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FAUP: OBJECTIVE ""

FLY ASH MANAGEMENT IN INDIA : AN INTEGRATED APPROACH

* Erstwhile

Fly Ash Mission (FAM) Commenced in

1994

OBJECTIVE
Confidence building in flyash disposal / gainful utilisation technologies

THROUGH
Technology Demonstration Projects with participation of industry.

Fly Ash Utilisation Programme (FAUP)

Technology Information, Forecasting & Assessment Council, Department of Science & Technology, Government of India

PARTNERS
Industry, Power utilities, R&D organisations, User agencies, Academia & acilitating/ Regulating Ministries/ Departments/ Agencies etc.

Visit us at : www.tifac.org.in

FLY ASH ... A

Cement Application Geotechnical Applications Filling Applications Ceramic Application Agricultural Applications

ASH GENERATION AND UTILISATION IN VARIOUS COUNTRIES

S. No.
1 2

RESOURCE MATERIAL
- Pozzolanic Characteristics - Engineering Properties - Near Inert Material - Morphological Properties - Physical & Chemical Properties

Country

Annual Ash Production (Million Tonne)

75 100 40 15 8 10 6 3 2 2 2 112

Ash Utilisation % of Ash Produced

65 45 85 50 60 85 75 85 100+ 100 100+ 38

Major Area of Utilisation

Cement, concrete, bricks, fill material Concrete, bricks, fill materials, cement Cement, concrete, minefill Cement, fill material Cement, concrete agriculture, fill material Blended cement, fill material Cement, fill materials, building materials . . . . . . . do . . . . . . . . . . . . . . do . . . . . . . . . . . . . . .do . . . . . . . . . . . . . . . do . . . . . . . . . . . . . . . do . . . . . . .

USA China Germany UK Japan Australia Canada France Denmark Italy Netherlands India

3 4 5 6 7 8 9 10 11 12

Indian Scenario Fly Ash Generation and Utilisation

1994 FA Generation FA Utilisation March 2005 FA Generation FA Utilisation ----112 Million Tonne 38% (42 Million Tonne) ----40 Million Tonne 3% (1.2 Million Tonne)

Indian Scenario Fly Ash Generation and Utilisation

..PROJECTIONS..

2012 FA Generation FA Utilisation --- 170 Million Tonne --- 100% (Target)

Fig 1 Ash generation and utilisation

Utilisation Areas- 1994

Total utilisation 1MnT / year
112

120 108 98 101

100 85 80 80 70 60 60 40 40 50

95 90

1 Cement Manufacture / - 89%

Substitution
42 33 25 22 16 19

Million tonne

2 Low Lying Area Fill 3 Brick Manufacturing

- 10% 1%

20 4.2 7 9.5

15

1.2 0
199394

2.5

95

96

97

98

99

2000

2001

2002

2003

2004

2005

Year Fly Ash Generation Fly Ash Utilisation

Utilisation Areas 2004-05

Total utilisation 42 MnT / year
1 Cement Manufacture / Substitution - 49% 2 Low Lying Area Fill 3 Roads & Embankments 4 Brick Manufacturing 5 Dyke Raising 6 Minefills 7 Agriculture 8 Others
17% 22%
5 4 6 7 8

PANIPAT ROPAR

FLYASH MISSION,TIFAC PROJECT SITES

DELHI RIHANDNAGAR ALLAHABAD FARAKKA

BHATINDA JAIPUR BHOPAL SARNI

2% 4%
3

BAKRESHWAR KHARAGPUR ANGUL CUTTACK

CHANDRAPU R MUMBAI
1

2% 1% 3%
2

NASIK RAICHUR METTUR VIJAYAWADA CHENNAI CHIDAMBARAM KOTHAGUDAM

THRUST AREAS
UTILISATION Roads & Embankments Building Components Hydraulic Structures Agriculture Related Studies & Applications Minefills Ash Pond Management Reclamation of Abandoned Ash Ponds Characterisation of Fly Ash Handling and Transportation Research & Development

SAFE MANAGEMENT

Fly Ash in Roads & Embankment

FACILITATION

ROADS & EMBANKMENTS

Technical Advantages
Good compaction High range of OMC 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)

ROADS & EMBANKMENTS

Economics 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 agricultural produce from the land which would otherwise have been Excavated for getting soil Used for fly ash disposal

Roads & Embankments

Okhla flyover

Okhla flyover

APPROACH ROAD EMBANKMENT, NIZAMUDDIN

APPROACH ROAD EMBANKMENT IN FLOOD ZONE, NIZAMUDDIN

SARITA VIHAR FLY OVER

Punjabi Bagh flyover

Rural Road at Raichur

Fly Ash in Building Components

TECHNICAL ADVANTAGES
Bricks & Blocks Better finish High strength Less water absorption No efflorescence Lower unit weight, less load on foundation

ECONOMIC SAVINGS Fly Ash Bricks & Blocks

Reduced Energy Consumption Reduces excavation of clay Lower cost of brick as compared to clay brick of same quality. Number of bricks required per unit volume of construction is less. Less consumption of mortar. Less number of joints in case of blocks . Plastering may be avoided or if it is to done, the thickness of plaster required is less.

Building at Kolkata

Buildings at Delhi

Clay Fly Ash Bricks

FLY ASH IN CEMENT, MORTAR & CONCRETE

FLY ASH IN CEMENT, MORTAR & 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 : 20-40%

TECHNICAL ADVANTAGES
Cement / Mortar / Concrete High long term strength Better workability Higher impermeability Less heat of hydration Corrosion resistance High resistance to aggressive environment More durability

ECONOMIC SAVINGS
BUILDING COMPONENTS Cement / Mortar / Concrete Saves on Clinker Cost Reduce Energy Consumption Reduces raw material (lime stone, iron ore etc.) cost Reduces overall consumption of cement
In roofing at Chennai

Flyash in Buildings
Cellular Light Weight Concrete

At HITEC City, Chennai

Fly Ash in Mining Sector

FLY ASH BRICKS & CONCRETE USED IN TIFAC BUILDING AT DELHI

PROJECTS UNDERTAKEN
1. Durgapur Raitwari Colliery, WCLChandrapur through Normal Surface Bunker & Katora Bunker
More than 12000 m pond ash stowed in panel Nos. 16,17, 18, 28 & 30 ( 6000 m pond ash & 6500 m pond ash mixed with sand)

RESULTS OF POND ASH STOWING Technical

Excellent flow characteristics

Good load bearing capacity of ash fill No subsequent settlement Good water percolation rate Load on barricade is very low Fines escaping through barricade <1%

2. PK-1 mine, SCCL- Manuguru

More than 10000 m pond ash stowed in panel No.SP-1

RESULTS OF POND ASH STOWING Environmental

No excavation and transportation of scarce river bed sand

Enormous reduction in water requirement Less water to be pumped out Discharged water is absolutely safe Large scale utilization of ash Release of coal stuck up in pillars

Satisfied with the experience of demonstrations of Pond Ash stowing in underground minefills, the project for large scale adaptation of the technology at SCCL-Manuguru has started. A complete mine panel of 1.5 lac m void capacity has been taken up for pond ash stowing at SCCL-Manuguru. A similar large-scale project is being planned at WCLChandrapur also.

AGRICULTURE APPLICATIONS
Fly Ash Improves Soil texture Reduces bulk density of soil Improves water holding capacity Optimizes pH value Improves soil aeration Reduces crust formation Provides micro nutrients like Fe, Zn, Cu, Mo, B etc. Provides macro nutrients like K, P, Ca, etc

Fly Ash in Agriculture

Agriculture Related Application of Fly Ash

Field crops Forestry Floriculture Reclamation of Wasteland

The produce as well as the biomass have been evaluated for toxicology, nutritional value as well as radioactivity and have been certified as good material for human and animal consumption. In some cases significant increase in minerals (iron and calcium) have been noticed which is beneficial.

Mustard in fly ash improved soil, Kharagpur, W. Bengal

Increased seed yield of sunflower with flyash at 60 t/ha, at Raichur, Karnataka

Cultivation of cabbage on coal ash amended soil at Dodhar, Rihandnagar (U.P.)

Saline soil reclamation using fly ash

Forestry at BTPS ash pond

Carnation at BTPS ash pond

Hydro Sector

USE OF FLY ASH IN HYDRO SECTOR

Fly ash not only provides solution to heat of hydration in mass concreting but also makes the concrete stronger,durable and more impervious.In Roller Compacted Concrete fly ash subsititutes around 65 per cent of cement. Thus, in addition to faster construction it makes construction more durable, economical and environment friendly.

AVENUES OF FLY ASH UTILISATION IN HYDRO SECTOR

AVENUES OF FLY ASH UTILISATION IN HYDRO SECTOR

Mass Concrete Conventional concrete with low ash content (10-15%) Conventional concrete with medium ash content (30-35%) Roller Compacted Concrete with high ash content (65-70%) Tunnel Lining
Reinforced cement concrete works Foundations Super-structures Pre-stressed concrete structure

CONT./2-

Shotcrete / Gunite Diaphragm walls for under seepage control CONTD./3-

Ghatghat Pumped Storage Scheme Upper Dam

AVENUES OF FLY ASH UTILISATION IN HYDRO SECTOR

AVENUES OF FLY ASH UTILISATION IN HYDRO SECTOR

Canals Canal lining : Insitu concrete, fly ash pre-cast tiles, fly ash bricks, CLC tiles Pre-stressed concrete, masonry, RCC Super-passages, aqueducts Canal structures, etc.

CONTD./3-

Grouting Gravity Dams River banks Concrete and Masonry Barrages Office / Residential Complexes Roads & Embankments Development of Land and Horticulture, etc.

RCC Layer Placement

Compaction by the roller passes

In-situ Density by Nuclear densiometer

SUCCESSFUL COMPLETION OF SADDLE DAM NO 1 TOTAL 14210 Cum QUANTITY OF RCC PLACED IN 38 DAYS

Other Products

GRANITE SUBSTITUTE
Fly ash content 60% Good finish, properties comparable to natural granite Developed by BHEL Pilot production started Used at BHEL Corporate Office, New Delhi

PAINT & ENAMELS

Flyash exhibits better extending properties (less

Handling and transportation Dry fly ash availability Handling and transportation Segregated collection of dry fly ash Bagging of dry fly ash Capability building

absorption) Flyash percentage 30-40% (in paints), 18-22% (in enamels) Corrosion & abrasion resistant Durable Developed by RRL-Bhopal.

dense phase conveying of flyash slurry and separate handling of flyash and bottom ash

Dadri thermal power station project

Safe Management ash pond Use of abandoned ash pond

Safe Management of Ponds

# Dyke design, construction & maintenance

Dyke constructed with flyash at Korba thermal power station, Madhya Pradesh

Human habitat on NFL Panipat ash pond

# Densification of ash ponds for Seismic stability Increasing the load bearing capacity

Forestry at Badarpur thermal power plant ash pond

Contd

Vibroflotation column technology at Vijaywada

Blasting technique at Mettur thermal power plant

CONFIDENCE BUILDING IN FA TECHNOLOGIES

Technology Demonstration Projects Participation of Stake-holder Agencies Dissemination of Information Multiplier Effects

CAPABILITY BUILDING
Workshops / Seminars Training programmes Experience Sharing Meets

Patiala

FLYASH MISSION, TIFAC INSTITUTIONAL LIN KAGES

Roorkee Kanpur

FACILITATION
Networking of Laboratories & Experts Consultancy Services Creating Awareness Policy Initiatives

Ludhiana Delhi

Dhanbad Calcutta Kharagpur

Bhopal Ahmedabad Vadodara Mumbai Raichur Bangalore Thiruvananthapuram Hyderabad Chennai Chidambaram

Jamshedpur

Bhubaneshwar

SUSTAINABLE USE OF FLY ASH

Update of Existing Standards / Specification Standards/ Specifications for new utilisation areas Develop Code of Practice Supply Chain Management Government Facilitation / Support

INDICATIVE LIST OF POLICY MEASURES

MOEF Notifications ( 14th Sept. 1999 & 27th Aug. 2003) Design guidelines for use of flyash in road embankments brought out by IRC ( IRC SP 58 : 2001 ) Use of fly ash for construction of rural roads has been approved and guidelines issued by IRC (IRC SP 20 : 2003 ) Revision of IS 3812 the code for specifications of PFA for its use in Cement/ mortar/ concrete (part 1) & as fine aggregate (part 2) - approved & under print. Cntd..

INDICATIVE LIST OF POLICY MEASURES

Specifications for other FA applications viz (i) lime pozzolana mixture applications, (ii) sintered applications, (iii) geotechnical and (iv) agricultural application are under preparation. Updation of IS:456 code of practice for plain and reinforced concrete has been updated with use of flyash. Minimum and maximum percentages of flyash in PPC have been increased to 15% and 35% respectively etc. Fly ash bricks standard ( IS 12894 ) has been updated.
Mental block lack of awareness

IMPEDIMENTS

Security & logistic constraints at power plants to streamline quick & easy delivery of ash Availability of ash in segregated form (bottom ash, pond ash, flyash of different fields Packaging of ash Quality control of flyash itself & its final products

APPROACH REQUIRED
$ Positive & pro-active attitude as well as actions $ Having a well staffed fly ash utilisation cell at regional/ local/ TPS level with adequate budgetary support to ensure
%

SUMMARY Fly Ash Utilisation Potential

S. U T IL IS A T IO N A R E A NO. 1 2 3 4 5 6 P O T E N T IA L / Y E A R U tilis a tio n B e n e fits (M n T o n s .) (R s . C r o r e s ) R o a d s & E m b a n k m e n ts 1 5 -2 0 100 B u ild in g C o m p o n e n ts B r ic k s / B lo c k s 30 30 C em ent 25 2500 M in e F ill 15 50+A ddn coal A g r ic u ltu r e 100 3000 R e c la m a tio n o f L o w 15 75 L y in g A r e a s W a s te la n d 100 E n o rm o u s D e v e lo p m e n t la n d s w o u ld b e re c o v e re d T o ta l >300 5855 1 .2 5 B illio n US$

Easy availability of fly ash

% Facilitation for fly ash users % Improving quality of fly ash and delivery mechanism % Close follow up & co-ordination with coming up infrastructure projects. % Co-ordination with local user agencies / institutions % To support R&D and dissemination of information on regular basis

CONCLUSION
Let Us Harness a Billion Dollar Resource That Has Been Wasted So Far

International Congress
& Exhibition & Business Meets
December 4-7, 2005, Venue : Convention Hall, Hotel Ashok, New Delhi, India
Organised by

Fly Ash Utilisation Programme (FAUP)

Technology Information, Forecasting & Assessment Council, Department of Science & Technology, Government of India

THANK YOU