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
China
USA
Germany
UK
Australia
Canada
France
Denmark
Italy
Nether land
Annual ash
production, MT
Ash utilization %
100
75
40
15
10
6
3
2
2
2
45
65
85
50
85
75
85
100
100
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