc arm of the Portland Cement Association) for its major andminor oxides by the X-ray Diffraction (XRF) method. The XRF. ~ysis showed that the flyash contains 42.5% Si02, 23.1%CaO, 11.1% A1203 a nd 4.0% F~03 (Table 1). As per theASTM 618 Specification, the ash is a Class C fly ash since (Si02 + J\l203 +F~03) is between50% and 70% by wt. The fly ash contains 3.42% carbon (average of two values, namely,3.08% and 3.76%; lab reports are included in the Appendix).

ECOMELT PRODUCTIONBased on the fly ash characteristics, a recipe for producing Ecomelt was determined. Thefeed mixture for Bcomelt production consisted of90% fly ash, 9% Modifier 1 (Limestone),and 1%Modifier 2 (Alumina). The modifiers are naturally occurring mineral materials.Because the ash contained particles as large as 1 em, it was milled to pass 60 mesh (250j.1m)prior to mixing with the Modifiers.

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Table 1. OXIDE ANALYSIS OF AVR FLY ASHAnalyte %wt.Si02 42.51Al203 11.10Fe203 3.96CaO 23.12MgO 2.49S03 3.60Na20 2.27K20 1.31TiOz 1.81P205 1.31Mn203 0.09srO 0.07Loss on Ignition 5.17Undetermined 1.18

Total 100.00

APPARATUSThe feed mixture was fused in a bottom-loading electric furnace shown in Figure 1. TheKanthal molybdenum disilicide ceramic heating elements are capable of producingtemperatures in the furnace up to 18000(; (3272F). The furnace is capable of controlled-atmosphere operation. Crucibles are introduced and withdrawn through the furnace bottom,resting on a ceramic pedestal which can be rotated by hand.The air is passed through a flow meter and then to an air inlet tube using a diaphragm pump.The tube is an aluminum oxide tube, extending down from the top of the furnace to slightlybelow the crucible rim. Because the air tube is off the crucible axis, it is used fully loweredto stir molten material by rotating the pedestal.The cylindrical fusion crucible has a capacity of 500 ml, and is made with 99 percentaluminum oxide. The inside diameter and depth are 6.6 em and 14.6 em, respectively.Fusion crucible is placed inside a guard crucible (not shown in Figure 1) of similar materialbut 1.2 em larger diameter to protect equipment from any escaping molten material from thefusion crucible.

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A ir inlet tube _H ea tin g e leme nts _-_ - -;- - -- _ __-

Air flow meter - _

~ -Insulation

T }- Furnace temperaturecontrol ler

- - -C ruc ible---Pedestal

- -HandleP edestal is ro tated to stir slag in c ruc ible

Figure 1. APPARATUS FOR ..ECOMELT SAMPLE PREPARATION

TEST PROCEDUREThe unit c an p ro cess abo ut 425 gm o f m aterial during a test. T herefo re, a series o f tests w e reco nduc ted to p ro cess all the f ly ash m aterial. T esting w as p erfo rm ed w ith the c ruc ibleunco vered in air. The m olten m aterial w as heated until no m ore so lid m atter rem ained in themelt, as detec ted by lo w ering the air tube to feel the c ruc ible bo tto m. T he final tem peratureranged fro m 1350 to 1400C (2462 to 2552F ). W hile at that tem perature, the m elt w asstirred by ro tating the p edestal w ith the air tube near the c ruc ible bo tto m.The m olten m aterial w as held at the abo ve sp ec if ied tem perature fo r abo ut 30 m inutes; thenthe p edestal w as lo w ered belo w the furnac e bo tto m. The fusio n c ruc ible w as rem oved f ro minside the guard c ruc ible w ith to ngs. The m olten m aterial w as p oured into ro om tem peraturew ater, w here it rem ained brightly lum ino us fo r several seco nds w hile under w ater. So me o fthe m elt w as to o visc ous to p our, o r began to so lidify in the co oling c ruc ible, so the c ruc iblew as thro w n into the w ater to quenc h the m aterial rem aining in the c ruc ible. T he quenchedm aterial is referred to as E co melt.T he Eco melt w as sep arated fro m the quench w ater by dec anting, and w as rinsed w ith p urif iedw ater befo re drying at 90C in an o ven.T he m olten m aterial w a s benign in its c orro sive behavio r to w ard ref rac to ries in the labo rato ry

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furnace. Dissolution of aluminum oxide crucible walls was negligible. This favorable resultmeans the material selection will be less problematic in engineering scale up.

ECOMELT CHARACTERIZATIONThe Ecomelt has a shiny, black, glassy appearance. It is easily crushed and pulverized.The Ecomelt was analyzed for total metals. metals leachability (US EPA TCLP). andamorphosity .

Leaching CharacteristicsThe Ecomelt was analyzed for total metals as well as metals leachability by CommercialTesting & Engineering Company (a testing lab), South Holland, Illinois. The fate ofAntimony (Sb), Molybdenum (Mo), and Vanadium (V) is of special interest to ~Therefore) the Ecomelt was analyzed for these metals as well as eight RCRA metals. Theresults are shown in Table 2; copies of the laboratory report are included in the Appendix.None of the metals was detected in the leachate except Barium. The concentration of Bariumin the leachate was 0.065 mgll; the regulatory limit for Barium is 100. Therefore, all heavymetals are immobilized within the Ecomelt matrix in its silicate network by ionic replacement,rendering it environmentally stable. The Ecomelt easily passes the EPA TCLP.

Table 2. TCLP RESULTS ON ECOMELT PRODUCED FROM AVR FLY ASHTCLp

RegulatoryEcomelt Limit

- - - - - - - - - - - - - - - - - - m ~ - - - - - - - - - . - - - - . -NDNDND

Metal FlyAs~.- mglkg (dry) -402319

AntimonyMolybdenumVanadiumArsenicBariumcadmiumChromiumLeadMercurySeliniumSilver

9.17306 . 92109 6NDND3.7

ND0.065NDNDNDNDNDND

5100155

0.215 Toxicity Characteristic Leaching Procedure.

/) L _ J I c . N D f 2 . , c.. ./( S'e Cd 11CIv T - L ()Lt1. CDrl4 C O N F ' O E N T \ A L


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Microscopic and X-Ray Diffraction MeasurementsBoth the microscopical and X-ray Diffiaction (XRD) tests were performed by CTL on theground Ecomelt sample. The sample was examined under an optical microscope using boththe plane-polarized and cross-polarized light. The amount of amorphous phase was visuallyestimated by CTL to be more that 98 percent (Figure 2). A broad hump in the XRD patternalso confirmed the amorphous (non-crystalline) nature of the Ecomelt (Figure 3).Based on the amorphous nature of the Ecomelt, as determined by the above tests, the materialis suitable for producing construction-grade cement.

Report_A VR]JyAsh.doc

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Cross-polarized light image of the Ecomelt powder dispersed in propylene glycoland viewed with 530-nm accessory plate. Amorphous material is the color of thebackground. Crystalline material is shown as the bright yellow-red crystal.Estimated amorphous content is 98% or greater.

Figure 2. PHOTOMICROGRAPH OF ECOMELT(Work Performed by Construction Technologies Laboratories, Inc.)

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! " " " - ' I : i ': 'iI __ ,__' r I

i

29 (CuKa)Figure 3. XRD PATTERN OF ECOMELT*

A Hump in pattern confirms the Amorphous nature of Ecomelt.(Work Performed by Construction Technologies Laboratories, Inc.)

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COMMERCIAL TESTING &ENGINEERING CO.G EN ER AL O FF IC ES : 1 91 9 S OU TH H IG HLA ND A VE .. S UIT E 2 10 -e. L OM BA RD . IL LIN OIS 6 014 8 TE L: 63 0- 95 3- 930 0 F AX : 6 30 -95 3-9306

~SGS M em ber o f tile S GS G ro up (S oc ie te G en 6ra le d e S urv eilla nc e)S IN CE 19 08 4J

~May 30, 2000ENDESCO SERVICES, INC.1700 S. MOunt Prospect RoadDes Plaines, IL 60018Attn: Anil Goyal, PhD, PE

ADDRESS ALL CORRESPONDENCE T1 61 30 V AN ORUNEN RS OU TH H OlLA ND , IL 60 4

T EL : (7 08 ) 3 31 -2 90F AX : (7 08 ) 3 33 -306

Sample identification byEndesco Services, Inc.

Kind of samplereported to us Fly AshSample taken at ------Sample taken by E nd es co S er vi ce s, Inc_

Date sampled ------D at e r ec eiv ed May 24, 2000

Sample ID: ARV1

Analysis Report No. 71-122841 Page 1of

Dry Basis, Carbon 3.76

!!tl!!mCarbon: ASTMD 5373

Respectfully submitted,~NGgENOl~:'J ME MBe : H o I : O O ~ . ,r -- -\

OVER 4 0 B RANCH LABORATOR IE S S TRATEG ICAL LY LOCATED IN P RI NC IP AL COAL M INING AREAS, T IDEWATER AND GREAT LAKE S POR T S, AND R IVER LOADING FAC tU~ W ate rm a r k e d F o r Y o u r P r o t e c t io n mw s A N D C O N D I'T lO N S O N R E VE R S E


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COMMERCIALTESTING. ENGINEERINGCO.GENERALOFFICES: 1919 SOUTH HIGHlAND AVE . . SU I TE 210-8. LOMBARD. ILLINOIS60148 TEL:630-953-9300 FAX:630-953-9306

~ SGS Member of the SGS Group (Socl6t6 Gt!Mrale de Surveillance)SINCE 19080May 30, 2000

A DD RE SS A lL C OR R ES PO ND EN CE T1 61 30 V AN D RU NE N RSOU TH HO L lA ND , IL 6047TEL : ( 7 08) 331 290FAX: ( 7 08) 333-306~ ENDESOO SBRVICES, INC.1700 S. Mount Prospect RoadDes Plaines, IL 60018Attn: Anil Goyal, PhD, PB S am pl e i de nti fi cat io n b yBndesco Services, Inc.

Kind of samplereported to us Fly AshSample taken at ------Sample taken by Endesco Services, Inc.

D at e sa mp le d - - - - - -Date received May 24, 2000

Sample ID: ARV2

Analysis Report No. 71-122842 Page 1of

Dry Basis, Carbon 3.0B

METHODCarbon : ASTM D 5373

Respectfully submitted.rERC IA L TEST ING & E NG IN E E RI NG CO.c. /J~' MEMBER~. \S o ut h H o ll an d L a bo ra to ryO V ER 40 B RA NCH L AB O RA TO R IE S sm AT EG IC AU .~ L OCAT ED IN P RIN CIP AL C OA L M IN IN G A REAS , T ID EWAT ER A ND O R EA T L AK ES P OR TS , A ND R IV ER L OA DIN G F AC IL IT

t#nal Watennarked For Your Protection T ER M S A N D C O NO IT 1 ON S O N R E VE R SE


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COMMERCIAL TESTING &ENGINEERING CO.G EN ER AL O FF IC ES : 1 91 9 S OU TH H IG HL AN D A VE " S UIT E 2 10 -B , L OM B AR D, I LL IN O IS 6 01 48 T E L: 6 30 -9 5 3- 93 0 0 F A X: 6 30 -9 53 -9 30 6

S IN CE '9 08 ~ "BGB Member of the SGS Group (Societe Generale de Surveillance)Committed To Excellence ADDR ESS ALL CO RR ESPO NDENCE16130 VAN DRUNEN

S OU TH H OL LA ND , IL 604T EL : ( 70 8) 3 31 -2 9F A X: ( 70 8) 3 33 -3 0

September 15, 2000

. ~ ENDBSCO SBRVZCBS, INC 1700 S. Mount Prospect RoadDes Plaines, IL 60018Attn: Anil Goyal, PbD, PB

Sample identification byBndesco Services, Inc.

Kind of samplereported to us BcomeltSample taken at ------ Sample ID: Bcomelt from AVR Fly Ash

Sample taken by Bndesco Services, Inc.Date sampled ------

Date received September 6, 2000Analysis Report No. 71-131591 Page 1 of 3

T OT AL A NAL YS IS : J IB 'l 'A LSPARAMETER CAS NO. RESULT FLG RLIMIT UNITS S METHOD DATE/TIME/ANALYST DJ:LFArsenic, As [7440-38-2] 9.1 0.75 lng/Kg SW6010 09/13/00 17:05 JWJ 1.0Barium, Ba [7440-39-3] 730 0.15 lng/Kg SW6010 09/13/00 17:05 JWJ 1.0cadmium, Cd [70640-43-9] 6.9 0.15 mg/Kg SW6010 09/13/00 17:05 JWJ 1.0Chromium, Cr [7440-47-3] 210 0.75 mg/Kg SW6010 09/13/00 17:05 JWJ 1.0Lead, Pb (7439-92-1] 96 0.75 mg/Kg SW6010 09/13/00 17:05 JWJ 1.0Selenium, Se [7782-49 -2] NO U 0.75 mg/'Kg SW6010 09/13/00 17:05 JWJ 1.0Silver, Ag [7440-22-4] 3.7 0.75 lng/Kg SW6010 09/13/00 17:05 JWJ 1.0Antimony, Sb [7440-36-0] 40 0.75 lng/Kg SW6010 09/13/00 17:05 JWJ 1.0Molybdenum, Me [7439-98-7J 23 0.75 mg/Kg SW6010 09/13/00 17:05 JWJ 1.0Vanadium, V [744-62-2] 19 0.75 mg/Kg SW6010 09/13/00 17:05 JWJ 1.0Mercury, Hg [7439-97-6] NO U 1.10 lng/Kg 7471 09/11/00 16:03 JC2 1.0

NO : Not detected at a concentration greater than LeO - Limit of Quantitation.Method Reference: USBPA: Test Methods For Bvaluating Solid Waste; SW-846, 3rd Bdition; Nov 19TCLP Extraction Procedure and Regulatory Levels: 40CFR; Part 261.24 and Appendix II.

Respectfully submitted,C OM ME RC IA L T ES TIN G & E NG IN EER IN G C O, MEMBER

r - 6: ~I ~--N "'U doulh Holland Laboratory OVER 40 BRANCH lABORATORIES STRATEGICAlLY LOCATED INPRINCIPAL COAL MINING AREAS, TIDEWATER AND GREAT LAKES PORTS, AND R LOADING FACIU

F465O r ig in al w a te rm ar ke d F o r Y o ur P ro te ct io n T EA M S A N D C O N D I l lO N S O N REVERSE


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COMMERCIAL TESTING &ENGINEERING CO.GENERAL OFFICES; 1919 SOUTH HIGHLAND AVE . SU IlE 210-8. LOMBARD. ILL INOIS 60148 ' TEL : 630 -953-9300 FAX; 630-953-9306

SINCE 19088 ~5iG5i Member of the SGS Group (Societe Gllnerale de SUrvei l lance)Committed To Excellence ADDRESS All CORRESPONDENCE TO

16130 V AN D RUN EN RSOUTH HOllAND. Il 60473TEL: (708) 331-290FAX; (70B) 333-3060~ september 15, 2000ENOESCO SBR~CBS, INC.

1700 S. MOunt Prospect RoadDes Plaines, IL 60018Attn: Anil Goyal, PhD, PE S am pl e i de nt if ic at io n byEndesco Services, Inc.

Kind of samplereported to us EcameltSample taken at ------ Sample ID: Ecamel t from AVR. Fly Ash

S am pl e t ak en by Bndesco Services, Inc.Date sampled ------

Date received September 6, 2000

Analysis Report Ho. 71-131591 Page 2 of 3

TOXICI"rY CHARAC'1'BRISTICLEACHATE PROCBDtJRB: HB'.rALSPARAMETER CAS NO. RESULT FLG RLIMIT UNITS S METHOD DATE/Tr.ME/ANALYST DILFArseniC, As [7440-38-2] NO u 0.10 mg/L SW6010 09/14/00 08:12 CBS 1.0Barium, Ba [7440-39-3] 0.065 0.050 mg/L SW6010 09/14/00 08:12 CBS 1.0cadmium, Cd [7440-43-9] NO u 0.020 mg/L SW6010 09/14/00 08:12 CBS 1.0C hr am i um , C r [7440-47-3] NO U 0.050 mg/L SW6010 09/14/00 08:12 CBS 1.0Lead, Pb [7439-92-1] NO u 0.10 mg/L SW6010 09/14/00 08:12 CBS 1.0Seleni um, Se [7782-49-2} NO U 0.20 mg/L SW6010 09/14/00 08:12 CBS 1.0silver, Ag [74040-22-4] NO u 0.020 mg/L SW6010 09/14/00 08:12 CBS 1.0Antimony, Sb [7440-36-0] NO u 0.20 mg/L SW6010 09/14/00 08:12 CBS 1.0Molybdenum, Mo (7439-98-7] NO u 0.10 mg/L SW6010 09/14/00 08:12 CBS 1.0Vanadium, V [744-62-2] NO u 0.050 mg/L SW6010 09/14/00 08:12 CBS 1.0Mercury, Hg [7439-97-6] NO u 0.0020 mg/L SW7470 09/13/00 16:05 JC2 1.0ND: Not detected at a concentration greater than LOQ - Limit of Quantitation.Method Reference: OSEPA: Test Methods For Evaluating Solid Waste; SW-846, 3rd Edition; Nov 198TCLP Extraction Procedure and Regulatory Levels: 40CFR; Part 261.24 and Appendix II.

R esp ectfu lly submitted,COMMERCIAL TESTING &ENGINEERING CO.(Jt,,tt>~. /? ~/ ~,/.7)' 0_ (._"~""-< ~, \~t;;/ , "t-' t. (,u-t.. '\ \\S o ut h H o ll an d Laboratory 'J

OVER 4 0 BRANCH LABORATOR IES STRATEGICALLYLOCATED IN P RIN CI ML C OA L M IN IN G A R E AS, nD EWATE R AND G R EA T L AK ES P OR TS, AN D ~ER LOADING FACIUTIEF-- 486Original Watennarked Fo r Your Pro tection TERMS N D C O N D I T IO N S O N REVERSE


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COMMERCIAL TESTING &ENGINEERING CO.GENERAl OFFICES: 1919 SOUTHHIGHlAND AVE.,SUIT!; 210-B, LOMBARD,IWNOIS 60148. TEL: 630-953-9300 FAX:630-953-9306

SINCE 1908@ Ii'SGS Member of the SGS Group (Societe Generale de Surveillance)Committed To Excellence

~ September 15, 2000ADDRESS ALL CORRESPONDENCE TO16130 VAN DRUNEN RDSOUTH HOLlAND, IL 60473TEL: (708) 331-2900FAX: (708) 333-3060

BN DBSC O S ER VI CE S, I NC .1700 S. MOunt Prospect RoadDes Plaines, IL 60018Attn: Anil Goyal, PhD, PH S am pl e id en ti fic at io n b yBn de sc o S er vic es , I nc .

Kind of samplereported to us BcomeltSample taken at ------ Sample ID: Ecomelt from AVR Fly Ash

Sample taken by Bndesco Services, Inc_Date sampled ------

Date received September 6, 2000Analysis Report No. 71-131591 Page 3 of 3

' l'OltICIT rB ARACTB RIST IC LB ACRAT B PROCB DU RB : METALSLEACHATB KATRU SPIDPARAMETER CAS NO. RBSULT FLG RLIMIT UNITS S METHOD DA TE /TI ME /A NA LYS T D IL FA rs en ic, A s (7440-38-2] 2.0 0.10 mg/L SW6010 09/14/00 08.20 CBS 1.0Arsenic, As (7440-38-21 100 , RBC SW6010 09/14/00 08:20 CBS 1.0Ba riu m, Ba (7440-39-3J 9.8 0.010 mg/L SW6010 09/14/00 08:20 CBS 1.0Ba riu m, Ba [7440-39-3] 98 t RBC SW6010 09/14/00 08:20 CBS 1.0C ad mi um , C d (7440-43-9] 2.0 0.020 mg/L SW6010 09/14/00 08:20 CBS 1.0C ad mi um , C d [7440-43 -9] 1 01 t RBC SW6010 09/14/00 08:20 CBS 1.0C hr om iu m, C r (7440-47-3] 2.0 0.050 mg/L SW6010 09/14/00 08:20 CBS 1.0C hr om iu m, C r [7 440-47 -3 ] 1 02 t RBC SW6010 09/14/00 08:20 CBS 1.0Lead, Pb (7439-92-1) 2.0 0.10 mg/L SW6010 09/14/00 08:20 CBS 1.0Lead, Pb [7439-92-1J 99 t RBC SW6010 09/14/00 08:20 CBS 1. 0Selenium, Se [7782-49 -2] 2. 0 0.20 mg/L SW6010 09/1 4/00 08:20 CBS 1.0S el en iu m, S e [77 82-49-2] 1 02 t RBC SW6010 09/14/00 08:20 CBS 1.0S il ve r, A g [7440-22-41 2.1 0.020 mg/L SW6010 09/14/00 08:20 CBS 1.0Silver, Ag [7440-22-4) 107 , RBC SW6010 09/14/00 08:20 CBS 1.0A nt im on y, S b [7440-36-0J 2.0 0.20 mg/L SW6010 09/14/00 08:20 CBS 1.0A nt im on y, S b [7440-36-0) 100 t RBC SW6010 09/14/00 08:20 CBS 1.0M ol yb de nu m, M o [743 9-98-7 ] 2.0 0.10 mg/L SW6010 09/14/00 08:20 CBS 1.0M ol yb de nu m, M e (743 9-98-7 ] 100 t RBC SW6010 09/14/00 08:20 CBS 1.0Vanadium, V (7440-62-2] 2.0 0.050 mg/L SW6010 09/14/00 08:20 CBS 1.0vanadium, V (7440-62-2J 101 0.00020 , RBC SW6010 09/14/00 08:20 CBS 1.0M er cu ry , Hg (7439-97-6J 0.0020 0.0020 mg/L SW7470 09/13/00 16.07 JC2 1.0M er cu ry , Hg [7439-97-6] 98 , RBC SW7470 09/13/00 16:07 JC2 1.0

MEMBER6: ~ < 4 ~ ~ .OVER 40 BRANCtf LABORATORIES STRATEGICALLY LOCATED IN PRINCIPAL COAL MINING AREAS, TIDEWATER AND GREAT LAKES PORTS, AND~ER LOADING FACILITIE

Respectfully submitted,COMMERCIAL TESTING & ENGINEERING CO.

F . . .a sOriginal Watermarted For Your Protection T ER M S A ND C O ND IT IO N S O N R EV ER SE

Coal Ash Destruction Report Sept. 2000

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