Vimal_Kumar.ppt

ICUFA-2013 [email protected], [email protected] WBPCB, Kolkata, 10-11, Jan.2013 www.c-farm.org [email protected]

C-FARM

“Fly Ash Management & Utilization:

Indian Scenario”

by

Dr. Vimal Kumar Scientist ‘G’ & Head, Fly Ash Unit, DST,

G.O.I. & Honorary Adviser

Centre for Fly Ash Research & Management

(C-FARM)New Delhi

ICUFA - 2013


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FLY ASH MISSIONA Collaborative Activity of :

Ministry of Power (MoP) Ministry of Environment & Forests (MoEF)Deptt. Of Science & Technology (DST )

Nodal Agency :Department of Science & Technology (DST)

Duration : 1994 to 2001

The activities are now being implemented by Fly Ash Unit (FAU), DST


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Objective:

Confidence building in flyash disposal / gainful utilization technologies

Through :

Technology Demonstration Projects with participation of industry.

Partners :

Industry, Power utilities, R&D organisations, User agencies, Academia & Facilitating/ Regulating Ministries/ Departments/ Agencies etc.

FLY ASH MISSION


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FLY ASH UNITObjective:

Focus is being continued on:

(i)Development of new / incremental technologies

(ii)Adaptation/large scale application of technologies

(iii)Preparation & updation of standards / specifications

(iv)Support & facilitation to other Government Ministries / Department


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FLY ASH UNITCurrent New Initiatives Use of fly ash in concrete for critical structures

such as building and foundation for rolling mills, turbo-generators in power plants, chimneys and cooling towers etc.

Construction of railway embankments with fly ash.

Induction of fly ash in academic curriculum. Preparation of Base Line Documents for each

area of fly ash utilization and management to work as road map for future activities and to aid the policy and strategy planning.


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Indian Scenario Fly Ash Generation and Utilization…... PROJECTIONS…...

1994

FA Generation --- 40 Million Tonne FA Utilisation --- 1 Million Tonne

2008


2011-2012


2031-2032

FA Generation --- 1000 Million Tonne

FLY ASH SCENARIO


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UTILIZATION AREAS – 2012

612%

57%

410%

75% 8

1%1

47%

29%

39%

1 cement manufacturing

2 Cement substitution

3 Road embankments

4 Low lying area filling

5 Ash bund raising

6 Mine fill

7 Brick manufacturing

8 Agriculture & others


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TECHNOLOGIES DEVELOPED

UTILISATION Roads & Embankments Building Components Hydraulic Structures Agriculture Related Studies & Applications Minefills

SAFE MANAGEMENT Ash Pond Management Reclamation of Abandoned Ash Ponds

FACILITATION Characterization of Fly Ash Handling and Transportation Research & Development


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Building at Calcutta


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FLYASH IN BUILDINGS

BUILDING COMPONENTS

In roofing at Chennai At HITEC City, Chennai


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Approach Road Embankment, Nizamuddin


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Approach Road Embankment in Flood Zone, Nizamuddin


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Rural Road at Raichur


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Increased seed yield of sunflower with flyash at 60 t/ha, at Raichur,

Karnataka


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Saline soil reclamation using fly ash


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Handling and Transportation

Dry fly ash availability

Handling and transportation

Segregated collection of dry fly ash

Bagging of dry fly ash Capability building

– dense phase conveying of flyash slurry and

– separate handling of flyash and bottom ash

Dadri thermal power station project


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Safe Management ash pond

Use of abandoned ash pond

Human habitat on NFL Panipat ash pond

Forestry at Badarpur thermal power plant ash pond


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Safe Management of Ponds Dkye design, construction & maintenance

• Seismic stability• Increasing the load bearing

capacity

Vibroflotation column technology at Vijaywada

Blasting technique at Mettur thermal power plant

Dyke constructed with flyash at Korba thermal power station, Madhya Pradesh

Densification of ash ponds for


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Value Added Products


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Wood Substitute


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Fly Ash Based Partitioning Material


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Fly Ash Based Paints & Enamels


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FLY ASH UTILIZATION & SAFE MANAGEMENT

POLICY AND STRATEGY


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POLICY AND STRATEGY Identification of laboratory scale work

which can be scaled up Niche application areas Field demonstration, scale-up and hands

on training Collaborative mode for transfer of

technology: setting up of initial few projects

Standards, specification and guidelines Statutory notifications and fiscal incentives Dissemination and sharing of information

and expertise


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CONFIDENCE BUILDING IN FA TECHNOLOGIES

Technology Demonstration Projects

Participation of Stake-holder Agencies

Dissemination of Information

Multiplier Effects


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CAPABILITY BUILDING

Workshops / Seminars

Training programmes

Experience Sharing Meets


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FACILITATION

Networking of Laboratories & Experts

Consultancy Services

Creating Awareness

Policy Initiatives


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SPREAD OF TECHNOLOGY DEMONSTRATION PROJECTS

METTUR

CHIDAMBARAM

RAICHUR VIJAYAWADA KOTHAGUDAM

MUMBAI ANGUL CUTTACK

KHARAGPUR

FARAKKA

SARNI

BHOPAL

JAIPUR

RIHANDNAGARALLAHABADBHATINDA

ROPARDELHI

PANIPATFLYASH MISSION,TIFAC

PROJECT SITES

BAKRESHWAR

CHANDRAPUR

NASIK

CHENNAI


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•Dhanbad

•Patiala

•Delhi

•Roorkee

•Kanpur

•Vadodara

•Mumbai

•Hyderabad

•Bangalore •Chennai

•Chidambaram

•Raichur •Bhubaneshwar

•Jamshedpur

•Kharagpur

•Ludhiana

FLYASH MISSION, INSTITUTIONAL LINKAGES

•Bhopal

•Ahmedabad

•Thiruvananthapuram

•Calcutta


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SUSTAINABLE USE OF FLY ASH

Update of Existing Standards / Specification Standards/ Specifications for new utilisation

areas Develop Code of Practice Supply Chain Management Technology Transfer and Facilitation

Mechanisms Government Facilitation / Support


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INDICATIVE LIST OF POLICY MEASURES

MOEF Notifications ( 14th Sept. 1999, 27th Aug. 2003 & 3rd Nov, 2009)

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 guidelines issued by IRC (IRC SP 20 : 2003 )

Revision of IS 3812 – the code for specifications of PFA for its use in Cement/ mortar/ concrete (part 1) & as fine aggregate (part 2) - approved & under print.

Contd……..


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INDICATIVE LIST OF POLICY MEASURES

Specifications for other FA applications viz (i) lime pozzolana mixture applications, (ii) sintered applications, (iii) geotechnical and (iv) agricultural application are under preparation.

Updation of IS:456 – code of practice for plain andreinforced concrete has been updated with use of flyash.

Minimum and maximum percentages of flyash in PPC have been increased to 15% and 35% respectively etc.

Fly ash bricks standard ( IS 12894 ) has been updated.

Contd……..


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STATE LEVEL MISSIONS / INITIATIVES

High Level Empowered Group – Tamil Nadu, Karnataka, Andhra Pradesh, Maharashtra, Delhi, Punjab, etc.

Fly Ash Mission – Kota, Rajasthan

Fly Ash Mission – Nagpur, Maharashtra

Fly Ash Mission - Odisha


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MoU Signing Ceremony with Russia

16th December, 2011 at The Kremlin, Russia Contd…

FLY ASH UNIT, DST


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MoU Signing Ceremony with Russia contd…

The Protocol of Intentions between the Department of Science and Technology, Government of India and the Interregional Association "Siberian Accord" Siberian Federal District, Russian Federation on fly ash utilization and safe management is for implementation of the mechanism similar to “Fly Ash Mission – India” in the Siberian Federal District, to facilitate development and application of technologies for utilization and safe management of fly ash, including import of technologies from India.

FLY ASH UNIT, DST


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CENTRE FOR FLY ASH RESEARCH & MANAGEMENT

(C-FARM)


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FORMATION OF C-FARM

C-FARM was established during June, 2007 to promote and undertake R&D for in-depth understanding and value addition to fly ash utilization as well as safe management and to develop technology delivery mechanisms, inter-alia, facilitation of large scale adaptation of fly ash technologies and capacity building.

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VISION

Protect environment through fly ash utilization and management

MISSION

Capacity building for eco-friendly management, value addition and utilization of fly ash

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To promote and undertake R&D for in-depth understanding and value addition to fly ash utilization as well as safe management and to develop technology delivery mechanisms, inter-alia, facilitation of large scale adaptation of fly ash technologies and capacity building.

OBJECTIVE

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1. Shri K.N.Agrawal, Former DG, CPWD - Chairman2. Prof. V.S.Raju, Former Director, IIT- Delhi3. Prof. D.V.Singh, Former VC, University of Roorkee 4. Shri Ajay K.Gupta, MD, M/s Macawber Beekay5. Shri S.J. Sibal, Former D.G., DGMS6. Shri G. Saran, Former D.G. (Roads)& Specl. Secretary, MoRTH7. Prof. S.P. Mehrotra, IIT-Gandhi Nagar & Former Director, NML,

Jamshedpur8. Shri R.D. Gupta, Former Director, NTPC & Former Member,

Electricity Regulatory Commission, U.P.9. Dr. A. K Chatterjee, Former Director, ACC Ltd.

HONORARY ADVISER

Dr. Vimal Kumar, Scientist ‘G’& Head, Fly Ash Unit, Department of Science & Technology, Ministry of Science & technology, Govt. of India

Former Chairman : Shri C.P.Jain, Former CMD, NTPC

BOARD OF DIRECTORS

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To undertake, promote and facilitate research and

development in the area of fly ash

To undertake, guide and facilitate scale-up and large scale adaptation of fly ash utilization and safe management technologies

To undertake and facilitate dissemination of information, training, technical forums and short term courses, etc. for capacity building

To develop wide network of technology delivery mechanisms

Strategic policy matters.

FUNCTIONS

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1. TO PROVIDE SCIENTIFIC AND TECHNICAL GUIDANCE / SUPPORT FOR:

Economical & Eco-friendly technologies for fly ash management & utilization at Thermal Power Plants

Value addition to fly ash & its applications

Durable and economical construction and development of infrastructure projects through fly ash

Use of fly ash for higher agriculture yield and reclamation of wasteland

Use of fly ash in back filling of mines and stabilization as well as a forestation of OB dumps

Ecological solutions through fly ash: conservation of water, power, natural resources and emission of CO2Contd….

ACTIVITIES

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2.TECHNOLOGY DEVELOPMENT / SOURCING / LARGE SCALE APPLICATION

3.TECHNICAL COURSES / TRAINING PROGRAMMES

4.CAPACITY BUILDING IN TECHNOLOGY ADAPTATION

5. INFORMATION SERVICES

6.STRATEGY AND IMPLEMENTAION PLANS FOR FLY ASH UTILIZATION & MANAGEMENT

Contd….

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Sl. No.

Agency Brief title of work done Status

1. M/s M. J. Bricks Ltd., New Delhi

Fly ash brick quality improvement & reduction in shop floor rejection

Completed

2. Indian Institute of Technology, New Delhi

Development of ash pond as a parking area.

Completed

3. M/s Mahindra life Spaces, Mumbai

Use of fly ash & it’s products in housing complex including awareness creation & training to architects, designers, consultants, vendors, builders and the staff & officers including decision makers.

Completed

4. M/s Tega Industry, Kolkata

Processing & beneficiation of fly ash. Completed

5. M/s Reliance Energy Ltd., Mumbai

Optimization of fly ash brick mix design & manufacturing process parameters.Optimization of use of fly ash in RMC for various grades of concrete with seasonal variations.

Completed

WORK DONE SO FAR


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Sl. No.


6. M/s Reliance Infrastructure Ltd., Noida

Use of fly ash in construction of the power plant.

Completed

7. M/s Enviro built India Pvt. Ltd., Nashik

Optimizations of CLC block technology mix design & steam curing.

Completed

8. Department of Forests, Odhisa

Development of technology for use of fly ash as “forestry nursery bed” material and in “forestry plantations” at Tamka and Sukunda Forest Range under Cuttack Forest Division, Odhisa

On-going

9. IDCO, Odhisa Reclamation of low lying area with fly ash, use of fly ash in plantations for development of green belt and use of fly ash in road construction.

Completed

10. M/s S. J. Associates, New Delhi

Conceptual feasibility report for fly ash based product.

Completed

WORK DONE SO FAR


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Sl. No


11. Jindal Steel Ltd., Jajpur

100% ash utilization for captive power plant of 2 X 125 MW capacity- plan & execution for 3 years, training of their manpower & handing over subsequent execution to them with back up support from C-FARM.

Completed

12. OPGCL, Odhisa

Feasibility study for use of dry fly ash from the silo for filling up of low lying areas within ITPs plant premises through high concentration slurry disposal system with indigenous pumping Reclamation system.

Reclamation of low lying areas with fly ash.

Completed

On-going

13. PWD, New Delhi

Along with IIT, Delhi, reclamation of ash pond for parking area.

Completed

14. NALCO, Odhisa

Reclamation of low lying area with fly ash & training of their manpower along with manual of methodology & site quality control.

Completed

WORK DONE SO FAR


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Sl. No.


15. Ministry of Water Resources, Govt. of India

Use of fly ash and fly ash bricks/blocks in the reconstruction, remodeling & improvement of embankments in Sunderbans and adjoining area in the districts of North and South 24-Paragana, damaged by severe cyclone “Aila” for cost reduction, durability and eco sustainability.

Completed

16. M/s Calcom Cement Ltd., Kolkata

Plan for utilization of 1.6 MnT fly ash per year from Tata Power Ltd., Maithon

Completed

17. Madhya Bharat Papers Ltd., Champa, C.G

Use of fly ash in agriculture, training & demonstration to farmers as well as staff & officer of MBPL.

Color removal of paper mill effluent by use of fly ash and development of use of spent fly ash.

On-going

On-going

18. SPCB, Odhisa

Preparation of Technology and Methodology Manual for Reclamation of low lying areas/abandoned quarries/laterite mines etc. with pulverized fuel ash.

Completed

WORK DONE SO FAR


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Sl. No.


19. MAHAGENCO, Mumbai

Fly ash brick manufacturing with pond ash.Awareness creation among construction industry for use of fly ash & its products.

Completed

20. DST, Govt. of India

Prepared “Plan & Strategy Document for increasing agriculture yield by at least 10% through fly ash”

Preparation of report on “Technology Forecasting and Assessment for Characterization of Fly Ash” for different utilization areas.

Completed

On-going

21. APGENCO, Hyderabad

Prepared 100% fly ash utilization executable plan for 1 X 500 MW Kakatiya Thermal Power Station at Bhupalpalli (Andhra Pradesh).

Completed

22. Aarti Steels Ltd., Cuttack

Plan for 100% utilization of fly ash (1200 tonne/day) being generated at their captive power plant at Cuttack.

Completed

23. JSW Energy Ltd., Ratnagiri

Fly ash management Completed

24. Bhushan Steel Ltd., New Delhi

Technical advise and guidance of fly ash at BSL TPPs at Meramandali, Orissa

On-going

WORK DONE SO FAR


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Sl. No.


25. GMR Energy, A.P. Ash Utilization study at Kakinada Completed

26. Lanco Anpara, Gurgaon

Preparation of ash utilization plan Completed

27. Himavat Power Pvt. Ltd., Gurgaon

Preparation of ash utilization plan Completed

28. TERI, New Delhi Providing technical help for preparation of Baseline Document for fly ash utilization in agriculture

On-going

29. NAARM, Hyderabad

Technology Forecasting and Assessment of Future Fly Ash in India

Completed

30. IMMT, Bhubaneswar

Engagement as Consultant Agency in Fly Ash Project

On-going

31. APGENCO, Hyderabad

Providing technical advice & guidance for utilization of KTPP, Kakatiya (APGENCO) for (i) Stowing of underground mine (ii) Backfilling of open cast mine and (iii) Stabilization of OB dump at SCCL, Bhupalpalli

On-going

WORK DONE SO FAR


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Sr. No.

Date Title Place

1. 17.10.2007 Technical training for manufacture of fly ash bricks with consistent quality at M/s. M. J. Bricks, Pvt. Ltd.

New Delhi

2. 02.11.2007 Technical seminar on fly ash handling and management of temporary ash pond in eco-friendly manner

M/s. Jindal Stainless (JSL), Jajpur, Orissa

3. 03.11.2007 Technical seminar on utilization of fly ash in concrete M/s JSL, Jajpur, Orissa

4. 11.01.2008 Technical seminar on fly ash use in agriculture M/s JSL, Jajpur, Orissa

5. 12.01.2008 Technical seminar on use of fly ash in concrete M/s JSL, Jajpur, Orissa

6. 22.04.2008 Technical seminar “optimization of mix design for fly ash based light weight cellular concrete blocks”

M/s Enviro Built Pvt. Ltd, Nashik

7. 23.04.2008 Technical seminar “use of fly ash alongwith Portland Pozzolana Cement (PPC) and manufacture / use of fly ash bricks”

M/s Mahindra Lifespace Developers Ltd., Mumbai

TRAINING/SEMINARS/WORKSHOPS ORGANIZED BY C-FARM


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Sr. No.

Date Title Place

8. 12.06.2008 Technical session for use of fly ash for reclamation of abandoned laterite mines

office of Collector, Jajpur Road, Bhadrak, Orissa

9. 08.10.2008 Training course “use of fly ash in various grades of concrete and optimisation for economics and durability”

Rosa TPP, Shahjahanpur, U.P.

10. 13.10.2008 Training course, “optimization of fly ash brick/block manufacturing technology”

Sasan TPP, Madhya Pradesh

11. 17.12.2008 Technical Session, “use of fly ash in manufacture of clay bricks and in concretes to improve quality and cost of production as well as conservation of natural resources / environment” alongwith Structural Engineering Research Centre (SERC), Chennai

Tamil Nadu Electricity Board, Chenna

12. 03.03.2009 National Seminar on new technologies for manufacture of fly ash bricks / blocks and measures for quality assurance

Bhubaneswar

13. 04.03.2009 Technical meeting, “use of fly ash in cultivation of paddy in red lateritic soils of Orissa for sustainable and enhanced productivity”

Central Rice Research Institute, Cuttak



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Sr. No.

Date Title Place

14. 04.03.2009 Technical session to enhance survival rate and productivity of forest plantation by use of fly ash

Divisional Forest Office, Cuttak

15. 18.03.2009 Technical session regarding economisation and green building concept through fly ash

IBC, New Delhi

16. 06.05.2009 Technical session on use of fly ash in concretes of critical structures, construction of embankments & reclamation of low lying areas

M/s MECON, Ranchi

17. 09.06.2009 Field training programme regarding use of fly ash in forest plantation for higher survival rate and productivity

Forest Ranges at Barabati, Cuttack Division, Orissa

18. 11.06.2009 Field training programme regarding use of fly ash in forest plantation for higher survival rate and productivity

Forest Ranges at kiajhara, Cuttack Division Orissa

19. 23.06.2009 Technical seminar, “design and construction of permanent ash pond with fly ash and optimisation of consumption of water and electricity in transportation of fly ash”

JSL, Jajpur, Orissa



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Sr. No.

Date Title Place

20. 26.06.2009 Technical Session regarding beneficial use of fly ash in forest plantation, reclamation of low lying areas and back filling of mines”

CPCB, New Delhi

21. 26 - 28.08.2009

Hands on training and guidance to farmers for use of fly ash in agriculture

MBPL, Champa, Chattisgarh

22. 09.03.2010 National Workshop on use of fly ash in agriculture New Delhi

23. 07.05.2010 Kisan Goshti on use of fly ash in agriculture along with MBPL, Champa Chattisgarh

Champa, Chattsigarh

24. 18.05.2010 Seminar and training on manufacture of quality fly ash bricks with pond ash along with Trimurtee Industries, Nashik

Nashik

25. 19.05.2010 Seminar on Fly Ash : an eco-friendly, economical and sustainable building material along with Trimurtee Industries, Nashik

Nashik

26. 26-27.08.2010

National Seminar on fly ash an opportunity for mining sector

New Delhi



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Sr. No.

Date Title Place

27. 09.09.2010 Brainstorming Workshop on “Use of Fly Ash in Agriculture”

New Delhi

28. 31.01.2011 Technical Seminar on use of fly ash in concrete and construction sector

Kolkata

29. 7-8.05.2011

National seminar on fly ash based amendments for amelioration of degraded soils to increase crop production in the gangetic plains along with National Institute of Ecology, Lucknow and Central Soil Salinity Research Institute, Karnal

Lucknow

30. 26.05.2011 Workshop on Use of Vermicomposted Fly Ash in Agriculture along with Visva Bharati University, Shantiniketan, W.B.

Visva-Bharati University, Shantiniketan W.B.

31. 03.06.2011 Consultative Meeting on Strategy and Policy for Fly Ash Utilization and Management towards Cleaner Environment

New Delhi



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Sr. No.

Date Title Place

32. 17.06.2011

Kissan Goshti on Use of Fly Ash for Cultivation of Vegetable Crops along with MBPL, Champa Chattisgarh

MBPL, Champa, Chattsigarh

33. 5-7.12.2011

National Conference on Fly Ash towards safe management and conservation of environment

ITC Kakatiya, Hyderabad

34. 27.02.2012

Seminar on Fly Ash : an eco-friendly, economical and sustainable building material along with Trimurtee Industries, Nashik

Paras TPP, Akola

35. 27.02.2012

Training on manufacture of quality fly ash bricks with pond ash along with Trimurtee Industries, Nashik (Afternoon Session)

M/s Mangal Industries, Akola

36. 28.04.2012

National Seminar on Industrial Growth vis-à-vis Pollution Control in Odisha in association with Odhisa Productivity Council, Bhubaneswar

Hotel Hindustan International, Bhubaneswar

37. 17-18.07.2012

National Seminar on “Prospects of fly ash as a mineral resource” in association with IMMT, Bhubaneswar

IMMT, Bhubaneswar

38. 24.08.2012

Industry Meet on “Fly Ash based products/technologies” in association with NML, Jamshedpur

NML, Jamshedpur

39. 07.11.2012

Brainstorming workshop on “Perspective of fly ash characterization”

C-FARM, New Delhi

40. 26.11.2012

2nd Annual Conference on “Fly ash utilization and Management” by India Infrastructure Pvt. Ltd., New Delhi with C-FARM as knowledge partner.

The Imperial, New Delhi



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•Data Base

•Web Site

•Library & Information

Services

•Quarterly Fly Ash Flier

(Proposed)

INFORMATION SYSTEM


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1.Institute of Minerals and Material Technology (IMMT), Bhubaneswar

2.National Metallurgical Laboratory, Jamshedpur

3.Central Pulp & Paper Research Institute, Saharanpur

4.Ashkings Enterprises, Nashik

5.Viswa Bharti University, Sriniketan, West Bengal

C-FARM: A Technology Development & Transfer

MechanismTechnology Transfer MoUs / Agreements


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CONCLUSIONFly Ash has been proved to be a useful material for many applications. Policy frame work and national strategy can make it possible to utilize all fly ashes in gainful manner. It would mitigate the environmental threat, generate employment and industrial wealth, conserve mineral resources, provide sustainable construction and agriculture including forestry and cleaner environment. It’s products including agriculture produce grown on fly ash with in safe limits.Thus, these may be used on large scale with no consequential impact on human health as well as the environment.

ICUFA - 2013


C-FARM

ICUFA - 2013

Vimal_Kumar.ppt

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