VERY GOOD EVENING

RECENT ADVANCES AND TECHNOLOGY FOR EFFECTIVE USE OF FLYASH

FOR MAKING HYBRID COMPOSITE TIMBER
-Opportunities for entrepreneurship

Asokan Pappu & Team

CSIR- Advanced Materials and Processes Research Institute
(AMPRI), Bhopal
 OVERVIEW

 Aim

 Hybrid Flyash Composites :CSIR-AMPRI’s Innovation highlights

• Potential raw materials & problems
• Manufacturing process: Fly ash Composite products
• Performance of Fly ash composites over traditional materials
• Applications & Opportunities

 Conclusion
 AIM

Convert Fly ash in to Hybrid Green Composites

 FLY ASH STREAM IN INDIA
Fly ash generation, 2017: ~ 240 MT/ Yr

Rihand STPP Fly ash :STPS, M.P.

Fly ash :Adhunik Power, Jamshedpur 4

 FLY ASH SAFE MANAGEMENT: INDIA IS LEADER

COAL ASH SPILLS IN NC RIVERS, USA

Dan River stream Power Station, NC
Cape Fear power plant in Chatham County
Source: http://pulse.ncpolicywatch.org/2015/02/20
http://www.northcarolinahealthnews.org/dan-river-coal-ash-spill-timeline/
Fly ash based Timber
R & D FOCUS
S&T innovation &
development of a energy
efficient hybrid Fly ash
green composite materials

Create opportunity for

sustainable manufacturing
for multifunctional
applications

AIM
 Develop new class of hybrid green composites
 Tech Commercialization & Create new Industries
 S&T intervention to Society and Environment
 INTRODUCTION
Development positioning: Hybrid Fly ash Composites
 Incremental and continual development
 Novel
• Neither available nor developed both in India and internationally
•CSIR-AMPRI’s R&D has Conferred Industrial Poster Award 2015 WOCA
by ACAA, UK, EPRI USA

LEADERS IN COMPOSITES:

Intl. Sheffield UK, Auckland NZ.,

Uni. Delaware, WSU, …
India: DRDO, HAL, NAL, IITs, …
Industries: Kineco Goa, TIPCO Wood,
Binani Mumbai, Hindoostan Mumbai
 PROBLEM ADDRESSED

Find alternative materials for Timber / GRP / Plastic

Avoid deforestation, utilise unexploited renewable resources
CHALLENGES
 Fly ash : ~ 240 MT/ Yr
 Natural fibres (NF) : ~ 400 MT/ Yr

Solution to FLY ASH management with a holistic approach

Reduce consumption of petroleum based products
Save environment & contributes for Clean India; Make in India program
…
 POTENTIAL RAW MATERIALS
PARTICULATES FROM WASTE STREAM :

Fly ash
Marble wastes
Agro wastes
…

RENEWABLE RESOURCES: NATURAL FIBRES:

Jute
Sisal
Hemp
…
BINDER SYSTEM : Polyester
Epoxy
PU…
 PHYSICO-CHEMICAL CHARACTERISTICS

S No Properties Fly Ash Pond Ash Clay Sand

1 Bulk density 1.13 1.25 1.87 1.59

(g/cm3)
2 Specific gravity 2.12 2.08 2.37 2.65
3 Porosity (%) 37.50 41.66 36.31 68.41
4 WHC (%) 44.98 47.39 43.69 24.65
5 pH 7.03 7.66 7.64 8.18
6 EC (dS/m) 0.498 0.238 0. 6506 0. 246
7 Particle Size (D90 ) 19.7 355 12.96 710.6
µm
8 Texture Silt Loam Medium Silty clay Sand
Sand
 CHEMICAL PROPERTIES
S. No. Properties Fly Ash Pond Ash Clay Sand

1 SiO2 57.99 60.65 60.65 95.18

2 Al2O3 21.91 16.22 16.22 0.67
3 Fe2O3 10.72 12.43 12.43 0.33
4 MgO 3.97 2.28 2.28 0.14
5 K2O 1.90 0.90 3.22 0.03
6 CaO 0.84 2.15 2.15 0.26

Chemical constituents Class F Ash Class C Ash

SiO2+Al2O3+Fe2O3 (%) > 70 > 50
CaO (%) < 10 > 10
 CHARACTERISATION
Trace elements in
ppm / ppb range RADIOACTIVITY PROPERTIES
Lead
Radionuclides Activity level of radionuclides
Zinc (Bq/kg) Fly Ash Pond Upper
Cadmium Ash Limit
Copper 40K (β Emitters) 314.0 281.8 925
Chromium ±2.84 ±6.44
226Ra (α Emitters) 67.20 54.13 370
Cobalt ±0.60 ±0.80
Nickel 228Ac (α Emitters) 77.27 74.03 259
Sodium ±3.06 ±9.57

Manganese
Sulphur
X-RAY DIFFRACTOGRAM / MINERALOGY OF FLY ASH

Q Q - Quartz – SiO2
M – Mullite – 3Al2O3 .2SiO2
H – Hematite – Fe2O3
A – Amorphous (Glassy phase)

M, A

H
A Q,M
H ,M H
M
M
M, A
A
MORPHOLOGY OF FLY ASH AND POND ASH

Sand
Fly ash

Pond Ash
 MANUFACTURING PROCESS: HYBRID COMPOSITES
RAW MATERIALS

NATURAL FIBRE POLYMER INDUSTRIAL WASTE

FIRE RETARDENCY GRINDING &

TREATMENT MIXING
PROCESSING

CALENDERING-MOULDING

CASTING

CURING

DEMOULDING

POST CURING

TESTING FOR QUALITY ASSESSMENT

FINAL PRODUCT
FLY ASH COMPOSITE PANEL DOOR
 HYBRID GREEN COMPOSITES
An alternative to :
• Wood / Timber
• Synthetic wood (MDF, Particle Board, Ply wood)
• Plastic and FRP / GRP Products
FLY ASH COMPOSITES DOOR SHUTTERS
FLY ASH COMPOSITES
FLY ASH COMPOSITES ROOFING SHEETS
 PROPERTIES OF COMPOSITES
WATER ABSORPTION (ASTM D 570-10)
22
RMP- Red mud polymer composites
FPC- Fly ash polymer composites 20
20 MPC- Marble waste polymer composite 18.5

18 RHB- Rice Husk Board

PB (EG)- Particle Board- Exterior grade15
WATER ABSORPTION (%)

16 EPS- Extended Polystyrene

14 MDF- Medium Density Fibre Board 12.5

12
9
10
8
6

4
1.58 1.3
2 0.27
0
RMP FPC MPC RHB PB(EG) EPS MDF TEAK
Wood
MATERIALS
COMPARISON OF AMPRI’S COMPOSITE WITH CONVENTIONAL MATERIALS
 TENSILE STRENGTH (ASTM D 638-10)
29
30
25
25
TENSILE STRENGTH (MPa)

22

20

15
RMP- Red mud polymer composites
FPC- Fly ash polymer composites
10 MPC- Marble waste polymer composite
4
3.25
5
0.405 0.425 0.65

0
RMP FPC MPC RHB PB(EG) EPS MDF TEAK

MATERIALS
Wood

COMPARISON OF AMPRI’S COMPOSITE WITH CONVENTIONAL MATERIALS

 COMPRESSIVE STRENGTH

95 94
100
90
COMPRESSIVE STRENGTH (MPa)

80
70 56
60
50
40
30
8.8
20
10
0
RMP FPC MPC TEAK Wood
MATERIALS

COMPARISON OF AMPRI’S COMPOSITE WITH CONVENTIONAL MATERIALS

 FLEXTURAL STRENGTH (ASTM D 790-10)

120
103 RMP- Red mud polymer composites
FLEXURAL STRENGTH (MPa)

100 92 FPC- Fly ash polymer composites

MPC- Marble waste polymer composite
RHB- Rice Husk Board
80 PB (EG)- Particle Board- Exterior grade
EPS- Extended Polystyrene
60 MDF- Medium Density Fibre Board

40
26 28

20 12.9 13.75 12.8

3.25

0
RMP FPC MPC RHB PB(EG) EPS MDF TEAK
MATERIALS Wood

COMPARISON OF AMPRI’S COMPOSITE WITH CONVENTIONAL MATERIALS

 INDICATIVE COST
DOORS size : 2x1 m (25-30 mm thick) Cost Rs.
A AMPRI Doors (Proto type): Water & termite
resistant Grade 4500-6000
B Commercial Doors
i) Teak wood 12000 /-
ii) Medium Density Fibre Board with lamination 5500/-
iii) GRP Solid door 12600/-
Panels (Price psf) Cost Rs
CSIR-AMPRI Panel products
i)High strength, water & termite resistant 8 mm t 40-60/-
Commercially available panel products
i) Ply 12 mm t 50-75/-
ii) Medium Density Fibre Board 12 mm t 40-50/-
iii) PVC 25mm t 110/- 26
iv)Teak (30mm t ) 225/-
HYBRID GREEN COMPOSITE MATERIALS
HYBRID GREEN COMPOSITES
HYBRID GREEN COMPOSITES
FLY ASH COMPOSITES PARTITION PANELS
HYBRID GREEN COMPOSITES
HYBRID GREEN COMPOSITES
 APPLICATIONS
Door, false ceiling, floor tile, wall tile, partition, roofing, furniture

Instant house

Demonstrated structure at CSIR AMPRI Bhopal

APPLICATIONS: HYBRID GREEN COMPOSITES

Pulley
Paper weight
FLY ASH COMPOSITES FURNUTURE
 ACHIEVEMENTS

Simple process, address multiple issues

Alternative for • Stronger than timber, synthetic wood, plastic and durable
 Timber
 MDF • Resistance to weather, corrosion, moisture, termite…
 Particle board • Fire retardant materials having self-extinguishing nature
 Ply wood
 New wood & • Cost effective & maintenance free products
 Plastic

Advantages HYBRID GREEN COMPOSITES

 HYBRID GREEN COMPOSITES: ADVANTAGES
 Uniqueness of Products:
 High strength to weight ratio
 Maintenance free green composite
 Use in multifunctional applications

Commercial Opportunities
Transforming FLY ASH into wealth in construction sector
 Convert lab research & Create start-up industries
 Enhance economy & employment
 Process know-how? is ready for commercialization
 FLY ASH COMPOSITES

Witness by the DG CSIR at CSIR-AMPRI Bhopal

 PROPERTIES OF FLY ASH COMPOSITES
Depends on :
 Particle size distribution
 Fibre to binder ratio
 Fibres orientation
 Types of binder
 Physico-chemical characteristics of Fly ash particulates & fibres
 Aspect ratio
 Interfacial bonding
 Processing conditions & casting technique
 Temperature, pressure, mixing, constituents concentrations
 ...
 COMMERCIALISATION AND BUSINESS PLAN
TECHNOLOGY LICENSED TO
1. M/s. VSM Industry, Surat Gujarat, 29 Aug 2015
Hybrid Wood Substitute Composite Materials (CM Wood)
2. M/s. Sidhhi Poly Matrix, Maharashtra, 26 September 2015
High-Performance Hybrid Composite Materials (HP- Composites)
3. M/s. Eco Bright Sheet Co. Pv. Ltd. Bhilai, CG., 7 Mar. 2017
Advanced Hybrid Wood and Wood Substitute Composite Materials (AC -Wood)
 TECHNOLOGY TRANSFERRED
Hybrid Wood Substitute Composite Materials
(CM WOOD)
LICENSED TO : M/s. VSM Industry, Surat Gujarat, 29 Aug 2015

Training & Complete tech services provided

 TECHNOLOGY TRANSFERRED
High-Performance Hybrid Composite Materials

(HP -Composites)

LICENSED TO : M/s. Sidhhi Poly Matrix, Maharashtra, 26 September 2015

Training & complete tech services provided during this project period
 TECHNOLOGY TRANSFERRED
Advanced Hybrid Wood and Wood Substitute
Composite Materials (AC -WOOD)

LICENSED TO : M/s. Eco Bright Sheet Co. Pvt. Ltd. Bhilai, CG., 7 Mar. 2017
Training & Complete tech services provided
 Bhopal Smart City
Development
Corporation

Expecting 12 more industries to

commercialize this technology
 FLY ASH COMPOSITES :PRODUCTS LAUNCHING

“ Your intervention will help us to take-up this technology

f new business creation”
NAI DUNIA
 CEMENT FREE CONCRETE
Technology ready for commercialisation:

Process know how for :

• High volume use of Fly ash
• High value added High strength Concrete products
 FLY ASH FOR HAZARDOUS JAROSITE WASTE RECYCLING
INTO A NON HAZARDOUS COMPOSITE BRICKS
Zinc industry waste
Aim: Immobilisation and recycling using fly ash

In India  Compressive strength-53kg/cm2

 Shrinkage- 4.2%
3.5 million tons/ year  Water absorption-16.5%
 Density- 1.6 g/cm3
 No toxicity as per USEPA TCLP norms

Processed Jarosite waste

with Fly Ash JAROSITE COMPOSITE BRICKS
47
 CONVERT WASTELAND INTO AGRUCULTURALLY
PRODUCTIVE LAND
LAB SCALE STUDIES RESULTS PILOT SCALE DEMONSTRATION
 North India : Rihand, Jhansi, Kanpur
South East India: Angul & Damanjodi
 Central India : Sarni , ….

Mechanism
Randomized Experiments
INCREASE IN EDIBLE YIELD OF CABBAGE WITH FLY ASH
No coal ash
Coal ash 650 t/ ha.in 1993
Coal ash 650 t/ha.+130 t/ha in each cropping
Cabbage yield (q/ha.)

500

400

300
200

100
I II III IV V VI
Rabi Cropping

Crop growth & yield increased : 16-48 %

Irrigation water saving: 32%
Food produces: Meeting the quality standards
 CONCLUSION

“ CSIR- AMPRI’s HYBRID GREEN FLY ASH COMPOSITES

– An emerging materials to fulfill multifunctional applications”

“ Your intervention will help for entrepreneurship

&
new business creation”

“ You ARE WELCOME for commercialization of the

Technology”
 FOR MORE DETAILS PLEASE CONTACT :

The Director
CSIR- Advanced Materials and Processes Research Institute,
Bhopal

OR

Dr. Asokan Pappu, Senior Principal Scientist &

Chairman Business Development Cell, CSIR-AMPRI
Professor, AcSIR, India
Email: pasokan@ampri.res.in; asokanp3@yahoo.co.in
Phone: 755 2489402, 9425600260
 CSIR, New Delhi
Acknowledgements: DST, Delhi
BMTPC, MOEF …
Dr. Avanish K. Srivastava, Director , C SIR- AMPRI , Bhopal

All my Team members, CSIR-AMPRI

Thanks to Dr. M. Saxena & YOU all !...

Special thanks to Mr. Ashwin Kumar, DG, MEF & Sponsors …