apgenco flyash ppt

1

PRESENTATION ONPRESENTATION ON

FLY ASH UTILISATIONFLY ASH UTILISATION

A SUCCESS STORY OF Dr. NARLA A SUCCESS STORY OF Dr. NARLA TATA RAO THERMAL POWER TATA RAO THERMAL POWER

STATIONSTATION

2

ANDHRA PRADESH POWER GENERATION CORPORATION

LIMITED (APGENCO) WAS FORMED FROM ERSTWHILE

APSEB UNDER ANDHRA PRADESH ELECTRICITY

REFORM ACT 1998 ON 01-02-1999 WITH THE

PRINCIPAL OBJECTIVE OF ENGAGING IN THE BUSINESS

OF GENERATION OF ELECTRICITY IN ANDHRA PRADESH

FORMATION OF APGENCO

3

ROLE OF APGENCO

• Responsible for

– Operation and Maintenance of all existing generating stations and those under construction by APGENCO

– Setting up new thermal and hydro power stations

– Refurbishment, renovation and modernization of Existing Thermal Power Stations

4

INSTALLED CAPACITY AT Dr.NTTPS

Station Unit Capacity (MW)

Date of Commissioning

VTPS Stage-I 1 210 01.11.1979

2 210 10.10.1980

Stage-II 3 210 05.10.1989

4 210 23.08.1990

Stage-III 5 210 31.03.1994

6 210 24.02.1995

Stage-IV 7 500 Under Construction and programmed for commissioning during March 2009

5

AWARDS WON BY Dr.NTTPS

1994-95 11.99 13.73 Productivity Award Gold








Medal ReceivedAward Received

Economic

Operation Award

( Rs Lakhs)

Productivity

Award

( Rs lakhs )

Year

VTPS qualified for meritorious productivity award for 19th

consecutive year since 1983-84. VTPS stood No.1 in India during 1997-98 and 2001-02 for achieving highest PLF.

6

FLY ASH UTILISATION AT

Dr.NTTPS DURING 1998-99 TO 2007-08

76.6183232423914342007-08

51.9115017622164722006-07

52.6111244421165382005-06

49.6103849220955692004-05

40.584009520758302003-04

20.746491522457922002-03

14.733353622693222001-02

15.336429723838352000-01

9.923082623220061999-00

5.713400623521681998-99

% Fly ash

Utilization

Fly Ash UtilizedFly Ash GeneratedYear

7

ASH UTILISATION AT

Dr.NTTPS DURING 1998-99 TO 2007-08

67.5201897429892932007-08

62.3172653527705902006-07

56.7150054726456732005-06

46.1120781426194612004-05

36.995703925947882003-04

19.153899028072402002-03

11.833353628366532001-02

18.254089729797942000-01

7.923082629025071999-00

4.613400629402101998-99

% ash UtilizationAsh UtilizedAsh GeneratedYear

8

MAIN FACTORS FOR SUCCESS

• Dry fly ash collection, storage and delivery systems are installed along with main equipment.

• Better quality of fly ash from VTPS strengthened initial confidence among users.

a) Proper grinding of coal is ensured

b) Optimum combustion of coal in furnace is ensured by continuously monitoring the air flow, fire ball etc. This has resulted low un-burnt carbon in the fly ash

• Availability of Cement plants of installed capacity 18.64 million tons per annum nearer to the project.

• Arranged the staff in shifts round the clock.

Contd..

9


• Early understanding of advantages of fly ash.

• Best efforts in dissemination of technical and financial benefits of fly ash among users (Through Press, Seminars, Circulation of material, IS codes etc.).

• Practical demonstration of fly ash products (By installing fly ash brick plants, using fly ash for roads, studies on fly ash for agriculture through ANGRAU).

• MOUs with cement plants for up-gradation of dry ash handling systems.

Contd..

10


• Encouraging brick manufacturing units by providing certain priorities. In addition to this, Government housing schemes encouraged the brick manufacturing units to utilize more quantity of ash.

• There is considerable demand from several eco-friendly housing schemes.

• As the demand for fly ash is more than the availability, some cement companies are lifting pond ash also for manufacturing PPC.

• Cement companies are insisted to carry fly ash in closed tankers instead of open tankers to minimize the ash pollution.

11

ORIGINAL DRY FLY ASH SYSTEMS INSTALLED

ALONG WITH MAIN EQUIPMENT

100%Vacuum + Pressure6

100%Vacuum + Pressure5

30%Vacuum - Hydrovector4




Efficiency of the

System

Method of CollectionUnit No.

Due to availability of dry ash handling facilities ash utilization

started from beginning but quantity of utilization was less. It picked up gradually due to various other measures.

12

BETTER QUALITY OF FLY ASH The fly ash collected from field wise and got tested. The field wise

characteristics are as follows.

Around 26001st Field

Around 32002nd Field

Around 45003rd Field

Around 46004th Field



Specific surface area cm2/gmField

The Cement Companies & Asbestos Industries started using fly ash from

2nd & 3rd fields for manufacturing PPC and Asbestos sheets respectively.

The demand from brick units was less.

Cenospheres are also issued from the ash ponds of other stations

13

USE OF FLY ASH FOR PPC COMPLIANCE OF IS-SPECIFICATIONS

1.5 max-Alkalies as Na2O

12.0 max0.29Loss on Ignition (LOI)

Above figures in percentage by mass

2.75 max1.24Total sulphur as SO3

Dr. NTTPS

5.0 max1.65MgO

70.0 min90.1SiO2 + Al2O3 +Fe2O3

35.0 min72.3SiO2

IS 3812 requirement

Test resultsConstituent

CHEMICAL PARAMETERS OF FLY ASH

14

USE OF FLY ASH FOR PPC

COMPLIANCE OF IS-SPECIFICATIONS

Contd..

Dr. NTTPS

0.15 max0.008Drying shrinkage %

0.80 max0.015Autoclave expansion %

3200 min3700Fineness cm2/gm

4.0 min5.3Lime Reactivity N/mm2

IS 3812 & IS 1489

requirement

Test value Property

PHYSICAL PARAMETERS OF FLY ASH

15

CEMENT PLANTS NEARER TO Dr.NTTPS

1.10 M/s Rain Commodities Ltd

0.85M/s NCL Industries Ltd

1.00M/s Penna Cement Industries Ltd

1.02 M/s Andhra Cements Ltd

2.00 M/s Madras Cements Ltd

2.16M/s Sri Vishnu Cements Ltd

2.76M/s My Home Industries Ltd

4.80M/s The India Cements Ltd

Installed

Capacity

(MTPA)

Name of the Cement Plant

Contd..

16

CEMENT PLANTS NEARER TO Dr.NTTPS

18.64Total

0.89Others

0.54 M/s Parasakti Cement Ind. Ltd

0.72M/s Ckoramandal Cements Ltd

0.80 M/s Deccan Cements

Installed

Capacity

(MTPA)

Name of the Cement Plant

17

DISSEMINATION OF TECHNICAL INFORMATION

Information on Technical and financial benefits of fly ash was disseminated through following means

• Press notifications

• Seminars

• Circulation of IS codes and technical information to various Govt departments like R&B, PR, Irrigation, Public Health, NHAI and other organizations. Requests made to incorporatefly ash based material and rates in the SSRs.

• Exhibitions

• Electronic media

• Appeals made to Govt. & APPCB to give directions to use fly ash based materials.

• APGENCO succeeded in bringing GO from GOAP regarding use of PPC and fly ash based materials by all departments.

18

IS CODES ON FLYASH

• IS codes on flyash and flyash based materials such as

IS 1489 (Part 1), IS 3812-1981, IS 12330-1988 IS

1727-1967 etc are collected and communicated to all

Govt departments for implementation.

19

PRACTICAL DEMONSTRATION OF FLYASH

BASED PRODUCTS

• Guidelines to all stations under APGENCO to use fly ash for in-house consumption.

• High volume fly ash concrete roads are laid.

• Mix proportions are communicated to use fly ash for various concrete & brick works

• Fly ash brick plants are installed at all the Thermal plants to infuse confidence among private brick manufacturers.

• Studies on fly ash for agriculture were done through ANGRAU.

20

Field tests using fly ash was conducted in 10 districts in Andhra Pradesh during last 3 years to establish the increase of yield and other benefits using fly ash transport subsidy given by Agriculture Department, Andhra Pradesh.

USE OF ASH FOR AGRICULTURE

11.75 lakhs10002004-053

15 lakhs 10002003-042

75 lakhs 50002002-031

Amount subsidy (Rs.)

No. of PlotsYearSl.No

The field studies indicate increase of yield but final results are yet to be received.

21

Research studies through 4 research stations of Acharya N.G. RangaAgricultural University, Hyderabad are taken up for different crops.

RESEARCH STUDIES THROUGH ANGRAU

RTSRiceRARS, Jagtial4

RTPPMaizeARS, Utukur3

KTPSMangoARS, Ashwaraopet2

VTPSa) Sugarcane

b) Rice

ARS, Vuyyuru1

TPS coveredCropsResearch StationSl.No

22

Increase of yield in tons/Ha is reported as follows.

RESEARCH STUDIES THROUGH ANGRAU Contd..

7.358.113.652) FP + Fly ash at RD

7.36.462.731) Farmers practice (FP)

Rice at Vuyyuru

Rice at Jagtial

Maize at Utukur

Treatments

FP: Farmers Practice – NPK 130 : 50 : 0

RD: Recommended Dose of fly ash

Rice : 10 tons/Ha

Maize : 15 tons/Ha

23

Results

�Application of fly ash to Maize at Utukur increased yield by about 1 ton/Ha over farmers practice

�At Jagtial, increase of paddy yield is recorded as 1.65 tons/Ha over farmers practice

�At Vuyyuru there is no increase of yield over farmers practice

�ANGRAU recommended for long term studies for consistent results

RESEARCH STUDIES THROUGH ANGRAU Contd..

24

YEAR 2002 – A TURNING POINT

• Till 2002, major bottleneck in utilization of flyash was

non-utilization of 1st field ash which is significant in

coal based TPS. Utilization of 1st field ash for PPC

started at RTPP by M/s Zuari Cements Ltd,

Yerraguntla and then onwards it got popularized

widely.

• Ash utilization picked up after utilization of 1st field

ash at VTPS.

• Demand has steadily increased.

25

MOUs FOR UPGRADATION OF EXISTING

DRYASH HANDLING SYSTEMS

• The demand for fly ash was extremely high.

• APGENCO proposed to upgrade the existing systems through cement companies with the following terms:

a) 80% of flyash extracted from each unit was allocated to cementcompanies having MOU with APGENCO for that unit.

b) 100% investment by cement companies

c) MOU period is 10 years

d) After 10 years cement companies will not have any

right on Plant & Equipment installed by them.

By doing so APGENCO saved considerable time in upgradation.

26

Following equipment installed for each unit

• 48 Nos transfer vessels

• 2 Nos transport air blowers of capacity 28 m3/min with 160 KW motors

• 1 No vent filter of capacity 12000 m3/hr

• PLCC panel

• 2 Nos instrument air compressors of 2 Cum/Min @ 7 kg/cm2

EQUIPMENT INSTALLED FOR

UPGRADATION OF UNIT-1,3&4

Contd..

27

• Necessary valves, bends, laterals, couplings, breakers, pipes, bag filters, fluidising blowers and other accessories

• Civil structures, MCC and PLC control room etc


UPGRADATION OF UNIT-1,3&4

28

Following equipment installed for each unit

3 Nos (2 W+1 S) Mechanical exhausters with guaranteed capacity of 2800 m3/hr with motor rating 75 KW

• 2 Nos Intermediate transfer tanks

• 2 Nos transport air blowers of capacity 2900 m3/hr with 132 KW motors

• 1 No vent filter of capacity 12000 m3/hr

• PLCC panel with manual operation

• 2 Nos instrument air compressors of 3 Cum/Min @ 7 kg/cm2


UPGRADATION OF UNIT-2

Contd..

29

• Necessary valves, bends, laterals, couplings, breakers, pipes, bag filters and other accessories

• Civil structures, MCC and PLC control room etc


UPGRADATION OF UNIT-2

30

PERFORMANCE AFTER UPGRADATION

93%M/s India Cements Ltd4

93%a) Sri Vishnu Cements

b) Visaka Industries Ltd

c) Hyderaba Industries Ltd

d) Sagar Cements

3

84%a) Home Industries Ltd

b) Rain Commodities

c) NCL Industries

2

84%a) India Cements Ltd

b) Sri Vishnu Cements Ltd

c) Andhra Cements

1

Fly ash extraction Up-gradation completed byUnit No.

31

PRESENT ASH UTILISATION DURING

2008-09

6

5

4

3

2

1

Sl.

No.

Sep-2008

Aug-2008

July-2008

June-2008

May-2008

April-2008

Month

83.4158984190709

84.2166403197630

85.6176684206427

93.9189342201600

82.0155328189329

82.0163646199447

% Fly ash

Utilization

Fly ash

Utilization in

MT

Fly Ash

Generation in

MT

33

Fly Ash Utilization at other stations of

APGENCO

--13.05%% Utilised

--162044Ash Utilised

13240199349512410781999-2000Ash Produced

--1.07%% Utilised

--12385Ash Utilised

108165115971311627441998-1999Ash Produced

--0.5%% Utilised

--4952Ash Utilised

107253104340910060401997-1998Ash Produced

62.5 MW500 MW420 MWInstalled capacity

RTS ‘B’KTPS VRTPPYear

34


20.9%3.7%32.3%% Utilised

2349544721315310Ash Utilised

1122371220469976302

2002-2003 Ash Produced

2%1.6%18.8%% Utilised

252517023188896Ash Utilised

12752410852361005552


1.50%-10.73%% Utilised

2400-126193Ash Utilised

1396057969401176004

2000-2001Ash Produced

35


67.4%18.9%63.9%% Utilised

71943169207385588Ash Utilised

106770895778603205


47.9%22.4%%54.2%% Utilised

52400238483445131Ash Utilised

1094001064937821224


18.0%27.2%41.4%% Utilised

23249296164369355Ash Utilised

1291801087354892345


36


79.05%41.87%57.52%% Utilised

102234451142845354Ash Utilised

12931710773121469548


67.09%29.68%57.92%% Utilised

62391356154521459Ash Utilised

930001199861900307


37

Status of fly ash utilization at NTPC Limited

81.062.713.3435.269.471600Farakka

90.721.471.6235.734.54840Dadri

60.870.641.0639.072.70440Tanda

100.002.392.3940.135.951050Unchar

32.711.183.6132.0011.052000Singrauli

61.101.863.0428.9010.512000Rihand

98.401.041.0638.002.79460Talchar(TPS)

17.621.206.8237.1116.383000Talchar(KAN)

37.831.906.0230.2316.603260Vindhyachal

81.101.081.3332.584.09705Badarpur

61.443.034.9439.5712.472100Korba

37.090.631.8833.985.431340Kahalgoan

71.471.832.2738.945.841000Simhadri

61.642.884.6738.7613.052400Ramagundam

%

Utilization

Fly Ash

utilization

In mtpa

Fly ash

Generation

In mtpa

Ash

Content in

%

Coal

Consumption

In mtpa

Installed

Capacity in

MW

Name of

TPS

apgenco flyash ppt

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