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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 Generation --- 112 Million Tonne
FA Utilisation --- 38% (42 Million Tonne)
Indian ScenarioFly Ash Generation and Utilisation
..PROJECTIONS
..
2012
FA Generation --- 170 Million Tonne
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
AVENUES OF FLY ASH UTILISATION IN HYDRO SECTOR
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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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-
AVENUES OF FLY ASH UTILISATION IN HYDRO SECTOR
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
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