Flyash

With the boom in population and industrial growth, the need for power has
increased manifold. Nearly 73% of Indias total installed power generation
capacity is thermal, of which 90% is coal-based generation, with diesel,
wind, gas, and steam making up the rest. Thermal power generation
through coal combustion produces minute particles of ash that causes
serious environmental problems.
Commonly known as fly ash, these ash particles consist of silica, alumina, oxides of iron, calcium, and
magnesium and toxic heavy metals like lead, arsenic, cobalt, and copper.
The 80-odd utility thermal power stations in India use bituminous coal and produce large quantities of
fly ash. According to one estimate, up to 150 million tonnes of fly ash will be produced in India in the
year 2000, primarily by thermal power plants and, to a lesser extent, by cement and steel plants and
railways. This poses problems in the form of land use, health hazards, and environmental dangers.
Both in disposal and in utilization utmost care has to be taken to safeguard the interest of human life,
wild life, and such other considerations.
The prevalent practice is to dump fly ash on wastelands, and this has lain to waste thousands of
hectares all over the country. To prevent the fly ash from getting airborne, the dumping sites have to
be constantly kept wet by sprinkling water over the area. The coal industry in USA spends millions of
dollars on lining fly ash dumping grounds. But in India, these sites are not lined and it leads to
seepage, contaminating groundwater and soil. It lowers soil fertility and contaminates surface and
ground water as it can leach into the subsoil. When fly ash gets into the natural draining system, it
results in siltation and clogs the system. It also reduces the pH balance and portability of water. Fly
ash interferes with the process of photosynthesis of aquatic plants and thus disturbs the food chain.
Besides, fly ash corrodes exposed metallic structures in its vicinity.
In Delhi, the problem of fly ash is particularly severe as three power stations are located here. Being
very minute, fly ash tends to remain airborne for a very long period leading to serious health problems
as the airborne ash can enter the body. It causes irritation to eyes, skin, and nose, throat, and
respiratory tract. Repeated inhalation of fly ash dust containing crystalline silica can cause bronchitis
and lung cancer.

Tackling the problem of fly ash

Fly ash management has taken considerable strides over the past few years. Researches have been
attempting to convert this waste into wealth by exploring viable avenues for fly ash management. Fly
ash is oxide-rich and can be used as the raw material for different industries.
Today, fly ash bricks can be used as a building material. The American Embassy in India has used fly
ash bricks in some of its recent construction. Use of fly ash as a part replacement of cement in mortar
and concrete has started with the Indian Institute of Technology, Delhi taking the lead. Use of fly ash
in the construction of roads and embankments has been successfully demonstrated in the country
and it is gaining acceptance. The NTPC (National Thermal Power Corporation) is setting up two fly
ash brick manufacturing plants at Badarpur and Dadri near Delhi.
At TERI, researchers have proven that fly ash dumps can be reclaimed by suitable addition of organic
matter and symbiotic fungi, making it commercially viable for activities like floriculture and silviculture.
TERI researchers have successfully reclaimed a part of an ash pond at the Badarpur Thermal Power
Station by introducing a mycorrhizal fungi-based organic bio-fertilizer. As the fungus germinates, it
sustains on the partner plant and quickly spreads to the roots and beyond. It improves the plant's
water and nutrient uptake, helps in the development of roots and soil-binding, stores carbohydrates
and oils for use when needed, protects the plants from soil-borne diseases, and detoxifies
contaminated soils. This helps in keeping both air and water pollution under control. It also helps

revive wastelands and saves millions of litres of precious water from going down the fly ash slurries.
Marigold, tuberose, gladiolus, carnation, sunflower, poplar, sheesham, and eucalyptus now grow at
the demonstration site of the power station.
Use of fly ash in agricultural applications has been well demonstrated and has been accepted by a
large number of farmers.
The National Capital Power Station of the NTPC has come up with an innovative technology for
commercial utilization of this by-product. Known as the dry ash technology, it is considered
environment-friendly. Under the dry ash technology, the fly ash is collected in huge mounds with a
filter bed provided at the bottom of the mound. Grass is planted on the slopes of the fly ash mounds
and polymer layering is also done to prevent the ash from being blown by the wind. Fly ash treated by
this method develops certain physical properties that make it more suitable for commercial purposes.

For more information on Flyash link to

www.flyash.com/

www.iflyash.com/

ASHCRETE (Fly Ash)

FLY ASH is a fine, glass powder recovered from the gases of burning coal during
the production of electricity. These micron-sized earth elements consist primarily of
silica, alumina and iron. When mixed with lime and water the fly ash forms a
cementitious compound with properties very similar to that of Portland
cement. Because of this similarity, fly ash can be used to replace a portion of
cement in the concrete, providing some distinct quality advantages. The concrete is
denser resulting in a tighter, smoother surface with less bleeding.
Fly ash concrete offers a distinct architectural benefit with improved textural consistency
and sharper detail. Fly Ash is also known as Coal Ash, Pulverized Flue Ash,
Pozzolona.
Our Grades:1. ASHCRETE MM-10
2. ASHCRETE MM-34
3. ASHCRETE - ULTRAPOZZ
To learn more about Flyash in detail click below:

What is ASHCRETE fly ash?

Features of fly ash?

What are the specifications of fly ash?

ASHCRETE Fly ash closely resembles volcanic ashes used in production of the
earliest known hydraulic cements about 2,300 years ago. Those cements were
made near the small Italian town of Pozzuoli - which later gave its name to the
term "pozzolan."
A pozzolan is a siliceous or siliceous / aluminous material that, when
mixed with lime and water, forms a cementitious compound. ASHCRETE Fly ash
is the best known, and one of the most commonly used, pozzolans in the world.
Instead of volcanoes, today's fly ash comes primarily from coal-fired
electricity generating power plants. These power plants grind coal to a powder
fineness before it is burned. ASHCRETE Fly ash - the mineral residue produced
by burning coal - is captured from the power plant's exhaust gases and collected
for use.
ASHCRETE Fly ash is a fine, glass powder recovered from the gases of
burning coal during the production of electricity. These micron-sized earth
elements consist primarily of silica, alumina and iron.
The difference between ASHCRETE fly ash and portland cement becomes
apparent under a microscope. ASHCRETE Fly ash particles are almost totally
spherical in shape, allowing them to flow and blend freely in mixtures. That
capability is one of the properties making ASHCRETE fly ash a desirable
admixture for concrete.
Some of the Projects, Our Fly Ash was used:1. Ras Laffan Port - Doha, Qatar
2. Doha Airport - Doha, Qatar
3. Jeddah Airport - Jeddah, Saudi Arabia
4. International Airport - New Delhi, India
.... Many More Endless List

Features of fly ash?

Spherical shape : Fly ash particles are almost totally spherical in shape,
allowing them to flow and blend freely in mixtures.

Ball bearing effect :The "ball-bearing" effect of fly ash particles creates a
lubricating action when concrete is in its plastic state.

Higher Strength : Fly ash continues to combine with free lime, increasing
structural strength over time.

Decreased Permeability : Increased density and long term pozzolanic action of

fly ash, which ties up free lime, results in fewer bleed channels and decreases
permeability
Increased Durability. Dense fly ash concrete helps keep aggressive compounds on
the surface, where destructive action is lessened. Fly ash concrete is also more
resistant to attack by sulfate, mild acid, soft (lime hungry) water, and seawater.

Reduced Sulfate Attack : Fly ash ties up free lime that can combine with
sulfate to create destructive expansion.

Reduced Efflorescence : Fly ash chemically binds free lime and salts that can
create efflorescence and dense concrete holds efflorescence producing
compounds on the inside.

Reduced Shrinkage : The largest contributor to drying shrinkage is water

content. The lubricating action of fly ash reduces water content and drying
shrinkage.
Reduced Heat of Hydration :The pozzolanic reaction between fly ash and lime
generates less heat, resulting in reduced thermal cracking when fly ash is used to
replace portland cement.
Reduced Alkali Silica Reactivity : Fly ash combines with alkalis from cement
that might otherwise combine with silica from aggregates, causing destructive
expansion.

Workability : Concrete is easier to place with less effort, responding better to

vibration to fill forms more completely.
Ease of Pumping. Pumping requires less energy and longer pumping distances are
possible.

Improved Finishing : Sharp, clear architectural definition is easier to achieve,

with less worry about in-place integrity.

Reduced Bleeding : Fewer bleed channels decreases porosity and chemical

attack. Bleed streaking is reduced for architectural finishes. Improved paste to
aggregate contact results in enhanced bond strengths.

Reduced Segregation : Improved cohesiveness of fly ash concrete reduces

segregation that can lead to rock pockets and blemishes.

Reduced Slump Loss : More dependable concrete allows for greater working
time, especially in hot weather.

What are the specifications of fly ash?

SPECIFICATIONS :
ASTM (West Conshohocken, PA USA)

ASTM C 618: Standard Specification for Coal Fly Ash and Raw or Calcined Natural
Pozzolan for Use as a Mineral Admixture in Portland Cement Concrete

ASTM C 311: Standard Test Methods for Sampling and Testing Fly Ash or Natural
Pozzolans for Use as a Mineral Admixture in Portland-Cement Concrete

ASTM D 5239: Standard Practice for Characterizing Fly Ash for Use in Soil
Stabilization

ASTM E 850: Standard Practice for Use of Inorganic Process Wastes as Structural
Fill

ASTM E 1861: Standard Guide for Use of Coal Combustion By-products in

Structural Fills

ASTM D 5370: Standard Specification for Pozzolanic Blended Materials in

Construction Applications

ASTM C 1240: Standard Specification for Silica Fume for Use in Hydraulic-Cement
Concrete and Mortar

IDOT (Illinois Dept. of Trans. Springfield, IL USA)

306.01: Special Provision for Fly Ash Modified Soils

308.01: Special Provision for Fly Ash Stabilized Soil Mixture Subbase

Special Provision for Cement-Fly Ash-Aggregate Mixture (CFAM) Base Course

Special Provision for Pozzolanic Base Course, Type A

Special Provision for Use of Fly Ash in P.C.C. Pavement, Base Course, Base Course
Widening

AASHTO

AASHTO Standard Specifications for Transportation Materials and Methods of

Sampling and Testing

EUROPEAN STANDARDS

BS 3892 Part 1 Fly Ash standard; Part 2 Fly Ash for Use as a Type II Addition

BS EN 450 European Standard for Fly Ash

BS EN 197 European Standard for Multiple Binders ( fly ash, cement, silica fume)
Allowed in Concrete

AUSTRALIA

Portland Cement -AS 3972-1991,

Fly ash -AS 3582.1-1991, and

Ground Granulated Blast Furnace Slag -AS 3582.2.

A.S. 1129 Fly Ash Specification

CANADA

CAN/CSA A23.5-97 Canadian Specification for Supplementary Cementing

Materials (includes fly ash)

GERMANY( Deutsches Instut fur Normung-Berlin)

DIN 1164-1 German Cement standard

DIN 1045 Reinforced Concrete Structures; Design and Construction

DIN EN 450 Fly Ash In Concrete-Definition, Demands and Quality control

ENV 206:1990 (CEN/TC 104) Beton - Eigenschaften, Herstellung, Verarbeitung

und Gtenachweis

EN 445:1996 (CEN/TC 104) Einpremrtel fr Spannglieder - Prfverfahren

EN 446:1996 (CEN/TC 104) Einpremrtel fr Spannglieder - Einpreverfahren

EN 447:1996 (CEN/TC 104) Einpremrtel fr Spannglieder - Anforderungen fr

blichen Einpremrtel

EN 450:1994 (CEN/TC 104) Flugasche fr Beton - Definitionen, Anforderungen

und Gteberwachung

EN 451-1:1994 (CEN/TC 104) Prfverfahren fr Flugasche - Teil 1: Bestimmung

des freien Calciumgehalts

EN 451-2:1994 (CEN/TC 104) Prfverfahren fr Flugasche - Teil 2: Bestimmung

der Feinheit durch Nasiebung

NETHERLANDS

NEN 3550 Dutch cement standard

UNITED KINGDOM (British Standards Institution- London)

B.S. 3892 PFA as a separate constituent in OPC

B.S. 6588 Blended cement containing PFA

B.S. 6610 Pozzolanic pulverized fuel ash cement

Flyash in U.S
A huge coal ash spill was discovered on February 2 at the Duke Energy power plant in North Carolina
that has caused significant damage to the Dan River. The spill was caused when a storm drain pipe
that runs underneath the 27-acre containment pond sprung a leak and allowed 82,000 tons of ash
mixed 27 million gallons to flow into the river. Officials have provided no timetable for the cleanup and
witnesses have described gray sludge two inches thick coating the riverbank for more than two miles.
The Dan River spill is not the only recent spill of coal ash. On December 22, 2008 a dike ruptured at
an 84-acre ash fill operated by the Tennessee Valley Authoritys Kingston Fossil Plant in Roane
County, TN. 1.1 billion gallons of coal fly ash slurry was released and covered over 300 acres with up

to 6 feet of sludge. The spill was larger than the Exxon Valdez, damaging neighboring properties and
contaminating nearby waterways.
Coal ash is the largest type of waste generated in the United States and in many other countries, with
over 100 million tons produced in the USA every year. Coal ash contains a toxic stew of chemicals
including lead, arsenic, mercury and radioactive uranium. The EPA is considering new rules to
regulate coal ash waste, despite protests from industry.
The size of this problem begs the question, is there any beneficial use for coal ash waste? And what
is being done around the world to address this common problem?
The EPA supports the beneficial use of waste products and defines it as the reuse in a product that
provides a functional benefit, replaces a product made from virgin raw materials, conserves natural
resources and meets product specifications and industry standards. Beneficial use of waste products
can contribute to a sustainable future by reducing production costs, reducing energy consumption and
greenhouse gasses.
Coal fly ash are lightweight particles captured in exhaust gas by electrostatic precipitators and bag
houses of coal-fired power plants. Fly ash is very fine with cement like properties and has long been
used as an additive in cement, though not without some controversy. Bottom ash is the larger, coarser
variety of ash collected at the bottom of the boilers. The ratio of fly ash to bottom ash ranges from
70:30 to 80:20 depending on the type of boiler and type of coal.
According to the EPA, beneficial uses of fly ash include serving as a raw material in concrete, grout
and cement or as a fill material in stabilization projects and road beds. Bottom ash is generally just
used as fill or snow control on roads. Around 43% of fly ash in the USA is currently recycled with the
largest use by far being the replacement of portland cement.
Critics have charged that recycling of fly ash in concrete building materials is dangerous because it
offers inferior structural capability and may result in indoor air contamination due to leaching
chemicals or caustic reactions with other materials. Variances in the chemical composition of fly ash
from different sources compounds the problem by making it difficult to assure the proper strength of
the final concrete products.
Traditional masonry takes significant volumes of energy to produce, concrete and brick making are
some of the biggest sources of greenhouse gasses. Clay bricks are produced in a kiln and fired at
2000 F for 3-5 days. The kilns are generally left running continuously even when no bricks are being
produced due to the difficulty in getting the temperatures up to optimum levels. Portland cement is

also a fired material and releases additional carbon emissions from the calcination of the limestone
feedstock. According to NIST (National Institute of Standards and Technology) the carbon footprint for
a cubic yard of fired clay brick is 991 pounds and 572 pounds for concrete brick.

New formulations for bricks manufactured from coal fly ash hope to address some of these problems.
Fly ash is increasingly being used throughout the world as ingredient for bricks and a variety of
recipes have emerged. Fly ash bricks get their strength and durability from the chemical reaction of fly
ash with water. Fly ash is combined with sand and pigments and formed with vibrocompaction and
cured with steam for two days and not fired. This method uses 85% less energy than traditional kiln
firing and the carbon footprint for a cubic yard of fly ash brick is 191 pounds.
CalStar is company stated in 2006 in Silicon Valley with production in Wisconsin that is producing fly
ash bricks using the method described above. They claim their bricks require 81% less energy to
manufacture, incorporate 37% recycled fly ash and emit 84% less CO2 during production. Lower
energy use and inexpensive raw materials allow CalStar to offer competitive pricing and high margins.
CalStar products have received numerous LEED certifications and green industry accolades. Critics
counter that the products have not proven themselves over time and may continue to leach toxic
chemicals.

CalStar Fly Ash Bricks

The leachability of toxins from fly ash is a critical issue in determining whether fly ash can be put to
beneficial use. It is well established that fly ash on its own is highly toxic. It is also well established that
those toxic chemicals can be safely contained in a crystalline matrix when the fly ash is subjected to
thermal or chemical treatments. When used to replace Portland cement, fly ash reacts with lime to
produce a glassy matrix that inhibits leaching. Firing of fly ash bricks will also produce the requisite
glassy matrix rendering them inert to leaching.
Vitrification is a thermochemical process that occurs at high temperatures around 1,500 C that melt
the ash and turn it into slag, a glass like substance similar to obsidian in appearance. Vitrified slag has
been subjected extensively to TCLP analysis (Toxicity Characteristic Leaching Procedure) and found
to be very stable and reliable at containing all toxins in the glass crystalline matrix. Vitrified slag has
been approved for use as a construction aggregate and fill material. The downside of this process is
the amount of energy required to melt the ash. High temperature gasifiers, such as plasma gasifiers,
will produce slag instead of ash and is more efficient than treating the ash in a separate process.
In Shanghai, China a new incinerator ash vitrification plant was commissioned in January 2014 that
uses a plasma torch supplied by Alter NRG of Calgary, Canada. The Westinghouse plasma torch
melts the ash and converts it into slag that has been approved for use as a construction material.
Though this plant is attached to a waste incinerator, not a coal plant, the same principles apply to coal
ash. The advantage of the plasma technology is that because of the extremely high temperatures it
produces, above 5,000 C, very hazardous medical and industrial wastes can be safely treated. Sales
of slag help offset the costs.

In India, approximately 150 million tons of fly ash are produced every year, and this number is growing
as new coal plants are added to meet growing energy demands. In order to combat the growing
problem of fly ash waste, the Indian government is mandating the production of fly-ash bricks and
compelling their use in new construction projects. Brick making is a traditional industry in India with
annual production of over 200 billion bricks and 76 million tons of CO2 emitted from the kilns. Since
bricks are made from clay, substantial quantities of top soil are disturbed every year acquiring the raw
materials.

Fly Ash Brick Production in India

Fly ash bricks were invented in 1990 by two Indian inventors using a different process than the one
used in the USA by CalStar. The Indian method uses a mix of fly ash, lime and gypsum that
completely replaces the use of clay from the soil. The bricks are regarded as high quality and strong
and do not require kiln firing. The World Bank has jumped on the bandwagon with a program that
enables entrepreneurs to earn carbon credits to offset setup costs. More than 16,000 fly ash brick
plants are now in operation throughout India, up from just 100 in 2000, consuming over 20 million tons
of fly ash every year. Fly ash bricks now account for about one-sixth of Indias annual brick production,
saving energy, soil, carbon emissions, and putting a toxic waste product to beneficial use.

It is clear that coal fly ash waste is a growing problem. Hundreds of millions of tons of ash waste lie in
dangerous piles near homes and waterways and more is being added all the time. It is also clear that
fly ash does have some beneficial properties when used in masonry, but that quality control and toxic
leachability issues must be addressed. Disguising toxic waste as a building material and putting it in
our homes is no solution, but with proper treatment these concerns can be alleviated. As concerns
over CO2 emissions grow by the day, masonry industries find themselves in the cross hairs and
solutions must be implemented to reduce emissions or else they face rising costs under any type of
carbon price regime. The coal power industry faces similar concerns as it is beset from all sides by
competitive pressures, increased environmental regulation, and waves of bad publicity and public
hostility due to waste spills. Increased manufacture of fly ash bricks offers a way forward for both
industries to improve their environmental performance and find new revenue streams, assuming that
competitive cost, performance and environmental benchmarks for these new bricks are achieved.