Fly Ash in India: From Waste Pollutant To Ecofriendly Resources

IJMSS Vol.
04 Issue-03 (March, 2016) ISSN: 2321-1784

International Journal in Management and Social Science (Impact Factor- 5.276)
FLY ASH IN INDIA: FROM WASTE POLLUTANT TO ECOFRIENDLY RESOURCES
DR. SANJAY KESHAORAO KATAIT

Assistant Professor,
Department of Commerce,
Shri Shivaji College of Arts and Commerce, Morshi Road,
Amravati.444603. (M.S.), India.
ABSTRACT:
Fly ash, a residue of burning of pulverized coal and lignite in thermal power stations, is now
being accepted as a resource material. Efforts to use fly ash began in India about a decade back and
have developed confidence in fly ash utilization technologies and its large-scale utilization. Previously
number of attempts was made through various Committees/ Groups to develop fly ash utilization
technologies. As a result, fly ash utilization in the country has increased from 1 million ton per year to
more than 45 million tone per year. The implementation and reutilization of fly ash in different
segment are dealt in this research paper.
KEYWORDS: Eco-friendly, Fly ash, India, Resources, Waste Pollutant, Utilization.
FLY
ASH
IN
INDIA:
FROM
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IJMSS Vol.04 Issue-03 (March, 2016) ISSN: 2321-1784
WASTE POLLUTANT TO ECOFRIENDLY RESOURCES
INTRODUCTION:
Rapid industrialization has resulted in increased use of natural resources, which brought serious
ecological and environmental imbalance due to heavy dumping of industrial wastes. The disposal of
the increasing amounts of solid waste fly ash is becoming a serious concern to the environmentalists.
Environmentally, sound management of waste is of major concern in maintaining the quality of the
Earths environment and especially in achieving sound and sustainable ecological development.
Coal based thermal power plants (CBTPT) have been a major source of power generation in
India, where 75% of the total power obtained is from coal-based thermal power plants. The coal
reserve of India is approximately about 200 billion tones and its annual production reaches 250
million metric tons approximately. About 70% of this is used in the thermal power generation sector.
In India, unlike in most of the developed countries, ash content in the coal used for power generation
is 30 - 40%. High ash means more wear and tear of the plant and machinery, low thermal efficiency of
the boiler, slogging, choking and scaling of the furnace and most serious of them all, generation of a
large amount of fly ash. India ranks fourth in the world in the production of coal ash as by-product
waste after USSR, USA and China.
EFFLUENT AND DISPOSAL:
Disposal and management of fly ash is a major problem in coal-fired thermal power plants.
Fly ash emissions from a variety of coal combustion units show a wide range of composition. All
elements below atomic number 92 are present in coal ash. A 500 MW thermal power plant releases
200 mt SO2, 70mt NO2 and 500mt fly ash approximately every day. Particulate matter considered as
a major source of air pollution constitutes fly ash. The fine particles of fly ash reach the pulmonary
region of the lungs and remain there for long period of time; they behave like cumulative poison. The
submicron particles enter deeper into the lungs and are deposited on the alveolar walls where the
metals could be transferred to the blood plasma across the cell membrane. The residual particles
being silica (40 - 73%) cause silicosis. All the heavy metals generally found in fly ash are toxic in
nature and provides a list of diseases caused due to the presence of these toxic metals. Fly ash can
be disposed-off in a dry or wet state. Studies show that wet disposal of this waste does not protect
the environment from migration of metal into the soil. Heavy metals cannot be degraded biologically
into harmless products like other organic waste. Studies also show that coal ash satisfies the criteria
for landfill disposal, according to the Environmental Agency of Japan fly ash can be treated as a by-
product rather than waste.
INTERNATIONAL STATUS:
FLY ASH PRODUCTION IN DIFFERENT COUNTRIES (Mt / Year):
Sr. IND CH USA GER UK AUS CAN FRAN DEN ITA NET
No.
% 112 100 75 40 15 10 6 3 2 2 2
(Source: http://www.tifac.org.in)
FLY ASH UTILISED IN DIFFERENT COUNTRIES (%):
Sr. IND CH USA GER UK AUS CAN FRAN DEN ITA NET
No.
% 38 45 65 85 50 85 75 85 100 100 100
NATIONAL STATUS:
Sr. Year Thermal power electricity Coal Ash generation

No. generation consumption (mt)
(mw) (mt)
01 1995 54000 200 75
02 2000 70000 250 90
03 2010 98000 300 112
04 2020 137000 350 140
In India, at present nearly 112 metric tons of fly ash is generated per annum and is expected
to rose up to 140 metric tons in 2020 approximately which largely responsible for environmental
pollution. In developed countries like Germany, 85% of the fly ash generated is being utilized,
whereas in India only 38% is being utilized which is great cause of concern.
PROBLEM TO BE INVESTIGATED:
Energy requirements for the developing countries in particular are met from coal-based
thermal Power plants. The disposal of the increasing amounts of solid waste from coal-fired thermal
power plants is becoming a serious concern to the environmentalists. Fly ash a coal combustion
residue of thermal power plants has been regarded as a problematic solid waste all over the world.
Indian coal has high ash content and low calorific value. Nearly 73% of the countrys total installed
power generation capacity is thermal of which coal-based generation is 90%. High ash content (30% -
50%) coal contributes to these large volumes of fly ash. Current annual production of Fly ash, a by-
product from coal based thermal power plant is about 112 million tons (MT) and as reviled from
literature, it is observed that foreign countries fly ash utilization is quite high as compared to Indian
applications which is merely 38% only. Some of the major 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.
OBJECTIVES OF RESEARCH:
1. To make proper application and maximum reutilization of fly ash.
2. To make proper application of fly ash in developing eco-friendly products.
3. To convert fly ash from pollutant source to economic, eco-friendly resources.
4. To minimize effluents and disposals.
5. To protect environment from pollution arising from fly ash.
6. To suggest some remedial measures to minimize level of pollution to protect and save
environment & also suggest some economic development avenues.
HYPOTHESES:
H0 Fly ash in thermal power is not properly managed and reutilized.
H1 Fly ash is exclusively used for horticultural and manufacturing of
eco friendly product.
H2 Conversion of fly ash from pollutant source to economic resources.
H3 Proper utilization and management of fly ash minimize effluents and
disposals and helps in environment protection.
REVIEW OF RELATED LITERATURE:

Ansari, F. A., of Fibre Toxicology Division, Indian Institute of Toxicology Research, Lucknow,
India, Gupta, A. K., National Institute of Disaster Management, Government. of India, Environment,
Climate-change and Disasters Cell, New Delhi, India and Yunus, M, of School for Environmental
Sciences, Babasaheb Bhimrao Ambedkar (Central) University, Lucknow, India strongly advocate in
their research article titled Fly-ash from Coal-fired Thermal Power pants: Bulk Utilization in
Horticulture A Long-term Risk Management Option that management of solid waste (fly ash) has
attained an apparent scenario for scientific & strategic concern in India due to large-scale
dependence on coal-based thermal power plants. Waste utilization as the best option of pollution-
prevention and disaster risk strategy has been worked out during previous decades to open doors for
fly ash utilization on various sectors of developmental and manufacturing sectors. However, the
large-scale and voluminous generation of fly ash averagely on regular basis calls for bulk utilization
options in a productive purpose like horticulture and for production of two important vegetable
crops, viz., Brinjal and Spinach, grown on fly ash substrate.
Manas Ranjan Senapati in his research article titled Fly ash from thermal power plants
waste management and overview strongly expressed that energy requirements for the developing
countries in particular are met from coal-based thermal power plants. The disposal of increasing
amounts of solid waste from coal-fired thermal power plants is becoming a serious concern to the
environmentalists. Coal ash, 80% of which is very fine in nature and is thus known as fly ash is
collected by electrostatic precipitators in stacks. In India, nearly 112 mt of fly ash is generated per
annum at present and is largely responsible for environmental pollution. In developed countries like
Germany, 80% of the fly ash generated is being utilized, whereas in India only 38% is being consumed.
Aakash Dwivedi and Manish Kumar Jain Department of Environmental Science and
Engineering, Indian School of Mines, Dhanbad, Jharkhand, India in his research article titled Fly ash
waste management and overview expressed that Fly ash (FA) a coal combustion residue of thermal
power plants has been regarded as a problematic solid waste all over the world. 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. He further emphasized that potential applications for coal fly ash as a raw material as
a soil amelioration agent in agriculture, use, in highway embankments, in construction of bricks, as an
aggregate material in Portland cement, filling of low lying areas etc in the manufacture of glass and
ceramics, in the production of zealots, in the formation of mesoporous materials, in the synthesis of
geo-polymers, for use as catalysts and catalyst supports, as an adsorbent for gases and waste water
processes, and for the extraction of metals. Thus fly ash management is a cause of concern for the
future.
Ahmad Shamshad, Fulekar M.H., and Pathak Bhawana of School of Environment and
Sustainable Development, Central University of Gujarat sector-30 Gandhinagar, Gujrat, INDIA
expressed in their research article titled Impact of Coal Based Thermal Power Plant on Environment
and its Mitigation Measure strongly advocates that the problem associated with fly ash has been
highlighted mitigated measure for fly ash has also been emphasize viz development of bricks, use of
fly ash for manufacturing of cement, development of ceramics, fertilizer, development of distemper
and use of fly ash in road construction and road embankment.
APPLICATION OF FLY ASH IN DIFFERENT SEGMENTS:
MATERIALS AND METHODS:

APPLICATION OF FLY ASH IN AGGRICULTURE:
Agriculture and waste land management have emerged as prime bulk utilization areas for fly
ash in the country. It improves permeability status of soil; improves fertility status of soil (soil health)
crop yield; improves soil texture; reduces bulk density of soil; improves water holding capacity
porosity; optimizes pH value; improves soil aeration; reduces crust formation provides micro
nutrients like Fe, Zn, Cu, Mo, B, Mn; provides macro nutrients like K, P, Ca, Mg, S etc; works as a part
substitute of gypsum for reclamation of saline alkali soil and lime. For exclamation of acidic soils; ash
ponds provides suitable conditions and essential nutrients for plant growth, helps improve the
economic condition of local inhabitants; crops grown on fly ash amended soil are safe for human
consumption & groundwater quality is not affected . Use of fly ash in agriculture has also proved to
be economically rewarding. The improvement in yield has been recorded with fly ash doses varying
from 20 tone/hectare to 100 tone/hectare. On an average 20-30% yield increase has been observed
out of 150 million hectare of land under cultivation, 10 million hectares of land can safely be taken up
for application of fly ash per year.
APPLICATION OF FLY ASH IN BRICKS AND CERAMIC:
The Central Fuel Research Institute, Dhanbad has developed a technology for the utilization
of fly ash for the manufacture of building bricks and ceramics. Fly ash bricks have a number of
advantages over the conventional burnt clay bricks. Unglazed tiles for use on footpaths can also be
made from it. Awareness among the public is required and the Government has to provide special
incentives for this purpose. Six mechanized fly ash brick manufacturing units at Korba are producing
about 60,000 bricks per day. In addition to this, two mechanized fly ash brick manufacturing units
have been set up by private entrepreneurs also at Korba, the total production being about 30,000
bricks/day. Apart from this about entrepreneurs have registered in DTIC proposals for establishing
ash brick units to give impetus to ash brick manufacturing. Orissa Government in India has banned
the use of soil for the manufacture of bricks up to 20 km. of a thermal power station. In the case of fly
ash-clay fired bricks, a mixture of clay and fly ash is fired. The un burnt carbon of the fly ash serves as
fuel for burning. Approximately 20-30% energy can be reduced by adding25-40% fly ash.
APPLICATION OF FLY ASH IN DETERGENT AND CEMENT:
In the presence of moisture, fly ash reacts chemically with calcium hydroxide and CO2
present in the environment attack the free lime causing deterioration of the concrete. A cement
technologist observed that the reactive elements present in fly ash convert the problematic free lime
into durable concrete. Fly ash can substitute up to 66% of cement in the construction of dams. Fly ash
in R.C.C. is used not only for saving cement cost but also for enhancing strength and durability. Fly ash
can also be used in Portland cement concrete to enhance the performance of concrete. Portland
cement is manufactured with Calcium oxide, some of which is released in a free state during
hydration. Studies show that one ton of Portland cement production discharges 0.87 tons of carbon
dioxide in the environment. Another Japanese study indicates that every year barren land
approximately 1.5 times of the Indian Territory need to be afforested to compensate for the total
global accumulation of carbon dioxide discharged into the atmosphere because of total global cement
production. Utilization of fly ash in cement concrete minimizes the carbon dioxide emission problem
to the extent of its proportion in cement.
APPLICATION OF FLY ASH IN FERTILIZERS , PAINTS & CHEMICALS:
Fly ash provides the uptake of vital nutrients/minerals (Ca, Mg, Fe, Zn, Mo, S and Se) by crops
and vegetation, and can be considered as a potential growth improver. Fly ash acts as effective soil
modifier and enhances its moisture retaining capacity and fertility. The improvement in yield has
been recorded with fly ash doses varying from 20 tone / hectare to 100 tone / hectare. On an average
20-30% yield increase has been observed. Out of 150 million hectare of land under cultivation, 10
million hectares of land can safely be taken up for application of fly ash per year. The fly ash treated
fields would give additional yield of 5 million tone food grains per year valued at about Rs. 3000
crores.
APPLICATION OF FLY ASH IN CONSTRUCTION, ROOFING, ROAD CONSTRUCTION & MINING:
The use of fly ash in large quantities making the road base and surfacing can result in low
valuehigh volume utilization technology demonstration projects at New Delhi, Dadri (U.P.) and
Raichur (Karnataka) have been successfully completed for use of fly ash in road / flyover
embankments. Guidelines have been prepared and approved by Indian Roads Congress (IRC) as
national standard. More than 10 multiplier effects have taken place across the country. In the recent
past CRRI offered advise/ consultancy services in the following road/embankment projects in which
fly ash was utilized. 1) Construction of plant roads at Budge-Budge thermal power plant using fly ash
based pavement specifications (Collaboration with CESC Ltd, Kolkata), 2) Construction of one km long
rural road near Raichur in Karnataka with fly ash based flexible/semi-rigid pavement composition
(Collaboration with Karnataka PWD and Raichur thermal power station executed as Fly Ash Mission
demonstration project), 3) Construction of 1.9 km long, 6 to 9 m high road embankment forming
eastern approach of the second Nizamuddin Bridge in Delhi using fly ash (Collaboration with Delhi
PWD and Indraprastha thermal power station, Delhi), 4) Construction of plant road and two rural
roads using fly ash (collaboration with National Capital Power Station, NTPC, Dadri, U.P).
SCOPE OF STUDY:
The scope of the study revolves around two prime focuses i.e. one from environmental
protection and other from organization point of view.
From environmental perspective: Eco-friendly product, pollutant free environment.
From organization Perspective: pollutant free environment, effective use of land, extra profit outlet
from bi-product.
LIMITATIONS OF RESEARCH STUDY:
1. The Study is restricted only to coal base thermal power plants generating fly ash within
India.
2. The study comprises of management, reutilization and marketing of waste with respect to fly
ash only.
3. The result arises from research work may or may not be applicable to other parts of
countries.
CONCLUSION:
Over a period of time, the image of fly ash has completely been changed from a Polluting
Waste to Eco-friendly Resource Material. The economic worth of fly ash has been significantly
understood by the people and it has now become an economic eco-friendly resources. The utilization
of fly ash which was about one million tonne per year in 1994 has now reached about 45 million
tonne per year. As compared to 2-3 major areas of ash utilization about a decade back, now about
more than 10 areas of ash utilization have been identified and fly ash has started being used in most
of them. With the significant progress made during last 10 years, it seems that the ash utilization is
heading forward in right direction, however, continued thrust and support of all stake holder agencies
at much higher levels would still be required to sustain the pace to accelerate it further.
REFERENCES
Adriano, D. C., Page, A. L., Elseewi, A. A., Chang A. C., and Straughan, I., 1980, Utilization and
disposal of fly ash and other coal residues in terrestrial ecosystems: a, review., Journal of
Environmental Quality, 9, 333344.
Aitken, R.L., and Bell, L.C., 1985, Plant uptake and phyto-toxicity of boron in Australian fly ash.
Journal of Plant and Soil, 84, 245-257.
Ansari F.A., Gupta A. K., and Yunus M., 2011, Fly ash from coal fed Thermal Power Plants: Bulk
Utilization in Horticulture-A long Term Risk Management Option, International Journal of
Environmental Research, Vol. 5, No. 1, pp. 101-108.
Carlson, C. L., and Andriano, D. C., 1993, Environmental impacts of coal combustion residues,
Journal of Environmental Quality., 22, 227-247. Recent Research in Science and Technology
2014, 6(1): 30-35 35
Fly Ash Mission, Technology Information, Forecasting and Assessment Council (TIFAC),
Department of Science and Technology, Ministry of Science and Technology, Government of
India, Technology Bhawan New Delhi, 1994.
Kumar Vimal and Mathur Mukesh, Clean environment through fly as utilization. Cleaner
Technology, Impacts/12/2003-2004, MOEF-CPCB, Govt. of India, 235-255, (2003)
Lokeshappa, B., and Dikshit, A.K., 2011, Disposal and management of coal fly ash, Proc. ICLST,
11-14
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Environ Radioact., 72(1-2), 35-40 (2004)
Palit, A., Coal ash utilization in India. Urja J., 1992, 32, 3944.
Pandey, V. C., and Singh, N., 2010, Impact of fly ash incorporation in soil systems. Agriculture,
Ecosystems and Environment 136, 1627.
Sahu, S. K., Bhangare, R.C., Ajmal, P.Y., Sharma, S., Pandit, G.G., and Puranil, V.D., 2009 ,
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thermal power stations in India., Journal of Micro chemical, 92, 92-96.
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&Utilization, New Delhi, India, February.
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Websites:
www.tifac.org.
www.flyash.info.
www.dst.gov.in
VANDE MATERAM

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IJMSS Vol.

04 Issue-03 (March, 2016) ISSN: 2321-1784

FLY ASH IN INDIA: FROM WASTE POLLUTANT TO ECOFRIENDLY RESOURCES

DR. SANJAY KESHAORAO KATAIT

WASTE POLLUTANT TO ECOFRIENDLY RESOURCES

FLY ASH PRODUCTION IN DIFFERENT COUNTRIES (Mt / Year):

FLY ASH UTILISED IN DIFFERENT COUNTRIES (%):

Sr. Year Thermal power electricity Coal Ash generation

H0 Fly ash in thermal power is not properly managed and reutilized.

H1 Fly ash is exclusively used for horticultural and manufacturing of

eco friendly product.

H2 Conversion of fly ash from pollutant source to economic resources.

H3 Proper utilization and management of fly ash minimize effluents and

disposals and helps in environment protection.

REVIEW OF RELATED LITERATURE:

APPLICATION OF FLY ASH IN DIFFERENT SEGMENTS:

MATERIALS AND METHODS:

APPLICATION OF FLY ASH IN BRICKS AND CERAMIC:

From environmental perspective: Eco-friendly product, pollutant free environment.

LIMITATIONS OF RESEARCH STUDY:

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