flyash management in india

7/27/2019 Flyash Management in India

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Fly Ash Utilisation Programme (FAUP)Technology Information, Forecasting & Assessment Council,

Department of Science & Technology, Government of India

FLY ASH MANAGEMENT IN

INDIA : AN INTEGRATED

APPROACH

Visit us at : www.tifac.org.in

OBJECTIVE

Confidence building i n fl yash disposal / gainful util isation

technologies

THROUGH

Technology Demonstration Projects with participation of

industry.

PARTNERS

I ndustry, Power uti li ties, R&D organisations, User agencies,

Academia & acili tating/ Regulating M in istries/ Departments/

Agenci es etc.

!! FAUP: OBJECTIVE""* Erstwhile Fly Ash Mission (FAM) Commenced in

1994

FLY ASH...A RESOURCE MATERIAL

Cement Application - Pozzolanic Characteristics

Geotechnical Appl ications - Engineering Propert ies

Filling Applications - Near Inert Material

Ceramic Application - Morphol ogical Pro perti es

Agricul tural App li cati ons - Phys ical & Chemi cal Prop ert ies

ASH GENERATION AND UTILISATION IN VARIOUS COUNTRIES

S.No.

Country Annual AshProduction

(Million Tonne)

Ash Ut ili sati on% of AshProduced

Major Area ofUtilisation

1 USA 75 65 Cement, concrete, bricks, fillmaterial

2 China 100 45 Concrete, bricks, fill materials,cement

3 Germany 40 85 Cement, concrete, minefill

4 UK 15 50 Cement, fill material

5 Japan 8 60 Cement, concrete agriculture, fillmaterial

6 Australia 10 85 Blended cement, fill material

7 Canada 6 75 Cement, fill materials, buildingmaterials

8 France 3 85 . . . . . . . do . . . . . . .

9 Denmark 2 100+ . . . . . . . do . . . . . . .

10 Italy 2 100 . . . . . . . .do . . . . . . .

11 Netherlands 2 100+ . . . . . . . . do . . . . . . .

12 India 112 38 . . . . . . . . do . . . . . . .

Indian Scenario

Fly Ash Generation and Utilisation

1994

FA Generation --- 40 Million Tonne

FA Utilisation --- 3% (1.2 Million Tonne)

March 2005


FA Utilisation --- 38% (42 Million Tonne)

Indian ScenarioFly Ash Generation and Utilisation

..PROJECTIONS

..

2012


FA Utilisation --- 100% (Target)


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Fig 1 Ash generation and utili sation

10198

95

9085

80

70

60

50

40

108 112

1.2 2.54.2

79.5

1516

19

2225

33

42

0

20

40

60

80

100

120

1993-

94

95 96 97 98 99 2000 2001 2002 2003 2004 2005

Year

Milliontonne

Fly Ash Generation Fly Ash Uti lisation

1

23

1

2

3

Cement Manufacture / - 89%

Substitution

Low Lying Area Fill - 10%

Brick Manufacturing - 1%

Utilisation Areas- 1994

Total utili sation 1MnT / year

1

2

3

4

56 7

8

1

2

3

4

5

6

7

8

Cement Manufacture / Substitution - 49%

Low Lying Area Fill - 17%

Roads & Embankments - 22%

Brick Manufacturing - 2%

Dyke Rais ing - 4%

Minefills - 2%

Agriculture - 1%

Others - 3%

Utilisation Areas 2004-05Total utili sation 42 MnT / year

METTUR

CHIDAMBARAM

RAICHURVIJ AYAWADA KO TH AGUD AM

MUMBAI ANGUL CUTTACK

KHARAGPUR

FARAKKA

SARNI

BHOPAL

JAIPUR

RIHANDNAGARALLAHABAD

BHATINDA

ROPARDELHI

PANIPATFLYASH MISSION,TIFAC

PROJECT SITES

BAKRESHWAR

CHANDRAPU

R

NASIK

CHENNAI

THRUST AREAS

UTILISATION

Roads & Embankments Building Components Hydraulic Structures Agr icu ltu re Relat ed Stu dies & Ap pli cati ons Minefills

SAFE MANAGEMENT

Ash Pond Managemen t Reclamation of Abandoned Ash Ponds

FACILITATION

Characterisation of Fly Ash Handling and Transportation Research & Development

Fly Ash

in

Roads & Embankment


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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 iseliminated

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 thermalpower plants

additional agricultural produce from the landwhich 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


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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.


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Buildings at Delhi

Building at Kolkata

Clay Fly AshBricks


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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


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ECONOMIC SAVINGS

Cement / Mortar / Concrete

Saves on Clinker Cost

Reduce Energy Consumption

Reduces raw material (lime stone, iron ore etc.) cost

Reduces overall consumption of cement

Flyash in Buildings

BUILDING COMPONENTS

Cellular Light Weight Concrete

In roofing at Chennai At HITEC City, Chennai

FLY ASH BRICKS & CONCRETE USED IN TIFAC BUILDING AT DELHI

Fly Ash

in

Mining Sector

PROJECTS UNDERTAKEN

1. Durgapur Raitwari Colliery, WCL-Chandrapur through Normal Surface

Bunker & Katora Bunker

More than 12000 mpond ash stowed in panel Nos.

16,17, 18, 28 & 30 ( 6000 mpond ash & 6500 m

pond ash mixed with sand)

2. PK-1 mine, SCCL- Manuguru

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

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


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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 completemine 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 WCL-

Chandrapur also.


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Fly Ashin

Agriculture

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


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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 animalconsumption. 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 withflyash at 60 t/ha, at Raichur, Karnataka

Cultivation o f cabbage on coal ash amended soilat Dodhar, Rihandnagar (U.P.)

Saline soil reclamation using fly ash


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Forestry at BTPS ash pond Carnation at BTPS ash pond

USE OF FLY ASH IN

HYDRO SECTOR

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

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%)

CONT./2-

Ghatghat Pumped Storage Scheme Upper Dam


Tunnel Lining

Reinforced cement concrete works

Foundations

Super-structures

Pre-stressed concrete structure

Shotcrete / Gunite

Diaphragm walls for under seepage control

CONTD./3-


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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

TOTAL 14210 Cum QUANTITY OF RCC PLACED IN 38 DAYS

SUCCESSFUL COMPLETION OF SADDLE DAM NO 1


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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


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PAINT & ENAMELS

Flyash exhibits better extending properties (less

absorption)

Flyash percentage 30-40% (in paints), 18-22% (in

enamels)

Corrosion & abrasion resistant

Durable

Developed by RRL-Bhopal.

Handling and transportation

Dry fly ash availability

Handling and transportation

Segregated collection of dry fly ash

Bagging of dry fly ash

Capability building

Dadri thermal power station project

dense phase conveying of flyash slurry and

separate handling of flyash and bottom ash

Safe Management ash pond

Use of abandoned ash pond

Human habitat on NFL Panipat ash pond

Forestry at Badarpur thermal power plant ash pondContd

Safe Management of Ponds

# Dyke design, construction & maintenance

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

# Densification of ash ponds for

Seismic stability

Increasing the load bearing capacity

Vibroflotation column

technology at VijaywadaBlasting technique at

Metturthermal 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


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FACILITATION

Networking of Laboratories & Experts

Consultancy Services

Creating Awareness

Policy Initiatives

Patiala

Delhi

Roorkee

Kanpur

Vadodara

Mumbai

Hyderabad

Bangalore Chennai

Chidambaram

Raichur

Dhanbad

Bhubaneshwar

Jamshedpur

Kharagpur

Ludhiana

FLYASH MISSION, TIFAC

INSTITUTIONAL LIN KAGES

Bhopal

Ahmedabad

Thiruvananthapuram

Calcutta

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 Notifi cations ( 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

guidelin es iss ued by IRC (IRC SP 20 : 2003 )

Revision o f IS 3812the code for specifications of PFA for its use in Cement/

mortar/ conc rete (part 1) & as fine aggregate (part 2) - approved & under prin t.

Cntd..

INDICATIVE LIST OF POLICY

MEASURES

Specifications for other FA applications viz (i) lime pozzolanamixture applications, (ii) sintered application s, (iii) geotechnical

and (iv) agricult ural application are under preparation.

Updation of IS:456code of practice for plain and reinfor ced

concrete has been updated with use of fl yash.

Minimum and maximum percentages of flyash in PPC have been

increased to 15% and 35% respectively etc.

Fly ash bric ks standard ( IS 12894 ) has been updated.

Mental block

lack of awareness

Security & logistic constraints at power plants to streamline quick & easy

delivery of ash

Avai labi lit y of ash i n seg regated form (bot tom ash, p ond ash, f lyas h of d iff erent

fields

Packaging of ash

Quality control of flyash itself & its final products

IMPEDIMENTS


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$ 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

%

Easy availability of fly ash

% Facilitation for fly ash users

% Improving quality of f ly ash and delivery mechanism

% Close follow up & co-ordination with coming up infrastructure projects.

% Co-ordination with local user agencies / institutio ns

% To support R&D and dissemination of information on regular basis

APPROACH REQUIRED SUMMARYFly Ash Utilisation Potential

S .N O .

U T IL IS A T IO N A R E A P O T E N T IA L / Y E A R

U t i l i s a t i o n( M n T o n s . )

B e n e f i t s( R s . C r o r e s )

1 R o a d s & E m b a n k m e n t s 1 5 -2 0 1 0 02 B u i l d in g C o m p on en ts

B r i c k s / B l o c k s 3 0 3 0C e m e n t 2 5 2 5 0 0

3 M i n e F i l l 1 5 5 0 + A d d n c o a l4 A g r i c u l t u r e 1 0 0 3 0 0 05 R ec la m a t i o n o f L ow

L y i n g A r e a s1 5 7 5

6 W a s t e l a n dD e v e l o p m e n t

1 0 0 E n o r m o u sl an d s w o u l d b er e c o v e r e d

T o t a l > 3 0 0 5 8 5 5

1 . 2 5 B i l l i o nU S $

CONCLUSION

Let Us Harness a Billion Dollar

Resource That Has Been Wasted

So Far

InternationalCongress

December 4-7, 2005,

Venue : Convention Hall, Hotel Ashok, New Delhi, India

& Exhibition & Business Meets

Organised by

Fly Ash Utilisation Programme (FAUP)Technology Information, Forecasting & Assessment Council,

Department of Science & Technology, Government of India

THANK YOU

flyash management in india

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