04 Subhash-chandra Use of Fly Ash in Different Countries

8/6/2019 04 Subhash-chandra Use of Fly Ash in Different Countries

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2/22/2011 Subhash Chandra Sr.Engineer AUD NTPC Noida

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USE OF FLY ASH INUSE OF FLY ASH IN DIFFERENTDIFFERENTCOUNTRIESCOUNTRIES

Presented

BY

Subhash Chandra

Sr. Engineer (AUD)


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Various areas of use of AshVarious areas of use of Ash


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Ash production and use inAsh production and use indifferent countriesdifferent countries

Country/Region

AshProduction

(Millionton)

AshUtilization

(Mt)

UtilizationRate

%

Year References

USA 134.7 55.6 42.0 2008 ACAA, 2009

China 120.02 69.6 58.0 2000 Wang, 2004

EU 15 56.4 52.4 92.9 2008 ECOBA, 2009

Australia 13.8 2.5 18.0 2008 ADAA. 2009

Japan 11.0 10.7 97.2 2006 JCOAL, 2010

Canada 6.6 2.3 33.0 2006 CIRCA, 2010

India 145 78 50 2009 FAU


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4

5. Gypsum Panel

Products

5% 6. Waste

Stabilization/Solidifi

cation

3%

4. Mining

Applications

11%

7. Other

3. Structural

Fills/Embankments7%

8. Disposal58%

2. Blended

Cement/ Raw Feed

for Clinker

3%

1.

Concrete/Concrete

Products /Grout

8%

Utilization of Ash in USA; Different avenuesUtilization of Ash in USA; Different avenues(based on ACAA, 2009)(based on ACAA, 2009)

Production 134.7 Million Ton

Utilization 55.6 (42%)

Disposal 79.06


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2/22/2011 Subhash Chandra Sr.Engineer AUD NTPC Noida 5

CCP Categories Fly AshBottom

AshBoilerSlag

FGD Total

1. Concrete/ConcreteProducts /Grout

9.809.80 0.560.56 -- 0.240.24 10.5910.59

2. Blended Cement/ Raw

Feed for Clinker2.442.44 0.720.72 -- 0.420.42 3.583.58

3. Flowable Fill 0.260.26 0.110.11 -- 0.040.04 0.410.41

4. StructuralFills/Embankments

4.654.65 2.942.94 0.060.06 1.361.36 9.029.02

5. Road Base/Sub-base 0.200.20 0.770.77 -- -- 0.970.97

6. SoilModification/Stabilization

0.670.67 0.190.19 -- 0.100.10 0.960.96

7. Mineral Filler in Asphalt -- -- 0.050.05 -- 0.050.05

8. Snow and Ice Control -- 0.480.48 -- 0.050.05 0.530.53

9. Blasting Grit/RoofingGranules

0.050.05 0.080.08 1.621.62 -- 1.741.74

10. Mining Applications 2.152.15 0.500.50 0.040.04 12.3112.31 15.0015.00

11. Gypsum Panel Products -- -- -- 7.297.29 7.297.29

12. WasteStabilization/Solidification

3.523.52 0.010.01 -- 0.220.22 3.743.74

13. Agriculture 0.100.10 -- -- 0.280.28 0.390.39

14. Aggregate 0.090.09 0.450.45 0.030.03 -- 0.570.57

15. Miscellaneous/Other 0.800.80 0.470.47 0.030.03 -- 1.301.30

Total UtilizationTotal Utilization 55.6

DisposalDisposal 79.06

ContCont


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Utilization of Ash in Europe (EU15); DifferentUtilization of Ash in Europe (EU15); Differentavenues (based on ECOBA, 2009)avenues (based on ECOBA, 2009)

Aerated concrete

blocks

11%

Grouting

7%

Subgrade

stabilisation

5%

Pavement base

course

9%

Infill

9%

Blasting grit

10%

Projection plaster

13%

Gypsum blocks

5%

Other uses

13%

Disposal

7%

Set retarder for

cement

11%

Production 56.42 Million TonUtilization 54.8 (92.9%)

Disposal 4.00


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Total Production 56.42 Mt56.42 Mt

Sector of use Fly Ash BottomAsh

BoilerSlag

Other

Cement raw material 3.8633.863 0.3110.311

Blended cement 2.462.46 0.0640.064 0.0050.005Concrete addition 5.765.76 0.0650.065 0.130.13

Aerated concrete blocks 0.6630.663 0.0090.009

Non-aerated concreteblocks

0.3110.311 0.8860.886 0.0490.049

Lightweight aggregate

Bricks + ceramics 0.0930.093 0.0190.019 0.0570.057

Grouting 0.3460.346 0.0150.015 0.0670.067

Asphalt filler 0.0950.095

Subgrade stabilisation 0.1280.128 0.1610.161 0.010.01

Pavement base course 0.0030.003 0.1220.122 0.4120.412

General engineering fill 1.5561.556 0.5160.516 0.0910.091

ContCont


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ContCont

Structural fill 1.8411.841 0.1820.182 0.0190.019

Soil amendment 0.040.04 0.0020.002

Infill 0.4460.446 0.0640.064

Blasting grit 603603 0.6030.603

Plant nutrition 0.0080.008

Set retarder for cement 0.6380.638

Projection plaster 0.8170.817

Plaster boards 5.5775.577

Gypsum blocks 0.3030.303

Self levelling floor screeds 1.5331.533

Other uses 0.0870.087 0.0680.068 0.1440.144 0.0860.086Reclamation, Restoration 17.07917.079 1.9011.901 1.8741.874

Temporary stockpile 0.8290.829 0.2160.216 0.3210.321

Disposal 2.2312.231 0.4590.459 1.3831.383


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Utilization of Ash in Australia; Different avenuesUtilization of Ash in Australia; Different avenues(based on ADAA, 2009)(based on ADAA, 2009)

Di l

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Production 13.76 Million TonUtilization 2.51 (18.0%)

Disposal 11.25


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Total Ash ProducedTotal Ash Produced 13.7613.76 MtMt

CCP Use (M Tonnes) FlyAsh

BottomAsh

Cenosphere

Combined

Category 1Category 1

Concrete/Concrete Products/Grout

1.551.55 0.020.02 0.000.00 1.571.57

Cement/ Raw Feed for Clinker

Mineral Fillers


Flowable Fill CLSM 0.310.31 0.220.22 0.000.00 0.530.53

Structural Fills/Embankments

Road Base/Sub-baseSoil Modification/Stabilization

Mineral Filler in Asphalt

Agriculture

Aggregate


Mining Applications (e.g.

Backfill)

0.110.11 0.000.00 0.000.00 0.110.11

WasteStabilization/Solidification

Miscellaneous/Other

Total of All Beneficially Used inTotal of All Beneficially Used in20082008

0.030.03 0.260.26 0.010.01 2.22

Total of All Sold in 2008Total of All Sold in 2008 1.971.97 0.240.24 0.000.00 0.29


ContCont


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Cement

66%

Public Works

13%

Disposal

3%Other

13%

Construction

Works

4%

Agriculture,

Forestry &

Fisheries

1%

Utilization of Ash in Japan; Different avenuesUtilization of Ash in Japan; Different avenues(based on JCOAL, 2006)(based on JCOAL, 2006)


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ItemElectric Power

UtilitiesGeneral

Industries Total

SectorSector Contents Qty % Qty % Qty %

CementCement

Raw material 48164816 61.6461.64 20692069 72.7572.75 68856885 62.6162.61

Admixture 103103 1.321.32 174174 6.126.12 277277 2.62.6

Ready mixed 109109 1.41.4 00 00 109109 1.021.02

TotalTotal 5028 64.35 2243 78.87 7271 66.23

PublicPublicworksworks

Soil treatment 209209 2.682.68 102102 3.593.59 311311 2.922.92

Public works 506506 6.486.48 3535 1.231.23 541541 5.085.08

Public works for

electric power 4646 0.590.59 00 00 4646 0.430.43Subgradestabilization 136136 1.741.74 162162 5.75.7 298298 2.82.8

Asphalt filler 1010 0.130.13 00 00 1010 0.090.09

Backfilling in coalmines 203203 2.62.6 00 00 203203 1.91.9

TotalTotal1110 14.21 299 10.51 1409 13.22

ContCont


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Construction worksConstruction works Construction board 227227 2.912.91 138138 4.854.85 365365 3.423.42

Lightweightaggregate 00 00 00 00 00 00

Concrete product 2929 0.370.37 11 0.040.04 3030 0.280.28

Others 00 00 00 00 00 00

TotalTotal 256 3.28 139 4.89 395 3.71

Agriculture, forestryAgriculture, forestry& fisheries& fisheries Fertilizer 5050 0.640.64 2222 0.770.77 7272 0.680.68Soil improvement 1010 0.130.13 7979 2.782.78 8989 0.640.64

Thawing material 00 00 00 00 00 00

TotalTotal 60 0.77 101 3.55 161 1.31

OthersOthers Sewage 22 0.030.03 11 0.040.04 33 0.030.03

Iron manufacture 1111 0.140.14 11 0.040.04 1212 0.110.11

Others 13461346 17.2317.23 6060 2.112.11 14061406 13.1913.19

TotalTotal 1359 17.39 62 2.18 1421 13.33


ContCont


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Road Base /

Subbase

2%

Wall Board

5%

er3%

sposal

70%

M

Application

1%

Concrete /

Grout

7%

Cement

12%

Utilization of Ash in Canada; DifferentUtilization of Ash in Canada; Differentavenues (based on CIRCA, 2010)avenues (based on CIRCA, 2010)


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Total Production 6.4 Mt

Uses Area Fly AshBottom

AshFGD

Gypsum Other Total

Cement 0.6380.638 0.1470.147 0.010.01 00 0.7950.795

Concrete / Grout 0.4720.472 00 00 00 0.4720.472

Mining Application 0.0890.089 00 00 00 0.0890.089Road Base /Subbase 0.0170.017 0.0940.094 00 00 0.1110.111

Wall Board 00 00 0.3130.313 00 0.3130.313

Other 0.0840.084 0.0060.006 0.0430.043 0.0390.039 0.1720.172

Disposal 4.454.45

ContCont


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Utilization of Ash in China; Different avenuesUtilization of Ash in China; Different avenues(based on Wang & Wu, 2004)(based on Wang & Wu, 2004)

D

6,8%

r

r

C v

g r g

,8%

R r

6, %

gr r

,8%

r

, %

In some developed areas, Shanghai, Nanjing and Nantongof Jiangsu Province and Nanchang of Jiangxi Province, theutilization rate of produced fly ash was 100% in the pastfive years and used extensively in geotechnical engineering

of road construction and wallboard materials


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Fly ash in high value added applicationsFly ash in high value added applications

Category High value-added applications

Mineralextraction

Alumina

Magnetite

Iron

CarbonCenospheres

Other minor and trace items


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Constructionand

engineering

Enhanced Pozzolana cement

Oil Well Cement

Decorative glass

Ceramic Fibers

Glazed floor and wall tilesAsh alloys

Synthetic marble

High ware resistance ceramic tile

Reflective material

Ultra light hollow sphere for arid zone

Continuous casting mould powder

Domestic cleaning powder

Synthetic wood

ContCont


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ContCont


Filler Mineral fillers

Distemper

Plastic fillers

Protective

material

Fire Bricks

Fire abatement applicationsGlass Ceramics

Foam insulation products

Anti-corrosion coating

Mineral Wool

Wastetreatmentmaterial

FGD Adsorbent

Synthetic Zeolites

Activated Cenospheres

Agriculture Cultivation

Potassium silicate fertilizer


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ContCont

These kinds of high value added productsconsume lower volume of fly ash than that ofconstruction, back fill and road pavementapplications

However, they have the potential in generatingconsiderable sales revenues for power plants andmanufacturers, which helps to prompt the

development of different high level Ashtechnologies


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EcoEco--Industry ParkIndustry Park

(A conceptual model)(A conceptual model)

EIP derived from the idea of industry

symbiosis could be realized to optimize andmaximize the use of Ash

Ash generated from the power plants are

used as feed stocks for various applicationsand the produced electricity is supplied to

those plants as primary energy source


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There is a need for concerted effort to promotethe "technically sound", "environmentally safe",

and "economically justified" utilization of Ash.

A number of researches and projects on highlevels utilization of Ash have been carried out inmany part of world, however, the majority ofwhich have not yet been commercialized.

It should be emphasized that transforming suchlaboratory- or pilot-scale technologies intoindustrial productivity is of the highest priorityfor increased use of Ash.

ConclusionConclusion


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Fly ash should be considered as anessential ingredient of concrete and

not merely for replacement of

cement or reduction in cost


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ThanQ?ThanQ?

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04 Subhash-chandra Use of Fly Ash in Different Countries