Fly Ash Scenario in NTPC Ltd

NTPC-at a Glance
Total Operating capacity 16 Coal based power stations (Owned) : 39,674 MW : 30,855 MW

7 Gas/Liquid Fuel based power stations (Owned) : 3,955 MW Coal based power stations under JV Gas/ Liq. Fuel under JV Coal based Projects under implementation Fly Ash Production during 2011-12 Fly ash production /annum by 2017 : 2924 MW : 1940 MW : 14,800 MW : 50.05 mt : 66 mt

Fly Ash Based Products & Utilization in NTPC

Fly Ash Products

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 Low lying land / wasteland development Road Embankment Construction Mine filling Agriculture

Fly Ash in PPC Manufacturing

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 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 all new up coming stations to facilitate bulk transportation of fly ash.

Fly Ash in Building Products

Set up fly ash brick plants at all coal based stations and utilizing 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 bricks available to other users. As per MoEF gazette notification 20% ESP fly ash is being kept reserve 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.

Use of Bottom ash as Replacement of sand

Successfully demonstrated in stowing of UG mine Bottom ash is also being utilized as filter / drainage layer in ash dyke raising work at Ramagundam and Farakka. At Dadri, bottom ash is being utilized as drainage layer in Ash Mound and fill material in road embankment construction. To promote use of bottom ash in concrete block making a study was carried out in association with National Council for Building Materials at Unchahar Study reveals that bottom ash can be used as part replacement of sand in concrete block making.

Low lying land Development

Land filling within NTPC premises is being done with ash only. At NTPC-Simhadri ash will be supplied on cost sharing basis for area development work of VPT and CONCOR project. To facilitate ash utilization out side of NTPC, ash is being transported at users door step on transportation cost sharing basis for Govt. projects with special approval.

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 lying development in spite of provision in gazette notification at Korba and Talcher-Kaniha. o Ash filling in low lying area development is not allowed in Environment Clearances of New/ Expansion projects by Expert Appraisal Committee of MoEF for Coal mining & Thermal power.

Wasteland development
Demonstration project is being taken up for forest wasteland development using ash in association with TFRI, Jabalpur & M.P. Forest department at Vindhyachal. Effort are being made to take up such projects at TalcherKaniha and Rihand stations. Issues:
o Forest department of MoEF needs to issue guidelines for use of ash in forest wasteland development for plantation.

Road Embankment Construction

NHAI and Road construction departments are being approached at Station as well as Corporate level for new road project in the vicinity of power plants. Awareness programme / workshops are being organised specially for executives and consultants of the project regarding provision of ash use. Ash is being utilized at Farakka, Tanda, Dadri, Badarpur and Ramagundam. ISSUES:
NHAI projects implemented on BOO system are reluctant to use ash. Provisions of gazette notification is need to implemented/ monitored with true spirit by MORTH/ Regulatory.

Mine Filling-sustainable area for pithead stations

Ash Filling in abandoned mine:
South Balanda abandoned Mine of Mahanadi Coalfield Limited was allocated to NTPC for Ash Filling. Studies Ash Characterization, Hydro-geological investigation & EIA cum EMP through CMPDI and obtained Consent from SPCB and DGMS, ash filling was taken up. Total ash produced at Talcher-Thermal power stations is being filled in this abandoned mine. To assess impact: base line data on Flora, Fauna, ground water and tracer studies are being taken up.

Mine Filling-sustainable area for pithead stations

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

Issues: As desired by Expert Appraisal Committee (EAC) of MoEF for Coal mining & Thermal power, MOEF/CPCB to issue guidelines for ash filling in mines.

Mine Filling-sustainable area for pithead stations

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 mine under 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 with OB 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 coal mines for demonstration projects by NTPC. Taskforce to take up with CIL for identification of mines for this purposes.

Mine Filling-sustainable area for pithead stations

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/G mines. 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.

Use of fly ash in Agriculture

It is established that use of fly ash in agriculture improves physical properties of soil, provides micro nutrients Fe, Zn, Cu, Mo, Mn etc and macro nutrients like K, P, Ca, Mg etc. and reduces pest incident which help to increase crop yield 1540%. To built up the confidence of farmers of vicinity of power, show case projects have been carried out at farmers fields at NTPC power plants. Farmers have come forward to use ash in agriculture as soil amender. Ash is being delivered to farmers agriculture fields by NTPC.

Promotional Activities
Pursuing Technical Institutes/ Engineering colleges for inclusion of Chapter Fly ash a Resource material for construction sector in Civil Engineering curriculum. IIT, Khadakpur, Jamia Milia Amiti, MTU have incorporated the chapter in Building Material subject. Distribution of literatures on use of fly ash in various applications. 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.

Ash Utilization in various segments by NTPC in 2011-12

Issue to cement industries; 73.61; 14.71% Road Embankment s; 17.97; 3.59% Land Development ; 68.74; 13.73% Mine filling; 11.68; 2.33% Unutilized; 225.19; 44.99% Brick, Block, Tiles 17.97; 3.59% Others; 43.13; 8.62% Ash Dyke Raising; 42.20; 8.43%

** Quantities are in lakh tonne

Ash Generation V/s Utilization trend in NTPC from 1991-92 to 2011-12 60.00

50.00 Quantity in million tonne

40.00

30.00

Ash Generation Ash Utilization

20.00

10.00

0.00
1991-92 1992-93 1993-94 1994-95 1995-96 1996-97 1997-98 1998-99 1999-00 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2000-01 2011-12

Ash Generation V/s Utilization in NTPC Yearwise

THANK YOU