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FLY ASH AS RESOURCE IN DEVELOPMENT OF SUSTAINABLE GREEN TECHNOLOGIES OF BUILDING PRODUCT THROUGH MINERAL POLYMERISATION

B.D.NAYAK AND B.K.MISHRA Institute of Minerals and Material Technology Bhubaneswar
Institute of Minerals & Materials Technology Bhubaneswar

The polymerized matrix of silica and alumina is cementitious and sets in atmospheric temperature to develop the strength. Institute of Minerals & Materials Technology Bhubaneswar .MINERAL POLYMERIZATION The formation of chain like three dimensional tetrahedral SiO-Al-O poly-sialate hydrated structures by the chemical reaction of oxide phases of silica and alumina in alkaline condition is termed as mineral polymerization. The strength of the polymerized phases ranges 6 to 60 Mpa.

• Soil stabilization • Encapsulation of disposable toxic materials • High strength composite materials Institute of Minerals & Materials Technology Bhubaneswar .APPLICATION OF MINERAL POLYMERIZATION • As an alternate to portland cement in making building and other materials.

ADVANTAGES OF MINERAL POLYMER PRODUCTS • Durable and resistance to chemicals and acids • Heat resistance and performance better than OPC • Sustainable in developing green technology • Suitable for bulk use of thermal plant ash and other wastes Institute of Minerals & Materials Technology Bhubaneswar .

MINERAL POLYMERIZATION OF FLY ASH • • Fly ash is a rich source for silica and alumina It is suitable to form silico-aluminate polymer structures through chemical reaction The chemical reaction of silica and alumina of fly ash in alkaline medium results in formation of Na2O Al2O3 4SiO2 2H2O ( analcite mineral) CaO Al2O3 3SiO2 3H2O (scolecite mineral with lime) as the binding phases • Institute of Minerals & Materials Technology Bhubaneswar .

Strength of mineral polymer based fly ash product 60 50 Crushing strength. Mpa 40 30 MIX-1 20 10 0 1 3 5 10 15 20 25 30 35 40 45 50 55 60 Curing period in days Institute of Minerals & Materials Technology Bhubaneswar Scolecite phase MIX-2 Analcite phase .

MINERAL POLYMER BASED FLY ASH PRODUCT Building brick with 95% fly ash Cement free concrete block with 75% fly ash Institute of Minerals & Materials Technology Bhubaneswar .

DURABILITY OF FLY ASH MIX MINERAL POLYMER PRODUCT 410 Portable w ater 400 Crushing Strength(Kg/Cm 2) 390 380 370 360 350 340 3 6 9 12 15 Months 18 21 5% Na2SO4 w ater Sea w ater 5 % HCL w ater 24 27 Institute of Minerals & Materials Technology Bhubaneswar .

Process steps on manufacture of fly ash building brick through mineral polymerization Weighing Mixing Casting Curing Institute of Minerals & Materials Technology Bhubaneswar .

COMMERCIAL MANUFACTURE OF FLY ASH BUILDING BRICK THROUGH MINERAL POLYMERIZATION AT NTPC. Scale of operation: 200kg mix per batch 3. Casting: 4. Curing: Hydraulic press Exposed to atmospheric air Institute of Minerals & Materials Technology Bhubaneswar . Mix Composition: 92 – 94% fly ash 2. KANIHA PROJECT 1.

Formulation of fly ash mix design for brick with chemical activator Mixing of fly ash Casting of cubes Institute of Minerals & Materials Technology Bhubaneswar .

Manufacturing of brick on plant condition at NTPC. Kaniha Project Institute of Minerals & Materials Technology Bhubaneswar .

Manufacturing of bricks at NTPC. Kaniha Plant Institute of Minerals & Materials Technology Bhubaneswar .

53-2.17 10 230 110 115 Institute of Minerals & Materials Technology Bhubaneswar .82-2.17 10 230 110 115 93 7 14 .18 2.17 10 230 110 115 Pilot plant conditions 94 6 14 .Properties of bricks manufactured on plant conditions Parameters Fly ash wt% Chemical activator wt% Water on wt% Pan mixture time (min) Operative mould size Length (mm) Breadth (mm) Width (mm) Brick property (30 days of atmospheric curing) Dry weight (kg) Dry brick strength (kg/cm2) Wet brick strength (kg/cm2) Water absorption (%) 2.95 71-107 68-70 11-13 103-134 79-100 10-11 142-197 141-166 11-12 95 5 14 .15-3.40 2.17 10 230 110 115 92 8 14 .70 34-40 36-44 17-23 3.95-3.

kg/cm 2 No.Brick properties on 30 days of atmospheric curing Mix composition ( wt%) Fly ash Chemical activator 200 180 160 Crushing Strength. 4 92 8 Dry crushing strength 140 120 100 80 60 40 20 0 5 6 7 8 W et crushing strength W t% of Chemical Activa tor Institute of Minerals & Materials Technology Bhubaneswar .2 94 6 No. 1 95 5 No. 3 93 7 No.

Cost of production of bricks (based on 6000 brick) Utilities 5% chemical Activator (Rs.47 Fly ash (16 tonne) Chemical activator Electrical @ Rs.) 3200 10240 360 600 150 75 200 14825 Rs.) 3200 8960 360 600 150 75 200 13545 Rs. 4/ per kWh Labour and Supervision Maintenance and Repair Plant Overheads Depreciation Total Cost of production per brick Institute of Minerals & Materials Technology Bhubaneswar .30 7% chemical Activator (Rs.) 3200 7680 360 600 150 75 200 12265 Rs.2.2.04 6% chemical Activator (Rs.2.

• More than 90% fly ash can be used in manufacture of building brick.CONCLUSION • Mineral polymerization is very effective for bulk utilization of fly ash in making building products. Institute of Minerals & Materials Technology Bhubaneswar . • The process is cost effective and environmental friendly. • High strength materials like concrete consisting of fly ash can be produced by making suitable mix design.

Institute of Minerals & Materials Technology Bhubaneswar .