Fly ash Utilization- Present vision

Pinaki Sarkar

CSIR- Central Institute of Mining and Fuel Research,Dhanbad, India

Power Generation Scenario (INDIA)

* Installed capacity:187549.62 MW * Contribution of thermal power : 123758.98MW (66%

of total) [72%]* 85% of total thermal power is coal based, [90%]

* During 2011-12 the coal consumption ( power) =415 million ton (against 253 million ton in 2002-03),

i.e., CAGR: 5.65%* Ash content of Indian coals : 30-50%

* For Developing Clean energy production mechanism

different steps have already been taken under the 12th five year

plan programme

* Clean energy Development- Brightest side of power generation

*Huge Fly ash generation – Darkest Side of electricity generation

.

Fly ash utilisation (INDIA): ~ 40% of total FA generation

Country Annual ash production, MT

Ash utilization %

China 100 45

USA 75 65

Germany 40 85

UK 15 50

Australia 10 85

Canada 6 75

France 3 85

Denmark 2 100

Italy 2 100

Nether land 2 100 Ref: Alam and Akhtar , Int Jr of emerging trends in engineering and development , Vol.1 [1] , (2011)

Progress of fly ash utilization in India also appears to be very

significant in respect of huge production and several constraints

towards implementation of utilization strategies.

(India -highest producer of fly ash in the world ?? )

What are necessary:

* Awareness about the Social, technological and commercial issues

*Confidence building for fly ash utilization in different sectors

(viz., Cement products, building bricks, Agriculture and as Fill

material)

*Continual improvement of fly ash disposal technology

Different modes of FA utilisation•Cement blending,• Building materials•Mine filling

•Road and pavement construction•Agriculture/soil amendment

•Concrete and mortar•Light weight aggregate

•Manufacture of asbestos products•Embankment / Land development

•Floor and wall tiles•Refractory bricks / tiles

•Paint Industry•Domestic scouring Powder ,etc

Contribution of CSIR-CIMFR ( Formerly, CFRI and CMRI)

Mine filling

Embankment / Land development,

Agriculture

Manufacturing of value added products

(bricks, tiles, etc.).

CFRI’s Fly ash Brick making technology

Lime bonded fly ash bricks (Steam curing, Accelerator), CCS ~100-150 kg/cm2, BD ~1.55 g/cc, water absorption ~20%, Durable under the saline condition., Saving in cement consumption : ~ 30% in plastering ~20% in Mortar. The process/ technology received NRDC award, CSIR technology award and Bangur Memorial award. The process was patented and commercialized.

CFRI’s Fly ash Brick making technology

In 1986, first commercial plant - Jagaddhatri Brick Industries Pvt. Ltd. ( Barrackpore) - 20, 000 bricks / day

Second plant - M/S Bright Bricks Pvt. Ltd. at Raichur, Karnataka- capacity 30000 bricks/ day

Thirumala Fly ash Tech Pvt. Ltd - Vijaywada

M/s S. S. Brick Field (P) Ltd.- Bandel

The Biggest plant : Pulver Ash Projects Ltd. , Bandel, capacity: 90,000 bricks per day

Past contribution of CFRI continues:

The Institute developed water curing technique

Durability parameters of FA bricks were examined by CFRI

The institute worked for the promotion of fly ash based brick manufacturing at different locations

and addressed different problems and concerns.

The institute has got patented process on ‘Fly ash based Domestic Scouring Powder’.

Utilisation potential of Fly ash:

depends on characteristics of available fly ash from different power plants

Typical Characteristics of Indian Fly ash:

SiO2: 49-67%, Al2O3: 16-29%, Fe2O3: 4-10%, CaO: 1-4%, MgO: 0.2-2%, TiO2: 1-2%, SO3: 0.1-2% alkalies: 1-2%, Unburned Carbon: 0.1 – 15%, Density (gm/cc): 1.9 -2.4; Particle size (micron): 8-22

Future technological advancement Vs some concerns

Super critical/ ultra-supercritical technology

Co-combustion technology ,

Oxy-fuel technology, etc.

Growing consumption of imported coals in blends with Indian coals

Fly ash characteristics are going to change ??

Fly ash utilization strategy to Change

Fly ash utilization aspects may be reviewed in respect of envisaged changes in power generation technology