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Fly Ash For Cement Plant

Fly ash, also known as flue-ash, is one of the residues generated in combustion, and comprises the fine particles that rise with the flue gases. Fly Ash is cement like fine grey powder consisting of the finely divided residue resulting from the combustion of Coal at coal-fired power station. It has pozzolanic properties and reacts chemically with calcium hydroxide at ordinary temperature to form insoluble compounds possessing cementitious properties. Fly ash particles are generally spherical in shape and reduce the water requirement for a given slump. The spherical shape helps to reduce friction between aggregates and between concrete and pump line and thus increases workability and improve pump ability of concrete. Fly ash use in concrete increases fines volume and decreases water content and thus reduces bleeding of concrete.
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The main objective of using fly ash in most of the cement concrete applications is to get durable concrete at reduced cost, which can be achieved by adopting one the following two methods:
  • Using Fly ash based Portland Pozzolana Cement (PPC) conforming to IS: 1489 Part-1 in place of Ordinary Portland Cement.
  • Using fly ash as an ingredient in cement concrete.
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The first method is most simple method, since PPC is factory-finished product and does not requires any additional quality check for fly ash during production of concrete. In this method the proportion of fly ash and cement is, however, fixed and limits the proportioning of fly ash in concrete mixes. The addition of fly ash as additional ingredients at concrete mixing stage as part replacement of OPC and fine aggregates is more flexible method. It allows for maximum utilization of the quality fly ash as an important component (cementitious and as fine aggregates) of concrete.
There are three basic approaches for selecting the quantity of fly ash in cement concrete:
  • Partial Replacement of Ordinary Portland cement (OPC)-the simple replacement method.
  • Addition of fly ash as fine aggregates the addition method.
  • Partial replacement of OPC, fine aggregate, and water- a modified replacement method.
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