FLY ASH

GENERATION UTILIZATION ADVANTAGE PRODUCTS SUSTAINABLE USE IMPEDIMENTS APPROACH

BY: SIDDHARTH BANSAL C07213, CIVIL( 8TH SEM)

FLY ASH

 Fly ash is one of the residues generated in combustion, and comprises the fine particles that rise with the flue gases. Ash which does not

rise is termed bottom ash. Nearly 53% of Indias total installed power generation capacity is produced by coal-based thermal power plants. The combustion of powdered coal in thermal power plants produces ash, which contains 80% fly ash and 20% bottom ash.

Chemical composition of fly ash

characteristics
Physical properties: fine powdery particles, glassy(amorphous) in nature, particle size similar to silt particles Specific Gravity: low( around 2) results in low dry density Grain size distribution: based on grain-size

they can be classified as sandy silt to silty sand Liquid limit: 22-64% for pond ashes, 45-104% for bottom ashes

Ash generation and utilization

Indian Scenario
Fly ash generation increased from one million tone in 1993-94 to 70 million tonne in 200708 Estimates prepared by Ministry of Power as well as Planning Commissions up to the year 2031-32 indicate that generation of fly ash

during year 2031-32 would be around 600 million tonne.

Background
Some of the CSIR Laboratories like Central Building Research Institute (CBRI) Roorkee, Central Fuel Research Institute (CFRI) Dhanbad, Regional Research Lab (RRL), Indian Institute of minerals and materials Bhubaneshwar, RRL (AMPRI) Bhopal, Central Glass and Ceramic Research Institute (CGCRI) Kolkata and Central Power Research Institute (CPRI) Bangalore intiated Research and Development Projects more than two decades back and developed a couple of technologies

 First plant for production of 3,0000 bricks/day was set up near Kolkata by CFRI Dhanbad.Manufacturers of machinery were also identified. In fact, there were manufacturers of machinesfor manufacturing of refractory bricks who switched over to manufacturing of machinery for flyash bricks. CFRI set up second plant at Bandel (near Kolkata) with German machinery.Simultaneously CBRI, Roorkee also came out with technology for manufacturing of fly ashbricks and it set up a plant at Okhla (near New Delhi) to utilise fly ash generated by the nearbyplant.

Area wise breakup of fly ash utilization

Cement Industries -7.04 Ready Mix Concrete -0.33 Asbestos -0.20 Clay Ash/ Fly Ash Bricks- 1.64 Land Fill -5.74 Ash Dyke Raising -6.24 Road/ Embankments -1.30 Mine Filling -1.14 Agriculture- 0.002 Export -0.73 Others- 0.02 Total -24.40

Areas of utilization
Manufacture of portland pozzolana cement Making flyash lightweight aggregate Cement/silicate bonded fly ash/clay binding

bricks and insulating bricks Pre-cast fly ash concrete building units Cellular concrete bricks and blocks,limepozzolana mixes and cement fly ash concrete Structural fill for roads, construction on sites,land reclamation etc

 As water reducer in concrete and sulphate resisting concrete.

Amendment and stabilization of soil

Fly Ash in Roads and Embankments

Technical Advantage
Good Compaction
High internal Angle of friction Free draining( less interruption due to rain) No large lumps to be broken(easy to spread) Light in weight( can be used on weak sub-

grades)

Economical Savings
No royalty to be paid as excavation of soil is eliminated

Reduces excavation cost of borrow material Normally reduces transportation cost Easy and faster construction leads to reduction in construction cost Saving in ash management expenditure of thermal power plants Additional agriculture produce which would otherwise have been

Okhla flyover

Sarita Vihar fly over

Fly Ash in Building Components

Technical Advantage
Bricks and blocks Better finish High strength Less water absorption No efflorescence Lower unit weight, less load on foundation

Economic saving
Reduced Energy consumption Reduces excavation of clay Lower cost of brick as compared to clay brick of same quality Less consumption of mortar Less no. of joints in case of blocks

Fly ash in cement , mortar and concrete

Ordinary concrete: 20-40% fly ash
Roller compacted concrete: 60-70% fly ash Cellular light weight concrete: 20-40% fly ash High performance concrete: 20-40% fly ash High volume fly ash concrete: 50-70% fly ash Fly ash in mortar: 40%

Technical Advantage
High long term strength
Better workability Higher impermeability Less heat of hydration Corrosion resistance High resistance to aggressive environment More durability

How Fly Ash Contributes to Concrete Workability

fly ash produces more cementitious paste

Economic Savings
Saves on clinker cost
Reduces energy consumption Reduces raw materials Reduces overall consumption of cement

Fly Ash in Agriculture

Coal ash is used to boost soil fertility in some cases but is also adding a dose of arsenic and other toxic substances

Effect of fly ash on yield of crops

Use of fly ash in hydro sector

 Fly ash not only provide solution to heat of hydration in mass concreting but also makes the concrete stronger, durable and more

impervious. In roller compacted concrete fly ash substitutes around 65% of cement. Thus in addition to faster construction, it makes the construction more durable, economical and environmental friendly

Avenues of fly ash utilization in hydro sector

Mass concrete Conventional concrete with low ash content Conventional concrete with medium ash content Roller Compacted concrete with high ash concrete

Canals 1.Canal lining, in situ concrete, fly ash pre cast tiles, fly ash bricks, CLC tiles 2.Pre stressed concrete, masonary,RCC 3.Super-passages, aqueducts 4.Canal structures

 Grouting
Gravity Dams River Banks Concrete and Masonary Barrages Office/Residential complexes Roads and Embankments Development of Land and Horticulture, etc.

other products

Fly ash ceramic tiles

Granite Substitute
Fly ash content 60%
Good finish, properties comparable to natural

granite

Paints and Enamels

Fly ash exhibits better extending properties
Fly ash percentage 30-40%(in paints) and 18-

22% in enamels Corrosion and abrasion resistant Durable

Sustainable use of fly ash

Update of existing standards/specification
Standards/specifications for new utilization

areas Develop code for practice Supply chain management Government facilitation/support

Impediments
Mental block
Lack of awareness Security & logistic constraints at power plants to

streamline quick and easy delivery of ash Availability of ash in segregated form( bottom ash, pond ash and field ash of various kinds Packaging of ash Quality control of fly ash itself and its final products

Approach Required
Positive and pro-active approach as well as actions Having a well staffed fly ash utilization cell at

regional local/TPS level with adequate budgetary support to ensure Easy availability of fly ash Facilitation for fly ash users Improving quality of fly ash and delivery mechanism Close follow up and co-ordination with coming up infrastructure project Co-ordination with local user agencies/institutions To support r& d and dissemination of information on regular basis

Thanks:)