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5 avril 2006 - 0 A STABILIZATION PROCESS OF MINERAL RESIDUE CONTAMINATED WITH HEAVY METALS AND ORGANIC COMPOUNDS G. Depelsenaire – SOLVAY
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5 avril 2006 - 1 [ Presentation Outline ] 1.The Novosol ® process 2.Potential applications 3.Process R&D 3.1. The process as applied to fly ash 3.2. The process as applied to polluted river or port sediments
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5 avril 2006 - 2 Step A HEAVY METAL STABILIZATION Step B ORGANIC COMPOUND DESTRUCTION 1. THE PROCESS TWO-STEP STABILIZATION OF MINERAL RESIDUE CONTAMINATED WITH HEAVY METALS AND ORGANIC COMPOUNDS Calcium phosphate formation Contaminated mineral residue H 3 PO 4 Step AStep B by binding to a calcium phosphate ( [Ca 3 (PO 4 ) 2 ]xH 2 O ) matrix formed by adding H 3 PO 4 by calcination (650°C - 900°C) Calories Organic compound destruction Usable stabilized mineral residue
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5 avril 2006 - 3 Potential applications Port and waterway dredging sediments Fly ash from municipal waste incinerators Automotive shredder residue Contaminated soil Industrial sludge ... Among these, the following have been so far treated in industrial pilot facilities: Fly ash from municipal waste incinerators River sediments 2.POTENTIAL APPLICATIONS
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5 avril 2006 - 4 u Research program - Began in 1993, with the Université Libre de Bruxelles (ULB – Professor DERIE) - Continued uninterruptedly since then, in partnership with several research institutes: * Ecole des Mines d’Albi (F) * Laboratoire des matériaux et de la durabilité des constructions à Toulouse (F) * BRGM – Orléans (F) * Ecole Centrale de Lille (F) * NJIT (USA) * Laboratoire Central des Ponts et Chaussées – Nantes (F) * EUROVIA (F) * Ecole Nationale de Travaux Publics de l’Etat – Lyon (F) * EEDEMS – Lyon (F) 3. NOVOSOL ® PROCESS R&D
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5 avril 2006 - 5 Europe - EP 0883585 B1(Jan. 12, 2000) - EP 0899000 B1(Nov. 3, 2004) USA - 6 132 355(Oct. 17, 2000) - 6 254 846(Jul. 3, 2001) 3.1. THE NOVOSOL ® PROCESS AS APPLIED TO FLY ASH 3.1.1. Patents
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5 avril 2006 - 6 Incorporation in road-building materials Sodium-rich residue Waste Furnace + boiler Raw flue gasses Filtration Dust-free gasses Processed gasses Filtration Stack Sodium bicarbonate Activated carbon Flue gas process Fly ash Chemical treatment Scrubber solution Dioxin-free, furan-free solid residue Grade I landfill siteSodium carbonate production Scrubbing ------------------------------------- NOVOSOL H 3 PO 4 Water Calories 3.1. THE NOVOSOL ® PROCESS AS APPLIED TO FLY ASH 3.1.2. Study of process and value recovery from products The REVASOL program: value recovery from flue gas scrubbing residue produced by the sodium bicarbonate-based Neutrec ® dry process Concentrated dioxin-free, furan-free standardized brine Ultimate wastes REVASOL pilot plant – Dombasle 1999 - 2003
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5 avril 2006 - 7 ADEME - Agence De l'Environnement et de la Maîtrise de l'Energie - Angers BERTIN Technologies - Tarnos BRGM - Bureau de recherches Géologiques et Minières - Orléans EMAC - Ecole des Mines d'Albi/Carmaux - Albi LCPC - Laboratoires Central des Ponts et Chaussées - Nantes Ets. Jean LEFEBVRE - Metz - Dourdan LMDC - Laboratoires des Matériaux et de la Durabilité des Constructions - INSA - Toulouse POLDEN - INSA - Lyon 3.1. THE NOVOSOL ® PROCESS AS APPLIED TO FLY ASH 3.1.2. Study of process and value recovery from products REVASOL program – Development of partnership studies
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5 avril 2006 - 8 Carried out by BERTIN in 1998 Built by SOLVAY at its Dombasle (Nancy) research centre in 1999 Operated by Solvay Process developed in 2000 20 metric tons of fly ash treated in the first half of 2001 3.1. THE NOVOSOL ® PROCESS AS APPLIED TO FLY ASH 3.1.2. Study of process and value recovery from products REVASOL program – Pilot plant process development
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5 avril 2006 - 9 Studies carried out by different research teams from 1998 to 2001 Selected strategies: Incorporation in concrete Incorporation in road-building materials Tested strategy: road construction (in juin 2002) Construction of a ‘test road’ (100 m 2 ) and a ‘control road’ (100 m 2 ) at Dombasle. Their leachates can be collected on impermeable membranes and continuously monitored. Construction of mini pilot units (4 m 2 ) for running accelerated aging tests on road-building materials. Their leachates, also collected on impermeable membranes, have been monitored until June 2003 3.1. THE NOVOSOL ® PROCESS AS APPLIED TO FLY ASH 3.1.2. Study of process and value recovery from products REVASOL program – Assessment of value recovery strategies
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5 avril 2006 - 10 3.1. THE NOVOSOL ® PROCESS AS APPLIED TO FLY ASH 3.1.2. Study of process and value recovery from products Test road at Dombasle: placement of the sand-gravel aggregate base course containing 12% treated fly ash (June 2002)
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5 avril 2006 - 11 3.1. THE NOVOSOL ® PROCESS AS APPLIED TO FLY ASH 3.1.2. Study of process and value recovery from products Test road at Dombasle: placement of the sand-gravel aggregate base course containing 12% treated fly ash (June 2002)
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5 avril 2006 - 12 * cas de percolation contaminée par de la chaux répandue sur la route 3.1. THE NOVOSOL ® PROCESS AS APPLIED TO FLY ASH 3.1.2. Study of process and value recovery from products Quality of the leach water collected beneath the ‘test’ road
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5 avril 2006 - 13 Patent applied for in October 2000 for processing port and waterway dredging sediments *European patent EP 1 341 728 B1(Nov. 23, 2005) Patent applied for in October 2002 due to technological advances – “NOVOSOL–Foam” 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.1. Patents
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5 avril 2006 - 14 Value recovery from stabilized materials Value recovered as calories for drying or electricity generation Sediments/Soil cont. 50% H 2 O Maturation and drying bed H 3 PO 4 Interim storage Calcination Site A Site B - Interim storage makes for: * Fast completion of the phosphatation & drying phase * Extra time for planning the calcination & value recovery phase * Extra time for selecting the best fuel for the calciner 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.2. Novosol foam Process operating chart
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5 avril 2006 - 15 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products European classification of contaminated sediments 17 05 05 * Dredging sludges containing hazardous substances Heavy metal levels above which sediments are considered hazardous
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5 avril 2006 - 16 Research and doctoral dissertation agreements with: - Ecole des Mines (Albi-Carmaux, France) - Ecole Centrale (Lille, France) - Ecole Nationale des Travaux Publics (Lyon, France) - Université P. Sabatier (Toulouse, France) Laboratory research 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products Process demonstration in pilot units
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5 avril 2006 - 17 Phosphatation mini pilot unit (Capacity: 400 l/h of sediments containing 50% H 2 O) 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products
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5 avril 2006 - 18 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products Industrial-scale phosphation pilot unit (designed and realized by Bertin Technologies) Capacity: 400 l/h of sediments containing 50% H 2 O
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5 avril 2006 - 19 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products Industrial-scale phosphatation and drying demonstration pilot unit at Farciennes (B)
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5 avril 2006 - 20 Mobile industrial-scale calcination pilot unit (designed and realized by Bertin Technologies) Capacity: 20 t / month of processed sediments 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products
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5 avril 2006 - 21 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products Mobile industrial-scale calcination pilot unit – General view
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5 avril 2006 - 22 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products Stabilizing performances of the NOVOSOL ® process when applied to river sediments in pilot units – Leaching with 0.5M acetic acid
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5 avril 2006 - 23 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products Stabilizing performances of the NOVOSOL ® process when applied to river sediments in pilot units – Leaching with water
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5 avril 2006 - 24 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products Value recovery through production of road construction materials River sediment sample treated by the NOVOSOL ® process for the ‘test’ road study Road construction material sample containing 40% treated river sediment Leaching results (x30402.2)
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5 avril 2006 - 25 Construction in December 2005 of a test road (100m2) comprising a sand/cement base course prepared with 30% NOVOSOL ® -treated river sediments The environmental impact (analyses of leachate collected beneath the ‘test’ road) and the mechanical performance of this road will be monitored for at least 1 year and 3 years at most. 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products Value recovery through production of road construction materials
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5 avril 2006 - 26 Detail of membranes 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products Construction of the ‘test’ road at Dombasle Base course (25cm thick) made of cement-stabilized sand containing 30% NOVOSOL ® -treated river sediments
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5 avril 2006 - 27 1- spreading and collecting of samples for molding 2- initial compaction with vibrating roller 3- compaction with P1 tires 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products Construction of the ‘test’ road at Dombasle 4- final screeding e= 0.25 m Base course (25cm thick) made of cement-stabilized sand containing 30% NOVOSOL ® -treated river sediments
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5 avril 2006 - 28 * cas de percolation contaminée par de la chaux répandue sur la route * Composition of the material (cement-stabilized sand) - Limestone 0/6 mm63% - NOVOSOL®-treated sediments30% - ROC SG hydraulic binder7% 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.3. Study of process and value recovery from products Value recovery through production of road construction materials Characteristics of the material* used to construct the ‘test’ road (cement-stabilized sand comprising 30% NOVOSOL ® -treated river sediments)
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5 avril 2006 - 29 Solvay grants access to the NOVOSOL ® technology by selling patent licenses for the use of the process. A separate license is granted for each individual project. Licenses are therefore time-limited and concern a limited geographic area. 3.2. THE NOVOSOL ® PROCESS AS APPLIED TO POLLUTED SEDIMENTS 3.2.4. Marketing strategy
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5 avril 2006 - 30 3.2. APPLYING THE NOVOSOL PROCESS TO CONTAMINATED SEDIMENTS 3.2.4. Marketing elements Main economic data for an industrial unit with a treatment capacity of 100 000 m 3 /year raw sediments 50% H 2 O, representing 150 000 tonnes/year dry material Assumptions : (1) Option 2 produces a material described as “Sand” by road manufacrurers (2) Novosol A : per tonne raw material, excluding the profit margin of the Novosol operator (3) Current landfilling costs – estimated trend (4) Landfilled material with a 20% water content (5) Material with a 10% water content before calcination (6) Road manufacturer takes the sand at zero cost
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5 avril 2006 - 31 Mineral residues Combustible waste Sediments with 50 % H 2 O Flying ash Mineral fine shredder residues Others Unit A Phosphatation - Drying H 3 PO 4 Unit B Calcination End product for reuse in road – brick - concrete pump INDUSTRIAL ECOLOGY- NOVOSOL® / FOAM Gas treatment Refuse-derived fuel (RDF) Dried sludge from wastewater treatment plant Others Gas treatment NEUTREC
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