Concrete is the second most consumed substance on Earth after water. Cement production is growing by 2.5% annually, and is expected to rise from 2.55 billion usages to 3.7- 4.4 billion tons by 2050. The production of cement releases greenhouse gas emissions both directly and indirectly and another major problem is dumping of fly ash and pond ash. Coal ash represents a major environmental problem. There has been steady rise in the production of fly ash over the years due to increased demand for power and the dependence on coal for producing electricity.
Fly ash landing cost is 1100-1200 Rs/Tons, whereas Pond Ash cost is 600-700 Rs/Tons. Thus, using pond ash is much better and sustainable option to reduce the manufacturing cost of cement and increase profitability, by employing effective POND ASH Drying Combustion chamber.
CONCLUSION
Ground coal bottom ash (POND ASH) and coal fly ash (DRY FLY ASH) produced by the same electrical power plant were tested in order to investigate the possible application of the POND ASH in Portland cement production. The clinker/cement factor has a direct impact on CO2 emissions; in other words, the lower the clinker/cement ratio, the lesser the CO2 emissions. Then, one of the most viable approaches to reduce CO2 emissions is the study of the viability of new cement constituents as the Pond ash.
The following conclusions can be drawn:
Pond ash and Dry fly ash produced by the same electrical power plant present similar chemical composition. In particular, Pond ash has a lower loss on ignition than Dry fly ash. This parameter is mainly attributed to unburned coal particles.
Ground coal bottom ash mortars, in general, showed compressive strength performances similar to those of coal fly ash cement-based materials. Activity is lower at early ages; therefore, the compressive strength of the mortar specimens at 28 days decreased gradually with the increasing of ground coal bottom ash or fly bottom ash or mixes of them.
From the mercury intrusion porosimetry (MIP), it can be concluded that both ashes contribute to the refill of the mortar capillary pores with the pozzolanic reaction products leading to a redistribution of the pore size. This PSD curve is flatter at 28 days than at seven days of curing.
The water demand for normal consistency increases when the amount of ashes increases in the cement independently of the type of ash used.
Consequently, ground coal bottom ash alone or mixed with coal fly ash is suitable to be used in cement production as a new main component in the Portland cement standards.
END NOTES
In the product like cement which is primarily a low value product, with high incidence of taxes and duties, high energy costs, the avenues available to a plant for reducing its costs are limited. In the present environment due to energy crisis and steep increase in the cost of energy and other input materials, it has become imperative to give serious thought on how to make operations and equipment efficient towards use of energy and adoption of latest technology equipment to retain the requisite competitive edge in the market.
Thus, costs cement manufacturing costs can be reduced by utilization of POND ASH Drying Combustion Chamber
WHY USE COMBUSTION CHAMBER INSTEAD OF HAG (HOT AIR GENERATOR)
The set-up Cost of HAG is much more than Combustion Chamber.
The operational cost of Combustion Chamber is less than HAG.
Variety of Fuels and Waste materials can be used easily in Combustion Chamber.
POINTS AT WHICH POND ASH DRYING COMBUSTION CHAMBER CAN BE EMPLOYED
At Mill Inlet
At Separator Fan // Process Fan
FUEL WHICH CAN BE USED IN COMBUSTION CHAMBER FOR HOT AIR GENERATION:
Wooden Pieces
Charcoal
Steamed Coal (size 50-200 mm)
Rice Husk
AFR
RDF
Pharma Waste etc.
OPTIMUM OPERATIONAL TEMPERATURE OF FURNACE
400-580 Deg. C, depending on requirements.
Advantages of using Pond-Ash V/s Dry Fly-Ash
S. No.
Parameters
Unit
Values
1
Cost of Dry Fly-Ash
Rs/Tonne
1100
2
Cost of Pond-Ash
Rs/Tonne
700
3
Cost of Drying Pond-Ash (As per basis of Coal)
Rs/Tonne
50
4
Processing cost of 1 Tonne of Pond-Ash (Removal of Moisture)
Rs
750
5
Moisture in 1 Tonne Pond Ash
%
15
6
Finished product after drying in furnace (Convert into Dry Fly-Ash)