New material for road construction and flue gas desulphurization

Preparation and applicability examination of a new product
obtained from processed oil derivative sludge with quick
lime (cao), using the "ortwed" process for road construction
and flue gas and assessment of environmental impact.

- The main goal of the project is the preparation of an environmental impact Report of an experimental ORTWED installation placed in 'ORLEN' S.A., especially the environmental impact of water vapour escaped during hydration process of spent oil wastes with burnt lime and the commercial application of the obtained product. Product resulting from the ORTWED Process (burnt lime powder or granulate containing oil derivatives from ORLEN'S sludge) will be examined from an environmental hazard point of view. Then the product utilized in road paving technologies and as a heat energy sorbing agent for desulphurization of flue gases will be checked to meet the Polish, European and American environmental laws and regulations. Finally, the product, on the basis of scientific work will obtain necessary ecological certificates and approval which will enable it to be applied in road construction as well as heat and power generating plants as a sorbent. - The second goal of the project is the preparation at technical scale of a method for the use of processed sludge containing oil derivatives (wastes from oil petroleum refinery) for road paving technologies. The product, obtained from sludge processing, using the ORTWED Method, has physico-chemical properties similar to those of lime. However, this material is less arduous and safer in use because it is not dusting, hydrophobic and can therefore be handled, transported and stored for long periods of time. This product application will allow neutralisation of large quantities of sludge devastating the natural environment and reduce cost of local road construction. - The third goal of the project is to obtain a new caloric flue gases sorbent based on the ORTWED product, which will contain spend oil hydrocarbons from refinery sludge and lime. In the scope of the envisaged scientific work, study on technology of sorbent production, its technical effectiveness and full-scale application of the product will be worked out. The obtained sorbent will significantly decrease running costs in heat and power generating plants and obviously utilize large amount of oil sludges. - The fourth goal of the project is the introduction to the Polish, EC and USA markets of an alternative product - less expensive than commonly used burnt lime - for stabilisation in road engineering and like flue gases sorbent in heat generating plants. The product is formed during the neutralisation of oil derivative wastes with burnt lime using the method (technology) and the process line of the Danish company ORTWED APS. The method consists of utilising the heat from the lime hydration reaction and utilising the process of a fast homogenisation for containment of wastes inside lime crystals as well as on their surface. On the basis of preliminary tests results carried out by the WARSAW UNIVERSITY OF TECHNOLOGY (PW), the ROADS AND BRIDGES RESEARCH INSTITUTE (IBDiM) and WROCLAW UNIVERSITY OF TECHNOLOGY (PWr), a 3.5 year long programme of theoretical and practical investigations was accepted which is to lead to full confirmation of technical and economic values of the product and the lack of any adverse effects on the environment. The performance of the programme will fulfil the following technological goals: 1. ORTWED process and Product environmental impact (Environment). - elimination of environmental adverse effect of ORTWED Process and end-Product, within the scope of experimental, research and scientific laboratory and full technical scale study. - collaboration with EUREKA project supporters to obtain environmentally safe product material (processed from oil petroleum refinery waste sludge and calcium oxide) which guarantee final industrial application of the Product without any risk or hazard. - environmental monitoring of the utilised end-product in road construction technologies, and power generating plants to fulfil complete inspection against environment. 2. Road pavement technologies (ROAD). - selection, on the basis of experimental tests, soils stabilised with the product that have the most suitable parameters, - preparation of a recipe for enhancement of the soil stabilisation effect with the product, together with indication of an acceptable percentage share of the product in the total mass of the material when supporting additives are used simultaneously (standard binders), - preparation of the methodology of product manufacturing using the ORTWED method, so that the product has optimum properties with regard to its application for road construction and the costs of its manufacture are economically feasible. 3. Flue gases sorbing agent (SORBENT). - selection, on the base of investigations of the influence of lime to oil refinery sludge ratio as well as grain size of applied calcium oxide used in ORTWED Process, the best quality sorbent material for flue gases desulphurization. - working out technological concept, in the scope of laboratory and full, technical-scale studies, of applying processed sorbent in power plant fluid boilers based on brown coal as commercial fuel. The project has been divided into four main stages for implementation in 2001-2004. All tests, examinations, analyses and investigations will be done with compliance to Polish, European and American Standards. Stage I - 2001: Environmental: 1. The initial stage of examination of physical and chemical properties of row material (waste oil sludge from refinery), and Product processed in ORTWED installation with different ratio of burnt lime addition according to environmental impact. 2. Full scale analytical study of the waste oil derivatives sludge from storage reservoir of the Water and Wastewater Department of ORLEN S.A. (pH, COD, total Fe, V, Zn, Ca, ether extract, petroleum compounds, disperse compounds, chloride and sulphate ions) in accordance with Polish, European and American standards and regulations. 3. The study of leaching contaminations from the product at the changeable quantity of quick lime (CaO) in static and dynamic conditions with distilled water, carrying out physical and chemical analyses of the eluates for metal ions and compounds mobility. Similar research work will be worked out with different additions of mineral salts (groundwater equivalent). Road: 1. Preliminary studies and investigation of the physico-chemical properties of the product obtained in ORTWED Process, in the field of road paving technologies ( burnt lime and hydrated calcium content, grain type compositions, soil stabilisation property). Sorbent: 1. Investigation and studies of the physic-chemical properties of the product (water and organic matter content, ignition temperature, flammable properties, adhesity, transportability, storage susceptibility) in the scope of future sorption and caloric properties dependent on oil containing water waste ratio to calcium oxide and CaO grain size. Stage II - 2002: Environment: 1. Ecological tests of sludges from the ORLEN S.A., the ORTWED technology product and of samples prepared in IBDiM during the fulfilment of Stage II. 2. Environmental investigations of tested road sections. 3. Ecological tests of fly ash produced in laboratory, half and full technical scale in the process of desulphurization of flue gases with calcium sorbent obtained from the ORTWED Process. 4. Similar study with flue gases (chemical composition) from fossil fuel combustion process. Road: 1. Tests of stabilisation of various soil and aggregate types with the product obtained on the test site (ORTWED processing plant) in the second half of 2001. Determination of admissible quantities of the Product addition to soil at with the technical and ecological requirements concerning road paving are met. 2. Tests of stabilisation of 3 sand types with the product and asphalt emulsion. 3. Selection and preparation of 3 (three) tested road sections with application of selected mix types prepared during Stage I and II, on the basis of the technological and environmental tests. 4. Control investigations (monitoring) during construction of the tested road sections (intermixture degree with soil, concentrations index, CBR, load capacity with VSS). 5. Monitoring and load capacity tests of the tested road sections during the post-performance phase (VSS, CBR, stabilized layer state). 6. Laboratory examination of fly ash from desulphurization process like road construction material (grain content, bond properties, mineralogy composition and others). 7. Studies on fly ash-aggregate-cement mixtures used for road pavement (grain content, sand suffix, material strength, freeze resistance and other). 8. Preparation of the test samples for environmental, physic and chemical inspection and examination in WARSAW's and WROCLAW's UNIVERSITIES OF TECHNOLOGY. Sorbent: 1. Comparative laboratory studies of the desulphurization efficiency of commercial and water-oil emulsion containing sorbent in the fossil fuel combustion process (easiness of plant feeding with sorbent, desulphurization efficiency, energy profit on account of organic matter in sorbent, composition and physicochemical properties of ash, chemical composition of flue gases, NOx and SO2 contents). 2. Experimental studies on desulphurization efficiency, fly ash properties, flue gases chemical composition and action of waste oil contained sorbent in combustion of fossil fuels in small boilers and commercial power and energy generated plant. Stage III - 2003 Environment: 1. The study of leaching contaminations in natural conditions from the bottom layer (end-product) modified with ORTWED processed material. Monitoring contaminations in 12 sampling spots installed on both sides of the three sections of roads tested. Each section will include three sampling spots where filtered groundwater samples will flow in and one more as a reference. 2. Further monitoring and environmental examination of the tested road section. 3. Co-participation in compiling of the requirements, recommendations and technical instructions in order to eliminate potential harmful environmental impacts of the end-product. 4. Co-participation in obtaining (environmental) attestation, certificates and technological acceptation for using ORTWED processing material (product) in road construction. 5. Partnering cooperation in compiling the report of environmental adverse effect of fluidic power plant boiler fuelled with brown coal with addition of sorbent containing oil wastes sludge such as a desulphurization agent. 6. Partnering environmental support in obtaining (also) environmental certificates, and approvals for utilisation of the ORTWED product such as a desulphurization agent. Road: 1. Monitoring and load capacity tests of the tested road sections after the initial period of exploitation with traffic including the autumn - winter period. 2. Preparation of the report for the technical approval of Product like road construction material. 3. Technical instruction submitting (for technical approval and certificates) of the product application in road construction with compliance with Polish, European and American laws and regulations. Sorbent: Working out of utilization technology of waste refinery oil contained sorbent like desulphurization agent in power and energy plant boilers, especially based on brown coal as commercial fuel (applications instruction, technical and technological guidelines, certificates and technical approvals). All documents will be prepared in accordance with Polish, European and American Standards. Stage IV - 2004 Eenvironment: 1. Co-participation in preparation of recipes, technical instructions, environmental approvals and certificates for utilisation in road construction of fly ash (containing calcium and sulphur oxides) from fluidal power plant boilers fueled with brown coal where flue gases were desulphurized with ORTWED Product. All dates and needed attestation be prepared with Polish, European and American Standards. Road: 1. Preparation of recipes and technological instructions for fly ash contained end-product from desulphurization process in fluidal type of boilers based on ORTWED Process such as road construction material with all the above- mentioned standards. After the technical approval is obtained for application of the product for road construction and for flue gases desulphurization in POLAND, the application for technical approvals of the EU, USA and other countries will be submitted. This will be possible because EU Directives and Standards will be applied in the technical, technological and environmental tests and examination. The participation of the Danish company in the project will also facilitate transfer of the results of practical tests on Polish roads as well as in power and energy generated plant to the conditions of the EU countries. The result of the EUREKA The project investigations will be the basis for environmentally-friendly neutralisation of oil derivative sludge (containing water-oil emulsion) from the 'ORLEN' S.A. concern using the reaction with burnt lime (CaO). Such a method will provide a solution to the issue of the proper use of these wastes (recycling) and eliminate a threat to the environment. The method prepared in the project will be used for recycling of the following wastes which include hydrocarbons like: oil contaminated diatomite earth, contaminated soils, sludge from gasoline stations, fuel bases, car services plants, sludge and wastes from oil and fuel storage plants, from tanks, contaminations from harbour terminals, wastes from tank cleaning, oil sludge from industrial and municipal wastewater treatment plants as well as wastes from other refineries and petrochemical plants. Simultaneously, the market will see the introduction of a full-value, cost-effective and environmentally friendly material for road construction and desulphurization of flue gases. The scale of the problem of oil derivative sludge neutralisation on the environmentally friendly way is large, not only in POLAND but also in other European countries and the USA. This EUREKA project may help to introduce the technical solution on a wide industrial scale. Keywords: sludge, neutralization, environment.
Project ID: 
2 695
Start date: 
Project Duration: 
Project costs: 
1 610 000.00€
Technological Area: 
Recycling, Recovery
Market Area: 

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.