International journal of emerging trends in Engineering and Development

Issue1, Vol 1August2011

FLY ASH UTILIZATION IN DIFFERENT SECTORS IN INDIAN SCENARIO

J.Alam1 and M.N Akhtar2
1

Associate Professor in Civil Engineering Department Aligarh Muslim University Aligarh India
2

P.G. Student in Civil Engineering Department Aligarh Muslim University Aligarh India

Abstract Current annual production of Fly ash, a by-product from coal based thermal power plant (TPPs), is about 112 million tonnes (MT). Some of the problems associated with Fly ash are large area of land required for disposal and toxicity associated with heavy metal leached to groundwater. Fly ash, being treated as waste and a source of air and water pollution till recent past, is in fact a resource material and has also proven its worth over a period of time. It is the action of human beings that determines the worth of any material. Materials having potential for gainful utilization remain in the category of waste till its potential is understood and is put to right use. Fly ash is one such example, which has been treated as waste materials, in India, till a decade back, and has now emerged not only as a resource material but also as an environment saviour. This paper presents different ways of using Fly ash in various sectors of civil engineering construction industry in India. Keywords: Fly ash, water pollution, TPPs.

1.1 Introduction
Fly ash is a naturally-cementatious coal combustion by-product. It is extracted by the precipitators in the smokestacks of coal-burning power plants to reduce pollution. About 120 coals based thermal power stations in India are producing about 112 million tonne fly ash per year. With the increasing demand of power and coal being the major source of energy, more and more thermal power stations are expected to be commissioned/ augment their capacities in near future. Fly ash has been considered as a Pollution Industrial Waste till about a decade back and was being disposed off in ash ponds. Indian coal has high ash content (35%-

RS PUBLICATION

Page 1

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

45%) and low calorific value (3500 kcal/kg 4000 kcal/kg) as a result of which huge quantity of fly ash is generated. It is expected to increase to about 200 MT per year by the year 2012. This would require about 4000 ha of land for the construction of ash ponds. Generally one acre of land is required per megawatt of power generation. Continuous studies have been carried out in India towards management of fly ash (FA), disposal and utilization. Out of total power generated of India, about 70% is produced by thermal power plants (TPPs). The Majority of thermal power plants 84% are run by coal; rest on gas (13%) and oil (3%). Thermal power plants uses 260 million tonnes (MT) of coal which is about 65% of annual coal produced in India The quality of flyash which depends on coal, coal particle fineness, percentage of ash in coal, combustion technique used, air/fuel ratio, burners used, and type of boiler. The Indian Government has taken a target of 31.1 million housing complex as per 2001 Census[1] out of which 24 million units are in rural area and 7.1 million units in urban areas, for that govt targeted the year 2010. In 1998, National Housing and Habitat Policy has been announced by the govt which aims for providing Houses for All and facilitating the construction of 20 lakh additional housing units (13 lakh in rural areas and 7 lakh in urban areas) annually, with emphasis on extending benefits to the poor and the deprived. Apart from the above housing needs, nearly 1% of the housing stock in the country is destroyed every year due to natural hazards. Large number of innovative alternate building materials and low cost construction techniques developed through intensive research efforts during last three to four decades satisfies functional as well as specification requirements of conventional materials/techniques and provide an avenue for bringing down the construction cost. Fly Ash, an industrial by-product from Thermal Power Plants (TPPs), with current annual generation of approximately 112 million tonnes and its proven suitability for variety of applications as admixture in cement/concrete/mortar, lime pozzolana mixture (bricks/blocks) etc. Cement and Concrete Industry accounts for 50% Fly Ash utilization, the total utilization of which at present stands at 30MT (28%). The other areas of application are Low lying area fill (17%), Roads & Embankments (15%), Dyke Raising (4%), Brick manufacturing (2%) and other new areas for safe disposal of fly ash is in paint industry, agriculture etc. Table 1 Fly ash generation and utilization in different countries S. No 1 Country India Annual ash production, MT 112 Ash utilization % 38

RS PUBLICATION

Page 2

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

2 3 4 5 6 7 8 9 10 11

China USA Germany UK Australia Canada France Denmark Italy Netherland

100 75 40 15 10 6 3 2 2 2

45 65 85 50 85 75 85 100 100 100

2.1 Classes of Fly Ash

According to ASTM C-618 Fly ash is broadly classified into two major categories: Class F and Class C fly ash. The chief difference between these two classes is the amount of calcium, silica, alumina, and iron content. The chemical properties of the fly ash are largely influenced by the chemical content of the coal burned (i.e., anthracite, bituminous, and lignite). 2.1.1 Class F fly ash The burning of old anthracite and bituminous coal typically produces Class F fly ash which contains less than 10% lime (CaO). Possessing pozzolanic properties, the glassy silica and alumina of Class F Fly ash requires a cementing agent, such as Portland cement, quicklime, or hydrated lime, with the presence of water in order to react and produce cementitious compounds. Alternatively the addition of a chemical activator such as sodium silicate (water glass) to a Class F ash can lead to the formation of a geopolymer. 2.1.1 Class C Fly ash Class C Fly ash produced from the burning of younger lignite or sub bituminous coal generally contains more than 20% lime (CaO). This type of ash does not require an activator & the contents of Alkali and sulfate (SO4) are generally higher as compare to the Class F Fly ash.

RS PUBLICATION

Page 3

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

Fig. 1 Typical ash colours (Class F & C Fly ash)

3.1 Disposal and market sources

In the past, fly ash produced from coal combustion was simply entrained in flue gases and dispersed into the atmosphere. This created environmental and health concerns that prompted laws which have reduced fly ash emissions to less than 1% of ash produced. Worldwide, more than 65% of fly ash produced from coal power stations is disposed of in landfills and ash ponds. In India alone, fly ash landfill covers an area of 40,000 acres (160 km2).The recycling of fly ash has become an increasing concern in recent years due to increasing landfill costs and current interest in sustainable development. As of 2005, U.S. coal-fired power plants reported producing 71.1 million tons of fly ash, of which 29.1 million tons were reused in various applications. If the nearly 42 million tons of unused fly ash had been recycled, it would have reduced the need for approximately 27,500 acre feet (33,900,000 m3) of landfill space. Other environmental benefits to recycling fly ash includes reducing the demand for virgin materials that would need quarrying and substituting for materials that may be energy-intensive to create (such as Portland cement).As of 2006, about 125 million tons of "coal-combustion by products," including fly ash, were produced in the U.S. each year, with about 43 percent of that amount used in commercial applications, according to the American Coal Ash Association Web site. As of early 2008, the EPA hoped that figure would increase to 50 percent as of 2011 [2].

RS PUBLICATION

Page 4

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

Some of the innovative and commonly manufactured eco friendly building material utilizing Fly Ash is covered below; 3.1.1 Cellular Light Weight Concrete (CLC) Blocks These are substitute to bricks and conventional concrete blocks in building with density varying from 800 kg/m3 to 1800 kg/m3. The normal constituents of this Foaming Agent based technology from Germany are cement, Fly Ash (to the extent 1/4th to 1/3rd of total materials constituent), sand, water and foam (generated from biodegradable foaming agent). Using CLC walling & roofing panels can also be manufacture. Foaming agent and the Foam generator, if used for production of CLC with over 25% fly ash content invites concession on import duty by Govt. of India [6]. 3.1.2 Development of Fly Ash Based Polymer Composites as Wood Substitute Fly ash based composites have been developed using fly ash as filler and jute cloth as reinforcement. After treatment, the jute cloth is passed into the matrix for lamination. The laminates are cured at specific temperature and pressure. Number of laminates is used for required thickness. The technology on fly ash Polymer Composite using Jute cloth as reinforcement for wood substitute material can be applied in many applications like door shutters, partition panels, flooring tiles, wall panelling, ceiling, etc. With regard to wood substitute products, it may be noted that the developed components / materials are stronger, more durable, resistant to corrosion and above all cost effective as compared to the conventional material i.e. wood. This technology has been developed by Regional Research Laboratory, Bhopal in collaboration with Building Materials & Technology Promotion Council (BMTPC) and TIFAC. One commercial plant has also been set up based on this technology near Chennai [7]. 3.1.3 Portland Pozzolana Cement Up to 35% of suitable fly ash can directly be substituted for cement as blending material. Addition of fly ash significantly improves the quality & durability characteristics of resulting

RS PUBLICATION

Page 5

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

concrete. In India, present cement production per annum is comparable to the production of Fly Ash. Hence even without enhancing the production capacity of cement; availability of the cement (fly ash based PPC) can be significantly increased [8]. 3.1.4 Ready mixed Fly Ash concrete Though Ready Mix concrete is quite popular in developed countries but in India it consumes less than 5 percent of total cement consumption. Only recently its application has started growing at a fast rate. On an average 20% Fly ash (of cementitious material) in the country is being used which can easily go very high. In ready mix concrete various ingredients and quality parameters are strictly maintained/controlled which is not possible in the concrete produced at site and hence it can accommodate still higher quantity of fly ash [7].

Fig.2 3.1.5 Fly Ash- Sand-Lime-(Gypsum /Cement) Bricks /Blocks Fly Ash can be used in the range of 40-70%. The other ingredients are lime, gypsum /cement, sand, stone dust/chips etc. Minimum compressive strength (28 days) of 70 kg/cm2 can easily be achieved and this can go up to 250 Kg/cm2 (in autoclaved type) [9].

RS PUBLICATION

Page 6

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

Fig.3 3.1.6 Fly Ash in Road Construction Fly ash can be used for construction of road and embankment. This utilization has many advantages over conventional methods. Saves top soil which otherwise is conventionally used, avoids creation of low lying areas (by excavation of soil to be used for construction of embankments). Avoids recurring expenditure on excavation of soil from one place for construction and filling up of low lying areas thus created. Fly Ash may be used in road construction for: i) Stabilizing and constructing sub-base or base. ii) Upper layers of pavements. iii) Filling purposes. Concrete with Fly Ash (10-20% by wt) is cost effective and improves performance of rigid pavement. iv) Soil mixed with Fly Ash and lime increases California Bearing Ratio (CBR), increased (84.6%) on addition of only Fly Ash to soil. Addition of Fly Ash has not shown any adverse effects on the ground water quality in the vicinity of experimental plots. V)National Highway Authority of India (NHAI) is currently using 60 lakh m3 of Fly Ash and proposed to use another 67 lakh m3 in future projects.

RS PUBLICATION

Page 7

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

Fig. 4 3.1.7 Roller compacted concrete Another application of using fly ash is in roller compacted concrete dams. Many dams in the US have been constructed with high fly ash contents. Fly ash lowers the heat of hydration allowing thicker placements to occur. Data for these can be found at the US Bureau of Reclamation. This has also been demonstrated in the Ghatghar Dam Project in India [7]. 3.1.8 Embankment Fly ash properties are somewhat unique as an engineering material. Unlike typical soils used for embankment construction, fly ash has a large uniformity coefficient consisting of claysized particles. Engineering properties that will affect fly ash use in embankments include grain size distribution, compaction characteristics, shear strength, compressibility, permeability, and frost susceptibility. Nearly all fly ash used in embankments are Class F fly ashes.

RS PUBLICATION

Page 8

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

Fig. 5 3.1.9Asphalt concrete Asphalt concrete is a composite material consisting of an asphalt binder and mineral aggregate. Both Class F and Class C fly ash can typically be used as a mineral filler to fill the voids and provide contact points between larger aggregate particles in asphalt concrete mixes. This application is used in conjunction or as a replacement for, other binders (such as Portland cement or hydrated lime). For use in asphalt pavement, the fly ash must meet mineral filler specifications outlined in ASTM D242. The hydrophobic nature of fly ash gives pavements better resistance to stripping. Fly ash has also been shown to increase the stiffness of the asphalt matrix, improving rutting resistance and increasing mix durability [7].

RS PUBLICATION

Page 9

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

Fig. 6

3.1.10 Use of Fly Ash in Agriculture The large volume of fly ash occupies large area of land and possesses threat to environment. As such, there is an urgent and imperative need to adapt technologies for gainful utilization and safe management of fly ashes on sustainable basis. Agriculture and waste land management have emerged as prime bulk utilization areas for fly ash in the country. The field demonstration experiments carried out under varied agro-climatic conditions and soil types across the country by various R & D Institutes / Universities on the cultivation of different field crops (cereals, pulses, oil seeds, sugar cane, vegetables, etc.) and forestry species with different doses of fly ash and pond ash as soil modifier / source of economical plant nutrients with and without organic manure bio-fertilizer and chemical fertilizers in respect to crop yield, soil health, quality of crop produce, uptake of nutrients and toxic heavy metals, ground water quality etc. have revealed the following: 1. It improves permeability status of soil. 2. 3. Improves fertility status of soil (soil health) / crop yield. Improves soil texture.

4. Reduces bulk density of soil. 5. Improves water holding capacity / porosity.

6. Optimizes pH value. 7. Improves soil aeration.

8. Reduces crust formation. 9. Provides micro nutrients like Fe, Zn, Cu, Mo, B, Mn, etc. 10. Provides macro nutrients like K, P, Ca, Mg, S etc. 11. Works as a part substitute of gypsum for reclamation of saline alkali soil and lime For reclamation of acidic soils. 12. Ash ponds provides suitable conditions and essential nutrients for plant growth, Helps improve the economic condition of local inhabitants. 13. Crops grown on fly ash amended soil are safe for human consumption &

RS PUBLICATION

Page 10

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

Groundwater quality is not affected. Keeping the above important findings in view, pond ash at a dose of 30-50 tonne per. Hectare on one time basis along with recommended dose of fertilizers / manures is recommended for its use agriculture/ forestry sector/wasteland management or cultivation of different cereals / pluses/ oil seeds / vegetables etc., the repeat application of which can be made after 4-5 years as it would have significant residual effect on the yield of succeeding crops over a period of 4-5 years. The abandoned ash ponds in the Vicinity of TPPs could also be safely reclaimed via suitable amendments for forestry/floriculture purposes.

4.1 Initiatives taken in the direction of creating Fly Ash grading facility at Thermal Power Plants.
As circular by CPWD, IS 456:2000 etc. specifies certain grade of fly ash (conforming to IS 3812) for cement/concrete applications which is not easily available at Thermal Power Plants. Even products like fly ash based bricks, blocks, tiles; pavers, etc. require fly ash of graded quality. Therefore, it was felt necessary to create some fly ash processing facility at TPP so that graded fly ash can be made available to end user. In this regard, letters have been issued to many Thermal Power Stations detailed presentation has been made to Central Electricity Authority and discussions are in progress with some of the TPPs [4].

4.1.1 Conversion of fly ash into wealth generator

(Excerpt from President A P J Abdul Kalam's address to the nation on the eve of the countries 56th Republic Day): As you are aware, the use of coal for power generation results in an increased quantum of fly ash production, which has reached about 100 million tonnes per year. All out efforts are needed to utilize this fly ash not only from environmental considerations, but also to avoid land usage for fly ash dumping. Though there has been a steady progress in fly ash utilization from 1990, we have a long way to go to reach the target of 100 per cent fly ash utilization. It is reported that the agricultural increase of grains is around 15 per cent, green vegetables 35 percent and root vegetables 50 per cent, when fly ash is mixed with soil. Toxicity tests have proved that there is no toxic element due to fly ash. But it has higher nutrients due to increased availability of iron and calcium. Fly ash can
RS PUBLICATION Page 11

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

become a wealth generator by making use of it for producing green building materials, roads, agriculture etc. Full utilization of the generating stock will provide employment potential for three hundred thousand people and result in a business volume of over Rs.4,000 crore.[3].

5.1 Conclusion
Fly Ash has become an important raw material for various industrial and construction applications. Its widely used in manufacturing of bricks, cement, asbestos-cement products and roads/embankments. The studied are carried out for improvement of agricultural crops, wastelands, and zeolites. This waste has found application in domestic and wastewater treatment, purification, paint and enamel manufacturing. In future, large-scale application of this waste product may be possible for recovery of heavy metals, reclamation of wasteland, and floriculture. The detailed investigations carried out on fly ash elsewhere as well as at the Indian Institute of Science show that fly ash has good potential for use in highway applications. Its low specific gravity, freely draining nature, ease of compaction, insensitiveness to changes in moisture content, good frictional properties, etc. can be gainfully exploited in the construction of embankments, roads, reclamation of low-lying areas, fill behind retaining structures, etc. It can be also used in reinforced concrete

construction since the alkaline nature will not corrode steel. This not only solves the problems associated with the disposal of fly ash (like requirement of precious land, environmental pollution, etc.) but also helps in conserving the precious top soil required for growing food. The future poses challenges to the scientists, technologists, engineers towards sound management of fly ash disposal & deposition technologies. The problem is not due to lack to technical competence but more of adoption, implementation and better management of improved & appropriate technologies. On the basis of studies carried out on fly ash utilization, it is sighted that use of fly ash in building construction posses great gains. Either fly ash used in brick manufacturing or in concrete mixes, it gives very good results in almost every aspect including good strength, economically feasible and environment friendly. The guideline for all thermal power stations as regards disposal techniques/ strategies should ensure minimum adverse impact on the flora & fauna of a particular place. The attempt should be to consciously reduce environmental damage to ensure more effective management of fly ash which India needs.

RS PUBLICATION

Page 12

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

References
[1] Census of India 2001. [2] MOEF Notification dated September 14, 1999 regarding Utilisation of Fly Ash and Amendments to this dated August 27, 2003. [3] Building Materials in India: 50 Years A commemorative volume published by BMTPC. [4] Circular by CPWD No. CDO/SE (RR)/Fly Ash (Main)/387 dated May 13, 2004. [5] Proceedings of the International Symposium on Concrete Technology for Sustainable Development in the Twenty First Century edited by P. Kumar Mehta, Hyderabad, India, February, 1999. [6] Singh G. B. Cellular Light Weight Concrete, The Construction Journal of India, September-October 1998, Vol. 1 issue 4. [7] Saxena Mohini and Prabhakar J. Emerging Technologies for Third Millennium on Wood Substitute and Paint from coal ash 2nd International conference on Fly Ash Disposal & Utilization, New Delhi, India, February 2000. [8] M. Ghrici, S. Kenai and M. Said-Mansour Mechanical properties and durability of mortar and concrete containing natural pozzolana and limestone blended cements Cement & Concrete Composites 29 (2007) 542549. [9] Xu Lingling, Guo Wei, Wang Tao and Yang Nanru Study on fired bricks with replacing clay by fly ash in high volume ratio Construction and Building Materials 19 (2005) 243247. [10] N. Degirmenci and B. Baradan Chemical resistance of pozzolanic plaster for earthen walls Construction and Building Materials 19 (2005) 536542. [11] Mustafa S ahmaran, Heru Ari Christianto and Ismail O zgu r Yaman Cement & Concrete Composites 28 (2006) 432440.

RS PUBLICATION

Page 13

International journal of emerging trands in Engineering and Development

Issue1, Vol 1August2011

[12] Kae Long Lin Feasibility study of using brick made from 1816.

municipal

solid

waste incinerator fly ash slag Journal of Hazardous Materials B137 (2006) 1810

[13] I.S. 3812, Specification for Fly ash as pozallana and admixture (First Revision) 1983. [14] I.S. 8112-43 Grade ordinary Portland cement specification (First Revision) 1989. [15] I.S. 2720-VII Methods of Test for Soil Part VII Determination of Water contentDry Density Relation using Light Compaction (Second Revision)

RS PUBLICATION

Page 14