Pond Ash Based Composite Cement Is The Cheapest

Pond Ash Based Composite Cement Is The Cheapest Green Cement Author: -Jitendra Kumar Dalai. Additional GM (Tech Services), Rourkela NSPCL O&M Conference, Delhi Date-16/03/2018.

Origin Of Concept • The concept of using pond ash emerged from Bureau of Indian Standards Document on Portland Pozzolona Cement – IS 1489 – Part 1 & Portland Pozzolona Cement ( Calcined clay based) – IS 1489 – Part 2. Pulverized Fuel Ash -IS 3812 • The General Thinking is Dry Fly Ash has cementitous properties , hence suitable for cement making. At the same time it is believed that the pond ash has lost cementitous properties hence not suitable for cement making.

• Gist Of IS 1489 – Part 1 in point no 3. 1 describes Pozzolana “ An essentially silicious material which while in itself possessing little or no cementitious properties”

Pond Ash Taken By Cement Factories • Based On IS 3812 Till 31 st March 2017 Cement Factory had taken nearly 200000 Tons of Pond Ash. • Taking Ash disposal / dumping cost at Rs 150/Ton, Pond Ash Taken by cement plant had given us Savings Worth Rs 3 Crs. • Disposal to Cement Plant Was Complience of Ash Utilisation Notification of Mo. EF.

But The Pond Ash Lifting Stopped from 01 st April 2017 We Were Verbally Informed That Slag Cement Manufacturing was Cheaper. We Were Left Between God &

Distance of cement units from Rourkela • OCL, (Dalmia Cement ) distance 50 KM. Capacity 6. 7 Million Tons, Primarily PSC. • Ultratech Cement Jharsuguda distance 130 KM. Capacity 4 million Tons/Anum Primarily PPC(Fly ash). Operates between 2 to 3 million Tons/Anum. • Shiva Cement Distance 55 KM. Primarily PSC. • KGN Cement 50 KM. Primarily PSC. • Chariot Cement 55 KM. Primarily PSC.

Availability Of Raw Material • Ultratech Cement, Jharsuguda, Brings lime clinker from its own plant at Bhatapara, Chhattisgarh, India. Nearly 300 KMS away from Jharsuguda. Plant located within a cluster of thermal power plants, like Vedanta 4 X 600+9 X 135 MW+OPGC IB 2 x 210 MW+ HINDALCO 1 x 67+1 x 32+3 x 100 MW+ADITYA BIRLA 3 x 150+ BHUSAN 4 x 130=5405 MW. Approximate Ash Generation above 50, 000 Tons/Day. • OCL, (Dalmia Cement ), Own Lime Quarry at a distance of 10. 5 KM, with cross country conveyor belt line. Major Slag lifter from RSP, Scouts Slag from other units. Flyash is available from various thermal units of Jharsuguda & Sundergarh , District. • Shiva Cement, KGN Cement, Chariot Cement very small operators capacity around 0. 1 MTPA Purchase Cement clinker from market.

Table 2: Composition of cement blends prepared by varying wt composition of pond ash and GBF slag Wt. proportions (%) Sl. Nos Cement Sample 1 OPC-Cont. 95. 0 - - 5. 0 2 PPC-Cont. PSC-Cont. COM-1 COM-2 COM-3 COM-4 COM-5 COM-6 COM-7 COM-8 COM-9 COM-10 COM-11 COM-12 COM-13 70. 0 25. 0 - 5. 0 55. 0 - 40. 0 50. 0 5. 0 40. 0 15. 0 40. 0 25. 0 30. 0 5. 0 40. 0 35. 0 20. 0 5. 0 40. 0 45. 0 10. 0 50. 0 5. 0 40. 0 50. 0 15. 0 30. 0 50. 0 25. 0 20. 0 50. 0 35. 0 10. 0 5. 0 60. 0 5. 0 30. 0 5. 0 60. 0 15. 0 20. 0 5. 0 60. 0 25. 0 10. 0 5. 0 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Clinker Pond ash BF Slag Gypsum

Table 3: Physical performance of composite cement blends Sl No Cement Sample Setting Time (Min) IST FST Comp. Strength (MPa) 3 d 7 d 28 d 90 d 120 d 180 d 360 d 1 OPC-Cont. 190 270 35. 5 48. 0 57. 5 58. 50 60. 50 61. 00 62. 00 2 PPC-Cont. 210 290 26. 0 35. 5 48. 0 65. 00 68. 50 70. 00 3 PSC-Cont. 215 285 26. 0 40. 5 57. 00 60. 00 61. 00 63. 00 4 COM-1 210 295 28. 0 39. 5 51. 5 57. 50 62. 50 63. 00 65. 00 5 COM-2 210 300 22. 5 32. 0 45. 0 54. 00 58. 00 60. 00 6 COM-3 205 300 18. 5 27. 5 40. 5 52. 00 55. 00 56. 00 58. 50 7 COM-4 200 300 17. 0 25. 5 37. 0 48. 00 51. 00 52. 00 54. 00 8 COM-5 190 310 13. 0 19. 0 35. 0 39. 00 44. 00 45. 00 46. 50 9 COM-6 170 275 29. 0 41. 0 52. 0 58. 00 63. 00 65. 00 67. 50 10 COM-7 190 275 25. 0 36. 0 49. 0 54. 50 60. 50 62. 00 64. 50 11 COM-8 175 295 23. 5 34. 5 48. 0 62. 00 63. 50 65. 00 12 COM-9 205 295 20. 0 32. 0 45. 5 52. 00 56. 00 57. 00 59. 50 13 COM-10 170 260 15. 5 22. 0 41. 0 45. 00 51. 00 52. 50 55. 00 14 COM-11 195 285 30. 0 44. 0 53. 0 60. 00 66. 00 67. 00 68. 00 15 COM-12 170 255 29. 0 39. 5 52. 0 60. 00 65. 00 66. 00 67. 50 16 COM-13 205 290 25. 0 33. 0 46. 0 57. 00 64. 50 65. 00 68. 00 17 COM-14 210 298 16. 0 23. 0 37. 0 49. 0 52. 00 52. 50 54. 50

CONTROL = Clinker 70% + Pond Ash 25%

CONTROL = Clinker 55% + GBFS 40 %

1. 0 Cost Sl No Cement Sample 1 OPC-Cont. 2 PPC-Cont. 3 PSC-Cont. 4 COM-1 5 COM-2 6 COM-3 7 COM-4 8 COM-5 9 COM-6 10 COM-7 11 COM-8 12 COM-9 13 COM-10 14 COM-11 15 COM-12 16 COM-13 Clinker 95. 0 70. 0 55. 0 40. 0 50. 0 60. 0 Wt. proportions (%) Pond ash BF Slag Gypsum 25. 0 15. 0 25. 0 35. 0 45. 0 15. 0 20. 0 25. 0 35. 0 15. 0 25. 0 40. 0 50. 0 40. 0 30. 0 20. 0 10. 0 40. 0 30. 0 25. 0 20. 0 10. 0 30. 0 20. 0 10. 0 5. 0 28 Days Strength 57. 5 48. 0 50. 5 51. 5 45. 0 40. 5 37. 0 35. 0 52. 0 49. 0 48. 0 45. 5 41. 0 53. 0 52. 0 46. 0 Cost of CEMENT Rs/Ton 4850 3650 3450 2610 2530 2450 2370 2290 3010 2930 2890 2850 2770 3410 3330 3250

Trial & Establishment • Continuous Lifting of Pond Ash started from Jan 2018. • Till Date (13/03/2018)They have Lifted 70000 Tons. • Expected Lift around 100000 Tons by 31 st March 2018 • For FY-18 -19 the Lift Will Be 30000 Tons/Month. • So Annual Disposal Will be around 360000+Tons

Thanks With Regards Jitendra Kumar Dalai. jk. dalai@nspcl. co. in 09777309111 09437047934