Fly Ash Utilisation

7/27/2019 Fly Ash Utilisation

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Fly Ash Scenarioin

NTPC Ltd


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NTPC-at a Glance

Total Operating capacity : 39,674 MW

16 Coal based power stations (Owned) : 30,855 MW

7 Gas/Liquid Fuel based power stations (Owned) : 3,955 MW

Coal based ower stations under JV : 2924 MW

Gas/ Liq. Fuel under JV : 1940 MW

Coal based Projects under implementation : 14,800 MW

Fly Ash Production during 2011-12 : 50.05 mt

Fly ash production /annum by 2017 : 66 mt


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Fly Ash Based Products&


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Manufacture of Portland Pozolana Cement and Cement concrete

Building products : Clay Ash Bricks/Fly Ash Bricks / AAC /Asbestos cement products

Bottom ash use as replacement of sand

Fly Ash Products

Road Embankment Construction

Mine filling

Agriculture


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Sustainable area of Fly ash utilization.

Strategy is station and location specific.

Agreements with cement manufacturers at Dadri, Unchahar,

Farakka and Tanda

More agreements are in pipeline at Vindhyachal, Rihand, Simhadri,Korba Talcher-Kaniha.

Fly Ash in PPC Manufacturing

Fly ash is issued free of cost at 10 stations (Singrauli, Vindhyachal,Korba, Sipat, Rihand, Tanda, Farakka, Simhadri, Talcher-Thermal,Talcher-Kaniha)

Issued on price at high demand sectors- Dadri, Badarpur,Ramagundam, Kahalgaon and Unchahar.

Creating rail loading facility at Ramagundam, Vindhyachal and allnew up coming stations to facilitate bulk transportation of fly ash.


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Set up fly ash brick plants at all coal based stations andutilizing bricks in own all types construction works.

Manufactured about 66 Crores fly ash bricks.

Set up mega brick plants at Dadri & Sipat to make fly ash bricksavailable to other users.

Fly Ash in Building Products

As per MoEF gazette notification 20% ESP fly ash is being keptreserve for fly ash brick/ blocks and tiles manufacturers.

Agreements with AAC blocks manufacturer at Badapur and

Dadri and for fly brick manufacturers at Dadri.

Fly ash off-take is from Simhadri, Ramagundam, Dadri,Badarpur, Talcher-Kaniha, Talcher-Thermal and Vindhyachal

and Sipat stations.


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Successfully demonstrated in stowing of UG mine

Bottom ash is also being utilized as filter / drainage layer inash dyke raising work at Ramagundam and Farakka.

At Dadri, bottom ash is being utilized as drainage layer in AshMound and fill material in road embankment construction.

Use of Bottom ash as Replacement of sand

To promote use of bottom ash in concrete block making astudy was carried out in association with National Council forBuilding Materials at Unchahar

Study reveals that bottom ash can be used as partreplacement of sand in concrete block making.


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Land filling within NTPC premises is being done with ash only.

At NTPC-Simhadri ash will be supplied on cost sharing basis for areadevelopment work of VPT and CONCOR project.

To facilitate ash utilization out side of NTPC, ash is being transported atusers door step on transportation cost sharing basis for Govt. projects with

special approval.

Low lying land Development

Issues:o No effective implementation by SPCB/ CPCB for ash use in filling with

100 km of power plant by construction agencies.

o SPCB are reluctant to give permission for ash filling in low lyingdevelopment in spite of provision in gazette notification at Korba andTalcher-Kaniha.

o Ash filling in low lying area development is not allowed in Environment

Clearances of New/ Expansion projects by Expert Appraisal Committeeof MoEF for Coal mining & Thermal power.


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Demonstration project is being taken up for forest wastelanddevelopment using ash in association with TFRI, Jabalpur &M.P. Forest department at Vindhyachal.

Effort are being made to take up such projects at Talcher-Kaniha and Rihand stations.

Wasteland development

Issues:o Forest department of MoEF needs to issue guidelines for use of ash in

forest wasteland development for plantation.


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NHAI and Road construction departments are beingapproached at Station as well as Corporate level for new roadproject in the vicinity of power plants.

Awareness programme / workshops are being organisedspecially for executives and consultants of the projectregarding provision of ash use.

Road Embankment Construction

Ash is being utilized at Farakka, Tanda, Dadri, Badarpur andRamagundam.

ISSUES: NHAI projects implemented on BOO system are reluctant to use ash.

Provisions of gazette notification is need to implemented/ monitored withtrue spirit by MORTH/ Regulatory.


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Ash Filling in abandoned mine:

South Balanda abandoned Mine of Mahanadi Coalfield Limited wasallocated to NTPC for Ash Filling.

Studies Ash Characterization, Hydro-geological investigation & EIA cumEMP through CMPDI and obtained Consent from SPCB and DGMS, ashfilling was taken up.

Mine Filling-sustainable area for pithead stations

Total ash produced at Talcher-Thermal power stations is being filled in thisabandoned mine.

To assess impact: base line data on Flora, Fauna, ground water and tracerstudies are being taken up.


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Ash Filling in abandoned mine: Mahanadi Coalfield Limited has allocated two quarries of Jagannath mine to

NTPC for Ash Filling.

Environmental studies have been taken up.

Results of studies would be submitted to MoEF and SPCB for permissionfor ash fillin .


Engineering for development of necessary infrastructure for ash filling inthe mine in ash slurry form is being carried out.

Issues:

As desired by Expert Appraisal Committee (EAC) of MoEF for Coalmining & Thermal power, MOEF/CPCB to issue guidelines for ash fillingin mines.


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Ash Filling in operating coal mine: MoEF Gazette notification stipulates for use of 25% fly ash on volume to

volume basis of

total materials used for external dumps of OB and

same percentage in upper benches of back filling of open cast mineunder guidance of DGMS.

Coal companies have yet to implement above stipulations.


Ministry of Coal identified two operating coal mines (i) Medapalli of SCCL (ii)Kaniha of MCL for demonstration project of random ash filling along withOB material.

NTPC completed lab scale for Medapalli mine and study reveals that ash

can be randomly filed along with OB in operating mines.

MoP has also constituted task force for identification of operating coalmines for demonstration projects by NTPC.

Taskforce to take up with CIL for identification of mines for this purposes.


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Bottom Ash Stowing in Underground Mine: Bottom ash being coarser material was found suitable for stowing of under

ground mines in place of sand.

Demonstration project ash was carried out at Ramagundam in SCCL U/Gmines.

About one lac m3 bottom ash was stowed in different intervals.


Now, SCCL has lifting botom ash for stowing of UG mine on regular basis.

At Korba, SECL has allocated Balgi mine for stowing.

Suitability of pond ash from NTPC Korba has been established.

Stowing with pond ash will be demonstrated in association with CIMFR.

Potential is for about 10 lac m3.


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It is established that use of fly ash in agriculture improvesphysical properties of soil, provides micro nutrients Fe, Zn,Cu, Mo, Mn etc and macro nutrients like K, P, Ca, Mg etc. andreduces pest incident which help to increase crop yield 15-

40%.

To built up the confidence of farmers of vicinity of power,show case ro ects have been carried out at farmers fields at

Use of fly ash in Agriculture

NTPC power plants.

Farmers have come forward to use ash in agriculture as soilamender.

Ash is being delivered to farmers agriculture fields by NTPC.


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Pursuing Technical Institutes/ Engineering colleges for inclusion of Chapter Fly ash a Resource material for construction sector in Civil Engineeringcurriculum.

IIT, Khadakpur, Jamia Milia Amiti, MTU have incorporated the chapter inBuilding Material subject.

Distribution of literatures on use of fly ash in various applications.

Promotional Activities

Making Documentary films

Periodical Advertisements in National dailies.

Organizing Workshops / Lectures for Engineers and Potential Users

Participation in Exhibitions and Display of Ash Based Products.


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Ash Utilization in various segments by NTPC

in 2011-12

Land

Road

Embankments; 17.97;

3.59%

Issue to

cement

industries;

73.61; 14.71%

Brick, Block,Tiles 17.97;

3.59%Ash Dyke

Raising;

42.20; 8.43%

Others;

43.13; 8.62%

Unutilized;225.19;

44.99%

Mine filling;

11.68; 2.33%

; 68.74;13.73%

** Quantities are

in lakh tonne


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Ash Generation V/s Utilization trend in NTPC from 1991-92 to 2011-12

30.00

40.00

50.00

60.00

tityinmillionton

Ash Generation

Ash Utilization

0.00

10.00

20.00

1991

-92

1992

-93

1993

-94

1994

-95

1995

-96

1996

-97

1997

-98

1998

-99

1999

-00

2000-01

2001

-02

2002

-03

2003

-04

2004

-05

2005

-06

2006

-07

2007

-08

2008

-09

2009

-10

2010

-11

2011

-12

Ash Generation V/s Utilization in NTPC Yearwise

Q

ua


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Fly Ash Utilisation

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