Opportunities & Challenges

in Fly Ash Utilization in

Indian Cement Industry
Presented by:
K.N.Rao Director Energy & Environment
ACC Limited

This report is solely for the internal use. No part of it may be circulated, quoted, or reproduced for distribution outside the company organization
without prior written approval from ACC Limited. This material was used during an oral presentation; it is not a complete record of the discussion.

Fly Ash Generation & Its Utilization In The Country

Source: CEA REPORT ON FLY ASH GENERATION AND ITS UTILIZATION DECEMBER 2011

ACC Limited

2nd Annual International Summit - FAU 2013, New Delhi

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Fly Ash Utilization In Cement Industry

During the year 2012, ACC has consumed ~4.6 Million Tonnes of Fly ash which is
equivalent to ~13% of Indian Cement Industry Fly Ash Consumption
Source: CEA REPORT ON FLY ASH GENERATION AND ITS UTILIZATION DECEMBER 2011

ACC Limited

2nd Annual International Summit - FAU 2013, New Delhi

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19.01.2013

Expected Fly Ash Absorption Capacity By Indian

Cement Industry

Year

Expected Fly ash

absorption in
Cement (million
tons per annum)
Assumptions:

2015
2020
2025
2030
2035
2040
2045

52.65
73.01
94.63
120.50
143.72
158.02
167.74

2050

177.45

Market share of PPC Cement is

assumed to be 65% of the total
cement production

The % of Fly ash utilization in

PPC is expected to increase
from ~23% in 2010 to ~35% in
2050

Source: WBCSD / CSI Low Carbon Technology Road Map for Indian Cement Industry

ACC Limited

2nd Annual International Summit - FAU 2013, New Delhi

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19.01.2013

Benefits of Fly Ash Utilization In Cement Manufacturing

ACC is the first Indian cement company to produce blended cement at
their Chaibasa unit in the year 1961 by using the blast furnace slag from
Tisco
In the year 1965 ACC produced flyash based blended cement (PPC)
Benefits of flyash utilization in cement manufacturing process:

 Substitution of fast depleting limited natural resources of limestone

 ~25 30% Conservation of fossil fuels like Coal, Oil & Gas etc can
be achieved due to the substitution of clinker with flyash

 ~15 20% Electrical energy savings which will reduce further

conserve fossil fuels due to avoidance of electricity generation

 CO2 reduction (direct): 220 280 Kg CO2 /t PPC (for Cement with
27 - 35% by mass fly ash)

 CO2 reduction (indirect): 1 KwH in specific power consumption

reduces CO2 emissions by 1 Kg hence, reduction in CO2 emissions
is expected to be 13 17 kg / t PPC (for Cement with 27 - 35% by
mass fly ash)
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ACC Limited

2nd Annual International Summit - FAU 2013, New Delhi

19.01.2013

Benefits of Fly Ash Utilization In Cement Manufacturing

 Possibility of releasing vast space occupied by wet fly ash ponds
subject to Governments support to Cement Industry

 Avoidance of ground water contamination due to open storage of

flyash

 Environment friendly disposal of flyash and creating economic value

while conserving
limestone)

the

fast

depleting

natural

resources

(coal,

ACC Limited

2nd Annual International Summit - FAU 2013, New Delhi

19.01.2013

Other Areas Of Flyash Utilization






Production of Synthetic Sand

Production of Aggregates
Production of Composite Cement
Production of Flyash Bricks for construction

ACC Limited

2nd Annual International Summit - FAU 2013, New Delhi

19.01.2013

Limiting factors/ Challenges for utilization of fly ash in

Indian cement industry


Substantial increase in the landed cost of Flyash at Cement plant

(earlier the flyash was given free of cost to cement plants)

Continuous increase of OPC demand in infrastructure projects

The maximum permitted level of fly ash in India is 35% as compared

to European standards maximum of 55% by weight for siliceous fly
ash in cement production

Lack of composite cement standard

Many Indian cement plants have reached 35% flyash addition limit

Lack of coincidence of limestone available locations and the power

plant locations resulting non-viability of manufacturing PPC

The long lead distances between flyash generation sources and

cement manufacturing units

ACC Limited

2nd Annual International Summit - FAU 2013, New Delhi

19.01.2013

Limiting factors/ Challenges for utilization of fly ash in

Indian cement industry


Insufficient Domestic R&D efforts to increase the quality of flyash (at

the point of generation as well as at the point of utilization)




High transportation cost of flyash

Lack of economically viable and proven technologies for utilizing

huge deposits of pond / dump ash

The Poor quality of Indian fly ash & large variation in terms of

High infrastructure cost for loading at power plant, unloading at

cement plant & transportation of flyash by special wagons/bulkers






Low lime reactivity

Low glass content
High Carbon content
Varying fineness level

ACC Limited

2nd Annual International Summit - FAU 2013, New Delhi

19.01.2013

Areas to be addressed to Enhance Fly Ash Utilization

In Cement Industry
Interms of policy support

 Need for modifications of existing standards and codes / new

standards for enhanced utilization of fly ash
manufacturing

in Cement

 Standard for Composite Cement

 Mandatory use of blended cements in Government Infrastructure
Projects

 Enhancing the consumer awareness about the blended Cements

 Cement Industry should be allowed to use 100% of their Captive
Power plants for cement manufacturing

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ACC Limited

2nd Annual International Summit - FAU 2013, New Delhi

19.01.2013

Areas to be addressed to Enhance Fly Ash Utilization

In Cement Industry
Interms of financial

 Concessional excise duty for flyash (PPC)/slag(PSC)/composite

Cement

 Concessional freight charges for the transportation of flyash if the

lead distance from the power plant to cement plant is more than
100 kms

 Government to develop proper rail connectivity to cement plants

to enable for the economical transport of flyash

 Power plants to create infrastructure facilities for the flyash

evacuation and loading

 Supply Flyash at free of cost to Cement Industry and power plants

may be suitably compensated

 Financing R&D initiatives for improving the quality of flyash

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ACC Limited

2nd Annual International Summit - FAU 2013, New Delhi

19.01.2013

THANK YOU

12

ACC Limited

2nd Annual International Summit - FAU 2013, New Delhi

19.01.2013