NTPC EFFORTS TO

ENHANCE

ASH UTILIZATION

V. K. MATHUR V. K. MATHUR V. K. MATHUR V. K. MATHUR

AGM / NTPCAGM / NTPCAGM / NTPCAGM / NTPC

Power Generation Scenario in IndiaPower Generation Scenario in India

Present Installed Capacity (31-09-08)

• Total Installed Capacity : 1,45,555 MW

• Coal Based Capacity : 76,989 MW (53%)

• Hydro Power Capacity : 36,348 MW

• Gas & Diesel based Capacity : 15,904 MW

• Nuclear & Renewable Energy Sources : 16,315 MW

• Capacity addition target by 2012 : 60,000 MW

(coal based capacity)

• Ash Generation during 2007-08 : 130 Million Tonne

• Estimated Ash Generation By 2012 ~ 210 Million Tonne

• Ash Utilization during 2007-08 : 70 Million Tonne (54%)

• Ash Generation in NTPC (2007-08) : 43 Million Tonne

• Ash Utilization in NTPC (2007-08) : 23.7 Million Tonne (55%)

Ash Generation at NTPC Stations-as on March 2008

22395430.05Total

300068.21Talcher-Kaniha

46010.60Talcher -Thermal

134018.46Kahalgaon

160033.39Farakka

100022.74Simhadri

260046.65Ramagundam

326050.19Vindhyachal

210049.35Korba

44010.55Tanda

105023.86Unchahar

200030.37Rihand

200036.08Singrauli

70513.31Badarpur

84016.22Dadri

MW CapacityTotal Ash Production Lakh Tonne / YearStation

Year wise Ash Utilization

0.33 0.47 1.05 1.792 2.2 2.25 2.44 2.74 3.04

3.76

5.677.52

12.7

16.7

20.8

23.7

0

5

10

15

20

25

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

Year

Qty

in M

illion tonne

ASH UTILIZATION IN NTPC

NTPC EFFORTS• Dry Ash Evacuation System (DAES)

• Building Products

• Agriculture

• Roads

• Mine Filling

• Research Studies

• Awareness Measures

Dry Ash Evacuation system

(DAES)

Dry Ash Evacuation system (DAES)

• 100 % DAES in all new

Plants and expansion units

• 20% DAES in all existing

Plants. Further

augmentation depending

upon requirement

• Long Term Agreements

signed with Cement

industries for 29.5 Lakh M/T

fly ash at four stations.

• New agreements with

cement industries being

signed through NVVN

Dry Ash Evacuation system (DAES)

• 52500 M/T Fly Ash exported through NVVN.

• JV’s being entered through NVVN.

• 950 M/T Cenospheresexported through NVVN

Increase in Issue of Fly Ash to Industries

0.04 0.05 0.110.40 0.56 0.74 0.91 0.89

1.20 1.211.69

2.163

3.10

4.60

5.67

7.45

8.70

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

10.00

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

Year

Qty

. in

Mil

lio

n T

on

ne

Ash Utilization in NTPC

Fly Ash bricks

• All NTPC Stations

Have Fly ash bricks

making plants for

demonstration

purposes to

encourage private

enterprenuers to set

up their plants

• Bricks being made for

inhouse consumption.

Fly Ash bricks

• In 2007-08, NTPC produced 7 crores fly ash bricks.

• This is being increased to 12 crore bricks by setting up 3 more brick plants at Sipat, Vindhyachal and Dadri.

• At Ramagundam, High Volume Clay-ash bricks are being made.

• About 5.2 lakh cum pond ash was utilized for these bricks during 2007-08.

Vibro Press

Agriculture

• Show case projects on use of fly ash in Agriculture being taken up at Simhadri, Unchahar, Singrauli, Dadri & Talcher-Thermal Stations involving nearby farmers and Agriculture university.

• Results at Simhadri are very encouraging. Initially only 5 farmers came forward for the study, the number has now gone to 25 farmers within one year.

View of Paddy crop on ash

mix plot at Simhadri

Road Embankment

• Allahabad bypass road embankment construction utilized 67 Lac Cum Pond Ash from Unchahar.

• Noida-Greater NoidaExpressway utilized 22 Lac Cum Pond Ash from Badarpur

• Low lying areas in NTPC being filled with Pond ash

Allahabad Bypass /

Unchahar Ash pond

Mine Filling

• At Talcher-Thermal, ash is being filled in South Balanda Mine, utilizing about 10 lakhs cum ash / annum (100%)

• Efforts are on to take up Random filling of ash along with over burden of an operating mine as a pilot study.

• Ministry of Coal has agreed for such study and asked coal companies to identify mines for the same.

• A documentary film on use of fly ash in mine filling is under production.

South Balanda Mine

STUDIES / DEMONSTRATION PROJECTS

Studies / Demonstration Projects

• NTPC & RDSO have signed an MoU for the study of

suitability of coal ash in Railway Embankment –

07.09.07

A study for design of the embankment has been

awarded to CRRI.

To validate the design of Rail

Embankment,another study has been awarded to

IIT Bombay for conducting Centrifuge model tests.

Kahalgaon MGR -10 km has been selected for

pilot study.

MGR extension / Railway siding at Talcher-Kaniha

are also planned to be taken up as part of study

Studies / Demonstration Projects

• Fly ash based concrete road are being constructed at Dadri and Farakka –study by CRRI.

• Roller compacted concrete pavement is being constructed at Ramagundam-study by CRRI.

• High volume fly ash- clay bricks / tiles using flux bonded technology taken up in association with National Institute of Inter Disciplinary Science & Technology, Trivandrum at Ramagundam

• Cold Setting Structural Bricks / Blocks with high volume fly ash in association with RRL Bhubaneshwar

Studies / Demonstration Projects

• Use of fly ash in Bituminous Road Surfacing taken up through CRRI.

Demonstration stretch shall be constructed at NTPC Dadri.

• Use of fly ash in Railway Concrete Sleepers

is being taken up in association with IIT, Kanpur.

• Use of Bottom ash in concrete block making is being taken up in association with National Council for Cement & Building material, Ballabhgarh at NTPC Unchahar.

AWARENESS MEASURES

AWARENESS MEASURES

• Documentary Films

• Workshops

• Advertisements in News papers

• Exhibitions

• Distribution of Booklets, Pamphelets etc

AWARENESS MEASURES

DOCUMENTARY FILMS

1. Coal Ash –as Fill Material –2001

2. Use of Fly Ash in Concrete & RMC Plants-(2004-05)

3. Clay Fly Ash Bricks --(2005-06)

4. Fly Ash Bricks --(2006-07)

5. High Volume Ash Clay Bricks –(2007-08)

6. Use of fly ash in mine filling –(Under preparation)

AWARENESS MEASURES

Workshops organized by NTPC:

1. Delhi PWD

2. Delhi Development Authority

3. Ghaziabad development Authority

4. Noida Authority

5. Greater Noida Authority

6. Municipal Corporation of Delhi (MCD)

7. New Delhi Municipal Council (NDMC)

8. Hyderabad Urban Development Authority

9. NHAI

10. Research Designs & Standards Organization (RDSO), Lucknow

11. M/S CES Delhi / Kolkata

12. M/S ICT Consultant

13. RITES

14. World Bank

15. Asian Development Bank

AWARENESS MEASURES

Advertisements

• Advertisements are being published on all India basis on frequent intervals

• Advertisements are theme based

--Various applications of fly ash

--Specific usage of fly ash-Cement & Concrete, Building products, Roads and Embankments, Agriculture, Mine filling etc

2006-072 2006-07

2006-07

2006-07

2007-08

2007-08