Novosol

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A STABILIZATION PROCESS OF MINERAL RESIDUE
CONTAMINATED WITH HEAVY METALS AND ORGANIC
COMPOUNDS
G. Depelsenaire SOLVAY
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Presentation Outline

• 1. The Novosol process
• 2. Potential applications
• 3. Process RD
• 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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1. THE PROCESS
TWO-STEP STABILIZATION OF MINERAL RESIDUE
CONTAMINATED WITH HEAVY METALS AND ORGANIC
COMPOUNDS
Step A HEAVY METAL STABILIZATION
by binding to a calcium phosphate (
Ca3(PO4)2xH2O ) matrix formed by adding H3PO4
Step B ORGANIC COMPOUND DESTRUCTION
by calcination (650C - 900C)
H3PO4
Calories
Usable stabilized mineral residue
Calcium phosphate formation
Contaminated mineral residue
Organic compound destruction
Step A
Step B
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• POTENTIAL APPLICATIONS

• 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

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3. NOVOSOL PROCESS RD

• 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 dAlbi (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 lEtat Lyon (F) EEDEMS
  Lyon (F)

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3.1. THE NOVOSOL PROCESS AS APPLIED TO FLY
ASH 3.1.1. Patents

• 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)

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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
Flue gas process
Sodium bicarbonate
Activated carbon

Furnace boiler
Filtration
Filtration
Stack
Waste
Raw flue gasses
Processed gasses
Dust-free gasses
Sodium-rich residue
Fly ash
REVASOL pilot plant Dombasle 1999 - 2003
Water
Scrubbing-------------------------------------NO
VOSOL
Scrubber solution
H3PO4
Chemical treatment
Calories
Concentrated dioxin-free, furan-free
standardized brine
Dioxin-free, furan-free solid residue
Ultimate wastes
Incorporation in road-building materials
Grade I landfill site
Sodium carbonate production
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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

• 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

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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

• 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

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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

• 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 m2) and a
  control road (100 m2) at Dombasle. Their
  leachates can be collected on impermeable
  membranes and continuously monitored.
• Construction of mini pilot units (4 m2) for
  running accelerated aging tests on road-building
  materials. Their leachates, also collected on
  impermeable membranes, have been monitored until
  June 2003

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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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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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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
cas de percolation contaminée par de la chaux
répandue sur la route
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3.2. THE NOVOSOL PROCESS AS APPLIED TO POLLUTED
SEDIMENTS 3.2.1. Patents

• 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 NOVOSOLFoam

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3.2. THE NOVOSOL PROCESS AS APPLIED TO POLLUTED
SEDIMENTS 3.2.2. Novosol foam Process operating
chart
H3PO4
Maturation and drying bed
Sediments/Soil cont. 50 H2O
Site A
Interim storage
- 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
Value recovery from stabilized materialsValue
recovered as calories for drying or electricity
generation
Site B
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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 sediments17 05 05 Dredging
sludges containing hazardous substances Heavy
metal levels above which sediments are considered
hazardous
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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

• Laboratory research

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)
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3.2. THE NOVOSOL PROCESS AS APPLIED TO POLLUTED
SEDIMENTS 3.2.3. Study of process and value
recovery from products

• Phosphatation mini pilot unit
  (Capacity 400 l/h of sediments containing 50
  H2O)

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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 H2O
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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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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
• (designed and realized by Bertin Technologies)
• Capacity 20 t / month of processed sediments

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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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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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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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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 materialsRiver
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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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

• 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.

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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
Detail of membranes
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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
2- initial compaction with vibrating roller
1- spreading and collecting of samples for molding
3- compaction with P1 tires
4- final screeding e 0.25 m
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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)
cas de percolation contaminée par de la chaux
répandue sur la route
Composition of the material (cement-stabilized
sand) - Limestone 0/6 mm 63 -
NOVOSOL-treated sediments 30 - ROC SG
hydraulic binder 7
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3.2. THE NOVOSOL PROCESS AS APPLIED TO POLLUTED
SEDIMENTS 3.2.4. Marketing strategy
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.
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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 m3/year
raw sediments50 H2O, 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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INDUSTRIAL ECOLOGY- NOVOSOL / FOAM
Mineral residues
Combustible waste
Sediments with 50 H2O
pump
H3PO4
Refuse-derivedfuel (RDF)
pump
Dried sludgefrom wastewatertreatment plant
Flying ash
GastreatmentNEUTREC
Gas treatment
Mineral fineshredder residues
Others
Others
Unit APhosphatation - Drying
Unit BCalcination
End product for reuse inroad brick - concrete
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