04 subhash-chandra use of fly ash in different countries
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8/6/2019 04 Subhash-chandra Use of Fly Ash in Different Countries
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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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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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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
l
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
Category 2Category 2
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
Category 3Category 3
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
DisposalDisposal 11.25
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
DisposalDisposal 2.8
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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Category High value-added applications
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
Category High value-added applications
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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