summary report flyash

HIGH VOLUME FLY ASHCONCRETE TECHNOLOGY

FLY ASHSTATUS SUMMARY REPORT

In INDIA

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HIGH VOLUME FLY ASH CONCRETE TECHNOLOGYFLY ASH STATUS SUMMARY REPORT IN INDIA

TABLE OF CONTENTS

Objective…………………………………………………………………………………7Background……………………………………………………………………………...7Source Of Fly ash In India…………………………………..……………………...7

Present Scenario on Fly ash in India………………………………………………..11 Ash Collection………………………………………………………………..12

Source of Fly Ash……………………………………………..………………………13 Ash Content in Indian Control………………………………………………………..13

Fly Ash………………………………..…………………………………………………13Fly Ash Transportation……………………………………………………………..15

Dry………………………………………………………….…………………………………16 Conditioned…………….………………………………………………………………….16 Stockpiled…………………….…………………………………………………………….16 Lagoon……………………………….………………………………………………….. ..16

Current Fly Ash Generation In India……………………………………………17Current Ash Utilization…………………………………………………………….18

Present Scenario………………………………….……………………………………..19 Fly Ash Concrete Applications/ Projects………………………………………..19

NTPC Dadri……………………………………………..………………….19 Road Construction and Paving……………………………………….20 HCC Project……………………………………………………………….20 ACC Road Project……………………………………………………….20 Other Projects……………………………………………………………20

Fact Sheets for States…………………………………………………………...21Conclusion & Recommendation……………………………………………….21Annexure……………………………………………………………………………23

Ministry of Environment & Forest………………………………………………23 Notification of Fly Ash…………………………………….…………23

Amendments…………………………..……………………………………………..23List of Major Thermal Plants…………………………………………………28Fly Ash Suppliers India……………………………………………………….32

Tanveer Enterprises………………………………………………………………33 Ash Tech……………………………………………………………………………..34

Fly Ash Fact Sheets……………………………………………………………35 Tamil Nadu……………………………………………..…………………………..35 Maharashtra…………………………………………………………………………38 Andhra Pradesh…………………………..………………………………………44 Uttar Pradesh……………………………………………………………………….49 Gujarat………………………………………………………………………………..55

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DISCLAIMER

General Information: The Summary Report has been prepared with the intention of providing a centralized information on the Fly Ash Availability and Use in India under the "High-Volume Fly Ash Concrete Technology" project, supported by Canadian International Development Agency (CIDA). The lead partners are the International Centre for Sustainable Development of Cement and Concrete (ICON), CANMET, Natural Resources Canada, and the Confederation of Indian Industry (CII). All the contents of this report are only for general information or use.

Copyrights: The report is for information and general use only. All copy rights for its production and distribution rests with CII and the HVFAC project. The report and its contents are not for commercial sale.

Accuracy of Information: No representations, warranties or guarantees whatsoever are made as to the accuracy, adequacy, reliability, completeness, suitability or applicability of the information to a particular situation. The report has been compiled based on the information provided by different agencies and CII & HVFAC project does not guarantee completely on the authenticity of the information.

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ACKNOWLEDGEMENT

CII and HVFAC Project Partners – CANMET acknowledges the support provided by National Thermal Power Plants (NTPC), State Electricity Boards & Captive Thermal Power Plants of industry for providing valuable information and data for the purpose of this report.

The project also acknowledges the contribution made by the industry partners, Hindustan Construction Company Ltd., The Associated Cement Companies Ltd., Grasim Industries Ltd. (Cement Business) Gujarat Ambuja Cements Ltd., for providing valuable information related to the Flay Ash Status and management in India.

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SUMMARY REPORT ON INDIAN FLY ASH

OBJECTIVE: The purpose of this report is to collate information regarding Fly Ash generation and use in India. The report is also intended to provide a ready reference for the users of Fly Ash in construction on the availability and use of Fly Ash, especially good quality Fly Ash in India.

BACKGROUND: India at present produces around 120 Million Tonnes of Ash per annum. The power requirements of the country is rapidly increasing with increase in growth of the industrial sectors. India depends on Thermal power as its main source (around 80% of power produced is thermal power), as a result the quantity of Ash produced shall also increase. Indian coal on an average has 35 % Ash and this is one of the prime factors which shall lead to increased ash production and hence, Ash utilization problems for the country. Out of the total ash produced , Fly ash contributes to a small percentage, majority being Pond ash and bottom ash.

This report provides a compilation of such fly ash along with its present areas of use potential areas of other uses.

1.0 Source of Fly Ash in India

According to Central Electricity authority of India, there are around 83 major coal fired thermal power plants and 305 hydro plants existing in India. As per the ministry of power statistics, the total installed generating capacity (Thermal + wind) during 2003-2004 was about 79838 MW and hydropower generation was 29500 MW. In addition to this, there are more than 1800 selected industrial units which had captive thermal power plants of >1MW.

Table 1 provides basic statistics for fuel and power generation at the coal fired power plants in India.

Table 1: Power and coal usage statistics at the thermal power plants in India

Sr.No Power Station Installed Capacity (MW/day)

Generation(MW/day)

Coal per unit of electricity (kg/KWH)

Million KWH per day(MU)™

1R Badarpur 705 502 0.81 14.87 2R I.P. Station 277.5 136 0.86 2.96

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3R Rajghat 135 62 0.83 1.93 4R Faridabad 165 131 0.97 2.96 5R Panipat 650 362 0.82 9.74 6R Bhatinda 440 300 0.73 6.83 7R Lehra 420 425 0.73 9.96 8R Ropar 1260 840 0.70 22.67 9R Kota 850 856 0.75 20.40 10R Suratgarh# 500 516 0.73 11.85 11P Anpara 1630 1630 0.70 37.71 12R Harduagang 385 135 1.02 3.07 13R Dadri 840 653 0.65 18.9 14R Obra 1442 1014 0.88 21.30 15R Panki 274 165 0.9 3.56 16R Paricha 220 80 0.88 1.75 17P Rihand 1000 960 0.66 24.09 18P Singrauli 2000 1545 0.61 44.06 19R Tanda 330 195 0.96 4.9 20R Unchahar 840 826 0.74 19.66 21 Kutch% 215 166 0.73 3.65 22R Sabarmati# 330 326 0.73 6.6 23 Dhurvaran 534 348 0.73 8.23 24R Gandhi Nagar 870 722 0.60 17.09 25R Sikka 240 225 0.67 4.99 26R Ukai 850 775 0.72 16.74 27R Wanakbori 1470 1048 0.67 25.14 28R Bhusawal 478 445 0.79 10.80 29R Chandrapur 2340 1705 0.79 44.39 30R Dahanu 500 412 0.62 10.77 31R Khaper Kheda 840 630 0.76 14.84 32R Koradi 1080 662 0.84 17.03 33R Nasik 910 810 0.74 17.6 34R Paras 58 29 0.82 0.96 35 Trombay 1150 658 0.73 15.61 36R Parli 690 625 0.80 14.73 37P Amarkantak 290 201 0.72 4.7 38R Sanjay Gandhi 840 770 0.72 17.19 39P Korba Ii&Iii 400 315 0.97 7.29 40P Korba West 840 630 0.68 14.48 41P Korba Stps 2100 2153 0.68 50.14 42R Satpura 1143 845 0.88 19.22 43P Vindhyachal 2260 2204 0.65 51.13 44R Kothagudem 1170 1004 1.08 22.39 45R Rayalseema 420 432 0.78 10.08 46R Nellore 30 23 1.21 0.45 47R Ramagundam 63 58 0.73 1.45 48P Rgundam(Stps) 2100 2160 0.63 50.65 49R Vijayawada 1260 1281 0.73 30.41 50I Ennore 450 157 0.94 3.75 51I Mettur 840 860 0.75 20.33 52 Neyvelli@ 600 550 12.77

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53I North Madras 630 646 0.76 15.2 54I Tuticorin 1050 1070 0.74 25.13 55R Raichur 1260 850 0.76 21.2 56R Barauni 310 40 1.06 1.25 57R Muzaffarpur 220 65 1.09 1.5 58R Patratu 770 274 0.96 5.23 59R Tenughat 420 200 0.87 4.8 60P Kahalgaon 840 745 0.84 17.7 61R Bokaro A&B 805 260 0.80 5.70 62R Chandrapura 750 100 0.79 3.39 63R Mejia 630 475 0.70 9.9 64R Durgapur-Dvc 350 300 0.62 7.2 65R Bandel 530 150 0.59 4.87 66R Calcutta 190 141 0.89 3.07 67 New Cossipore 130 50.6 2.11 68R S.Gen Station 135 136 0.62 3.26 69R Durgapur -Dpl 390 93 0.74 4.39 70R Kolaghat 1260 1210 0.73 29.0 71 Bakreshwar* 630 383 0.77 9.2 72R Santaldih 480 150 0.60 3.6 73R Titagarh 240 240 0.64 5.76 74R Budgebudge* 500 500 0.77 12 75P Farakka 1600 1470 0.83 34.95 76P Talcher-Ntpc 460 390 1.01 9.4 77P Talcher-Stps 1000 490 0.75 11.60 78 Ib Valley Tps 420 406 0.91 9.70 79R Bongaigaon 240 0 0.66 0.8 80 Chandrapur(Assam) 60 7.82 0.66 0.33 81 Namrup 30 5.13 0.66 0.21 TOTAL

All India 53216 0.73

* Kg/KWH are the average for the Eastern region# Kg/KWH are the average for the western region@ Lignite is used as the fuel™ Based on monthly averageR Rail feed plantP Pit-head plantI Inter modalNote: Amarkantak and Amarkantak Extension are merged together. Similarly Korba II and III are merged together.

Some of the prominent Power Plants which are also producing and providing good quality Fly Ash includes the following:

RoparKotaAnnaparaDadri

RihandSingrauliUnchaharChandrapur

DahanuTrombayVindyanchalRaichur

RamagundamKorba

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PRESENT SCENARIO ON FLY ASH IN INDIA

• Over 75% of the total installed power generation is coal-based • 230 - 250 million MT coal is being used every year • High ash contents varying from 30 to 50% • More than 110 million MT of ash generated every year • Ash generation likely to reach 170 million MT by 2010 • Presently 65,000 acres of land occupied by ash ponds • Presently as per the Ministry Of Environment & Forest Figures, 30% of Ash

is being used in Fillings, embankments, construction, block & tiles, etc.

1.1 Ash Collection

Ash can be collected in following categoriesDry Fly AshDry ash is collected from different rows of electrostatic precipitators. It is available in two different grades of fineness in silos for use as resource material by different users. Bottom AshBottom ash is collected from the bottom of the boiler and transported to hydro bins and then ash mound for use in road embankment. Conditioned Fly AshConditioned fly ash is also available in ash mound for use in land fills and ash building products.

Source of Fly Ash:

2.0 Ash Content in Indian Coal

The quality of coal depends upon its rank and grade. The coal rank arranged in an ascending order of carbon contents is:

Lignite --> sub-bituminous coal --> bituminous coal --> anthracite

Indian coal is of mostly sub-bituminous rank, followed by bituminous and lignite (brown coal). The ash content in Indian coal ranges from 35% to 50%.

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The coal properties including calorific values differ depending upon the colliery. The calorific value of the Indian coal (~15 MJ/kg) is less than the normal range of 21 to 33 MJ/Kg (gross).

According to National Thermal Power Corporation (NTPC), coal is used for approximately 62.3% of electric power generation in India, oil and gas accounts for 10.2%, hydro's share is 24.1%, nuclear, wind, and other contribute remaining 3.4%.

Figure 1: Geographical location of major thermal power plants in India

3.0 Fly Ash

Fly ash is a fine, glass powder recovered from the gases of burning coal during the production of electricity. These micron-sized earth elements consist primarily of silica, alumina and iron. When mixed with lime and water the fly ash forms a cementitious compound with properties very similar to that of Portland cement. Because of this similarity, fly ash can be used to replace a portion of cement in the concrete, providing some distinct quality advantages. The concrete is denser resulting in a tighter, smoother surface with less bleeding.

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Fly ash concrete offers a distinct architectural benefit with improved textural consistency and sharper detail. Fly Ash is also known as Coal Ash, Pulverized Flue Ash, Pozzolona.

Typical Chemistry of Coal Fly Ash (in Wt.%)

ClassF* ClassF* ClassC* Class C*low-Fe high-Fe high-Ca low-Ca

SiO2 46-57 42-54 25-42 46-59Al2O3 18-29 16.5-24 15-21 14-22Fe2O3 6-16 16-24 5-10 5-13CaO 1.8-5.5 1.3-3.8 17-32 8-16MgO 0.7-2.1 0.3-1.2 4-12.5 3.2-4.9K2O 1.9-2.8 2.1-2.7 0.3-1.6 0.6-1.1Na2O 0.2-1.1 0.2-0.9 0.8-6.0 1.3-4.2SO3 0.4-2.9 0.5-1.8 0.4-5.0 0.4-2.5LOI 0.6-4.8 1.2-5.0 0.1-1.0 0.1-2.3TiO2 1-2 1-1.5 <1 <1

As per ASTM StandardsIndian Standard (IS) On Fly Ash is as annexure

4.0 Fly Ash Transportation

Fly ash can be supplied in four forms:

Dry: This is currently the most commonly used method of supplying fly ash. Dry fly ash is handled in a similar manner to Portland cement. Storage is in sealed silos with the associated filtration and desiccation equipment, or in bags.

Conditioned: In this method, water is added to the fly ash to facilitate compaction and handling. The amount of water added being determined by the end use of the

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fly ash. Conditioned fly ash is widely used in aerated concrete blocks, grout and specialist fill applications.

Stockpiled: Conditioned fly ash not sold immediately is stockpiled and used at a later date. The moisture content of stockpiled ash is typically 10 to 15%. This is used mainly in large fill and bulk grouting applications.

Lagoon: Some power stations pump fly ash as a slurry to large lagoons. These are drained and when the moisture content of deposited fly ash has reached a safe level may be recovered. Because of the nature of the disposal technique, the moisture content can vary from around 5% to over 30%. Lagoon fly ash can be used in similar applications to stockpiled conditioned fly ash.

5.0 Current Fly Ash Generation in India

The current electricity generation (as on March 31, 2004) in India is about 1,12,058 MW, 65-70% of which is thermal (mostly coal based).

According to an estimate 100,000 MW capacity or more would be required in the next 10 years due to continually increasing demand for electricity.

In India fly ash generation is around 110 million tonnes / year and is set to continue at a high rate into the foreseeable future.

Presently majority of the coal ash generated is being handled in wet form and disposed off in ash ponds which is harmful for the environment and moreover ash remains unutilized for gainful applications.

India has sufficient coal reserves. In India almost 65-70% of electricity production is dependent on coal which produces a huge quantity of Fly Ash as residue which is allegedly a waste product in Thermal Power Stations.

Fly Ash has a vast potential for use in High Volume fly ash concrete especially due its physic-chemical properties. A good amount of research has already been done in India and abroad on its strength and other requisite parameters.

Current fly ash generation and utilization in six major states; Gujarat, Maharashtra, Tamil Nadu, Rajasthan, Andhra Pradesh and Uttar Pradesh is presented in the

present report

6.0 Current Ash Utilization

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According to the MOEF Gazette Notification dated Sept. 14, 1999, the existing power stations have to achieve 20% ash utilization within three years and 100% utilization in 15 years from the date of notification. New Stations have to achieve 30% ash utilization within 9 years and 10% ash utilization within 3 years and 100% utilization within 4 years and 100% annual increase.

Presently, out of 110 million tonnes of Total ash generated, about (30%) is being utilized. Therefore thermal power stations are under great pressure to find useful applications of fly ash. The technology utilizing fly ash in high volume fly ash concrete can provide an avenue for utilization of fly ash on a bulk scale.

PRESENT SCENARIO:

Fly Ash Concrete Applications / Projects

NTPC Dadri The NCPS Dadri project has the unique distinction of having Asia's first 100% dry ash extraction with transit ash storage silos and final storage place converted to a green ash mound.

Dadri ash has been used successfully in the following applications: • Land fills • Road embankments • Road construction • Portland Pozzolona cement • Building products Concrete

Road Construction and Paving

Ash has been used in concrete roads and roller compacted concrete roads which are not only durable,

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but have long service of 30-35 years without much maintenance in comparison to WBM and Bituminous Macadam roads.

HCC ProjectsDevelopment of high strength and high performance triple blended concrete for the Bandra-Worli Sea Link project.* High performance concrete for RAPP (5&6) incorporating fly ash.& Development of high volume fly ash concrete mixes for pavement quality concrete for various road works

ACC Road Project

ACC has constructed demonstration roads using high volume fly ash concrete with upto 50 % replacement at its Greater Noida and Faridabad Ready Mix Plants.It has also constructed a small demonstration patch at Tikaria-Amethi, in its Cement Plant.

Other Projects

1. Construction of road (experimental basis about 1.00 Km length) using fly ash, at Raichur,Karnataka.This Project was implemented by PWD(Public Works Department),Raichur and CRRI.(Central Road Research Institute)

2. Use of Roller Compacted concrete technology using high doses of fly ash for construction of Saddle Dam and upper Dam of Ghatghar pumped storage Scheme near Nashik, have been implemented in joint co operation of Maharashtra Irrigation Department,Central Soil and Mineral Research Station,University of Roorkee.

FACT SHEET FOR STATES:

India has a number of thermal power plants located all over the country. A state wise fact sheet for Fly Ash has been prepared. In the first step only six states have been selected. The selection of these states have been done keeping in view the amount of fly ash produced in these states and the amount of infrastructure development taking place in these states or planned for future.The states thus selected are Tamil Nadu, Karnataka, Uttar Pradesh, Maharashtra, Andhra Pradesh & Gujarat.

CONCLUSION & RECOMMENDATIONS:

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The Fly Ash Summary Report provides a clear indication on a number of areas related to Fly Ash generation and use in the India.India produces a lot of Ash in its Thermal Power production process , but the quality of Ash produced is a major hindrance in its widespread utilization. The Fly Ash constitutes only a small fraction of the Total Ash produced, primarily because of the Technological Limitation of the Power Plants which are mostly old and still produce coarse and wet ash which is difficult to use for construction purposes.Also Wet Ash is difficult to handle ands transport, resulting in formation of huge Ash Ponds.Based on the information gathered, collated & analyzed, some of the Recommendations for enhancing use of Fly Ash in construction is as follows :

• Dry Collection Systems at thermal Power Plants needs to be enhanced.• Facilities needs to be provided on-site at thermal power plants for conversion of

coarser fly ash into finer one.• Most of the finer fly ash is being sourced by cement plants for their PPC

production, hence the Fly Ash available for construction is limited. The same may be better organized so as to enable the construction companies to access it more easily.

• Good transportation facilities need to be created and organized for enabling easy availability at point of use for the construction companies.

• Greater awareness to construction companies need to be provided for use of fly ash in construction.

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ANNEXURE

MINISTRY OF ENVIRONMENT AND FORESTS

Notification on Fly AshNew Delhi, the 27th August 2003.

S.O. 979 (E):- Whereas a draft of certain amendments to the Government of India in the Ministry of Environment and Forests notification number S.O.763 (E) dated 14th September, 1999 (hereinafter referred to as the said notification) which the Central Government proposes to make under sub-section (1) and clause (v) of sub-section (2) of section 3 of the Environment (Protection) Act, 1986 (29 of 1986) read with clause (d) of sub-rule (3) of rule 5 of the Environment (Protection) Rules, 1986, were published in the Gazette of India, Extraordinary, Part II, Section 3, Sub-section (ii) dated the 6th November, 2002 vide S.O. 1164 (E), dated the 5th November, 2002 inviting objections and suggestions from all persons

likely to be affected thereby before the expiry of sixty days from the date on which copies of the Gazette containing the said draft amendments were made available to the public.

And, whereas copies of the said Gazette were made available to the public on 27th November 2002; And, whereas all the objections and suggestions received from all persons likely to be affected thereby in respect of the said draft notification have been duly considered by the Central Government;

Now, therefore, in exercise of the powers conferred by sub-section (1) and

clause (v) of sub-section (2) of section 3 of the Environment (Protection) Act, 1986 (29 of 1986) read with clause (d) of sub-rule (3) of rule 5 of the Environment (Protection) Rules, 1986, the Central Government hereby makes the following amendments to the said notification, namely: -

AMENDMENTS1. In the said notification, in the preamble, for the words "fifty kilometers”, the words "one hundred kilometres” shall be substituted.

2. In the said notification, in paragraph 1, - (a) in sub-paragraph (1), for the words "fifty kilometers”, the words "one hundred

kilometres” shall be substituted; (b) after sub-paragraph (1), the following sub- paragraphs shall be inserted, namely: -

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"(1A) Every construction agency engaged in the construction of buildings within a radius of fifty to one hundred kilometres from a coal or lignite based thermal power plant shall use fly ash bricks or blocks or tiles or clay fly ash bricks or cement fly ash bricks or blocks or similar products or a combination or aggregate of them in such construction as per the following minimum percentage (by volume) of the total bricks, blocks and tiles, as the case may be, used in each construction project, namely:-

(i) 25 per cent by 31st August 2004; (ii) 50 per cent by 31st August 2005; (iii) 75 per cent by 31st August, 2006; and (iv) 100 per cent by 31st August 2007.

In respect of construction of buildings within a radius of 50 kilometres from a coal or lignite based thermal power plant the following minimum per centage (by volume) of use of bricks, blocks and tiles shall apply: -(i) 50 per cent by 31st August 2004;(ii) 100 per cent by 31st August 2005.

(1B) The provisions of sub-paragraph (1A) shall be applicable to all construction agencies such as Housing Boards and those in the private sector builders of apartments, hotels, resorts and cottages and the like. It shall be the responsibility of the construction agencies either undertaking the construction or approving the design or both to ensure compliance of the provisions of sub-paragraph (1A) and to submit such returns as may be called for and compliance reports to the State Government or Union territory Administration”;

(c) for sub-paragraph (2), the following sub-paragraphs shall be substituted, namely: -

“ (2) The authority for ensuring the use of specified quantity of ash as per sub-paragraph (1) shall be the concerned Regional Officer of the State Pollution Control Board or the Pollution Control Committee, as the case may be. (2A) The concerned State Government shall be the enforcing and monitoring authority for ensuring compliance of the provisions of sub- paragraph (lA).”;

(d) in sub-paragraph (3), for the words, brackets and figure “under para (1)” the words, brackets and figure “under sub-paragraph (1)” shall be substituted; (e) after sub-paragraph (3), the following sub-paragraphs shall be inserted, namely: -

“(3A) A decision on the application for manufacture of fly ash bricks, block, and tiles and similar other fly ash based products shall be taken within thirty days from the

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date of receipt of the application by the competent authority. A decision on consent to establish the brick kiln shall be taken by the Pollution Control Board or the Pollution Control Committee, as the case may be, within a period of thirty days from the date of receipt of application by it.

(3B) In case of non-compliance of the provisions of sub-paragraph (1) of paragraph 1, the competent authority, in addition to cancellation of consent order issued to establish the brick kiln, shall move the district administration for cancellation of the mining lease.

(3C) All authorities sanctioning or renewing any land, soil or clay mining lease shall not grant such lease or extension of lease or renewal to clay brick, block or tile manufacturing unit within a radius of one hundred kilometres of the coal or lignite based thermal power plant in cases where the manufacturer does not mix a minimum of 25 per cent by weight of fly ash or pond ash in the manufacture of bricks or blocks or tiles. The cancellation of mining lease shall be decided by the district administration after giving the holder of such lease an opportunity of being heard. To enable the competent authority to verify the actual use of ash, the thermal power plant shall maintain month-wise records of ash made available to each brick kiln.

(3 D) It shall be sufficient compliance of this notification if within twelve months from the date of issue of this notification, manufacturers of clay bricks, blocks and tiles located within a radius of 50 to 100 kilometres of a coal or lignite based thermal power plant comply with the provisions of sub-paragraphs (1) and (2).”.

(f) in sub-paragraph (4), after brackets and letters “(AIBTMF)”, the words “or a representative of local brick kiln owners association, federation, group.” shall be inserted;

(g) after sub-paragraph (4), the following sub-paragraphs shall be inserted, namely: -

"(5) No agency, person or organization shall, within a radius of 100 kilometres of a thermal power plant undertake construction or approve design for construction of roads or flyover embankments in contravention of the guidelines/ specifications issued by the Indian Road Congress (IRC) as contained in IRC specification No. SP: 58 of 2001. Any deviation from this direction can only be agreed to on technical reasons if the same is approved by Chief Engineer (Design) or Engineer-in-Chief of the concerned agency or organization or on production of a certificate of "Pond ash not available” from the thermal power plant(s) (TPPs) located within 100 kilometres of the site of construction. This certificate shall be provided by the TPP within two working days from the date of making a request for ash.

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(6) Soil required for top or side covers of embankments of roads or flyovers shall be excavated from the embankment site and if it is not possible to do so, only the minimum quantity of soil required for the purpose shall be excavated from soil borrow area. In either case, the topsoil should be kept or stored separately. Voids created due to soil borrow area shall be filled up with ash with proper compaction and covered with topsoil kept separately as above. This would be done as an integral part of embankment project within the time schedule of the project.

(7) No agency, person or organization shall within a radius of 100 kilometres of a coal or lignite based thermal power plant allow reclamation and compaction of low-lying areas with soil. Only pond ash shall be used for compaction. They shall also ensure that such reclamation and compaction is done in accordance with the bye-laws, regulations and specifications laid down by the authorities mentioned in sub- paragraph (3) of paragraph 3.”.

3. In the said notification, in paragraph 2, (a) for the marginal heading “Utilisation of ash by Thermal Power Plants”, the

marginal heading “Responsibilities of Thermal Power Plants” shall be substituted;

(b) for the opening words, “All coal or lignite based thermal power plants shall utilise the ash generated in the power plants as follows: -”, “Every coal or lignite based thermal power plant shall take the following steps to ensure the utilisation of ash generated by it, namely: -”;(c) in sub- paragraph (1), -(i) after the words “products such as cement, concrete blocks, bricks, panels”, the words “or a combination thereof” shall be inserted;(ii) the following shall be added at the end, namely: -“ The thermal power plants have to ensure availability of fair quantity of ash to each user including brick kilns.”;

4. In the said notification, after paragraph 2, the following paragraph shall be inserted, namely: - “2A. Utilization of fly ash for reclamation of sea. “Subject to the rules made under the Environment (Protection) Act, 1986, (29 of 1986) reclamation of sea shall be a permissible method of utilization of fly ash.”.

5. In the said notification, in paragraph 3, the following sub-paragraphs shall be inserted, namely: -“(2A) All agencies including the Central Public Works Department and State Government agencies concerned with utilization of fly ash for construction purposes shall, within three months from the 1st day of September, 2003 make provisions for

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the use of fly ash and fly ash based bricks, blocks or tiles or aggregates of them in the schedule of approved materials and rates. (2B) All agencies undertaking construction of roads or fly over bridges including Ministry of Road Transport and Highways (MORTH), National Highways Authority of India (NHAI), Central Public Works Department (CPWD), State Public Works Departments and other State Government Agencies, shall, within three months from the 1st day of September, 2003 –

a. make provisions in their tender documents, schedules of approved materials and rates as well as technical documents, including those relating to soil borrow area or pit as per sub-paragraph (7) of paragraph 1; and

b. make necessary specifications/guidelines for road or fly over embankments that are not covered by the specifications laid down by the Indian Road Congress (IRC).” .

[F.No.16-2/95-HSMD] (Dr. V. Rajagopalan) Joint Secretary to the Govt. of India Footnote. - The principal notification was published in the Gazette of India, Part II, Section 3, sub-section (ii) vide S.O.763 (E) dated 14.9.1999.

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List of Major Thermal Power Plants

Plant Owner LocationCity State

Fuel Total Capacity

(MW)TAMIL NADU

Mettur Tamil Nadu SEB Mettur Tamil Nadu Coal 840North Chennai Tamil Nadu SEB Chennai Tamil Nadu Coal 630Ennore Tamil Nadu SEB Ennore Tamil Nadu Coal 450Neyveli Zero CMS India Ltd. Neyveli Tamil Nadu Coal 250

MAHARASHTRAChandrapur Maharashtra SEB Durgapur Maharashtra Coal 2,340Trombay (coal-fired section)

Tata Power Co. Ltd. Mumbai Maharashtra Coal;Natural Gas,

1150

Koradi Maharashtra SEB Koradi Maharashtra Coal 1,100Nasik Maharashtra SEB Nasik Maharashtra CoalKhaperkheda Maharashtra SEB Khaperkheda Maharashtra Coal 840Parli Maharashtra SEB Parli Vaijnath Maharashtra Coal 690Dahanu BSES Ltd. Thane Dist. Maharashtra Coal 500Bhusawal Maharashtra SEB Jalgaon Maharashtra Coal 483

ANDHRA PRADESHRamagundam NTPC Karimnagar

Dist.Andhra Pradesh

Coal 2,100

Vijayawada Andhra Pradesh, Power Generation Corp.

Krishna Andhra Pradesh

Coal 1260

Kothagudem Andhra Pradesh, Power Generation Corp.

Paloncha Andhra Pradesh

Coal 1180

Simhadri NTPC Paravade Andhra Pradesh

Coal 1,000

Rayalaseema Andhra Pradesh, Power Generation Corp.

Cuddapah Dist.

Andhra Pradesh

Coal 420

Vizag Steel Works *

Rashtriya Ispat Nigam Ltd.

Visakhapatnam

Andhra Pradesh

Coal 236

ORISSATalcher NTPC Angul Orissa Coal 1,970Angul Smelter National Aluminum

Corp. Ltd.Angul Orissa Coal 720

Ib Valley OPGC; AES Barhanpalli Orissa Coal 420Rourkela Works *

Steel Authority of India Ltd.

Rourkela Orissa Coal 269

Choudwar Indian ChargeChrome Ltd. (ICCL)

Choudwar Orissa Coal 108

20


KARNATAKARaichur KPCL Raichur

Dist.Karnataka Coal 1,470

Torangallu Works *

Jindal Tractebel, Power Co. Ltd.

Torangallu Karnataka Blast Furnace Gas;Coal

260

MADHYA PRADESHVindhyachal NTPC Sidhi Madhya

PradeshCoal 2,260

Satpura Madhya Pradesh SEB Betual Dist. Madhya Pradesh

Coal 1,143

Sanjay Gandhi Madhya Pradesh SEB Umaria Dist.

Madhya Pradesh

Coal 840

Amarkantak Madhya Pradesh SEB Shahdal Madhya Pradesh

Coal 300

NTPC BALCO NTPC Korba Madhya Pradesh

Coal 270

Raigarh Works * Jindal Steel & Power Ltd.

Raigarh Madhya Pradesh

Coal 112

Nagda Works * Melodeon Exports Nagda Madhya Pradesh

Coal 106

CHHATTISGARHKorba STPS NTPC Bilaspur Chattisgarh Coal 2,100Korba West Chattisgarh SEB Bilaspur Chattisgarh Coal 840Korba East Chattisgarh SEB Bilaspur Chattisgarh Coal 400

WEST BENGALFarakka NTPC Murshidabad West Bengal Coal 1,630Kolaghat West Bengal Power

Development Corp.Medinipurt Dist.

West Bengal Coal 1260

Bakreshwar West Bengal Power Development Corp.

Birbhum Dist. West Bengal Coal 630

Mejia DVC Durlavpur West Bengal Coal 630Bandel West Bengal SEB Hooghly West Bengal Coal 530Budge Budge CESC Ltd. Calcutta West Bengal Coal 500Santaldih West Bengal SEB Santaldih West Bengal Coal 480Durgapur West Bengal SEB Burdwan West Bengal Coal 405Durgapur DVC DVC Waria West Bengal Coal 350Titagarh CESC Ltd. Titagarh West Bengal Coal 240Cossipore CESC Ltd. Calcutta West Bengal Coal 225Mulajore CESC Ltd. Shyamnagar West Bengal Coal 150Durgapur Works *

Steel Authority of India Ltd.

Durgapur West Bengal Coal 140

Southern CESC Ltd. Calcutta West Bengal Coal 135UTTAR PRADESH

Singrauli NTPC Sonebhadra Uttar Pradesh Coal 2,050

21


Dist.Anpara UPRVUNL Mirzapur

Dist.Uttar Pradesh Coal 1,630

Obra UPRVUNL Obra Dist. Uttar Pradesh Coal 1,550Rihand NTPC Sonebhadra

Dist.Uttar Pradesh Coal 1,000

Dadri (coal-fired section)

NTPC Dadri Uttar Pradesh Coal 840

Unchahar NTPC Rai Bareilli Uttar Pradesh Coal 840Renusagar * Hindalco Industries

Ltd.Renukoot Uttar Pradesh Coal 619

Harduaganj UPRVUNL Harduaganj Uttar Pradesh Coal 440Tanda NTPC Faizabad Uttar Pradesh Coal 440Panki UPRVUNL Panki Uttar Pradesh Coal 279Paricha UPRVUNL Jhansi Uttar Pradesh Coal 220

GUJARATWanakbori Gujarat SEB Sevalia Gujarat Coal 1,470Gandhi Nagar Gujarat SEB Gandhi

NagarGujarat Coal 870

Ukai Gujarat SEB Ukai Dam Gujarat Coal 850Dhuvaran Gujarat SEB Anand Gujarat Coal 534Sabarmati Ahmedabad Electric

Co. Ltd.Sabarmati Gujarat Coal 450

Surat Gujarat Industrial Power Corp. Ltd. (GIPCL)

Surat Gujarat Coal 250

Sikka Gujarat SEB Sikka Gujarat Coal 240Kutch Gujarat SEB Kutch Gujarat Coal 210

BIHARKahalgaon NTPC Kahalgaon Bihar Coal 840Barauni Bihar SEB Hazaribagh

Dist.Bihar Coal 310

Jamshedpur Works *

Tata Iron & Steel Co. Jamshedpur Bihar Coal 238

Muzaffarpur Bihar SEB Kanti Bihar Coal 220JHARKHAND

Bokaro DVC Bokaro Jharkhand Coal 805Patratu Jharkhand SEB Patratu Jharkhand Coal 770Chandrapura DVC Chandrapura Jharkhand Coal 750Tenughat Jharkhand SEB Bokaro Dist. Jharkhand Coal 420Bokaro Works * Steel Authority of

India Ltd.Bokaro Jharkhand Coal 287

PUNJABRopar Punjab SEB Ropar Punjab Coal 1,260Guru Hargobind Punjab SEB Bhatinda Punjab Coal 860

22


HARYANATau Devi Lal Haryana Power

Generation Corp. Ltd.Panipat Haryana Coal 860

Faridabad Faradibad Power Systems Ltd.

Faridabad Haryana Coal 165

RAJASTHANSuratgarh Rajasthan RV

Utpadan NigamSuratgarh Rajasthan Coal 1,000

Kota Rajasthan RV Utpadan Nigam

Kota Rajasthan Coal 850

DELHIBadarpur NTPC New Delhi Delhi Territory Coal 720Indraprastha Indraprastha Power

Generating Co. Ltd.New Delhi Delhi Territory Coal 248

Rajghat Delhi Transco Ltd. New Delhi Delhi Territory Coal 135ASSAM

Bongaigaon Assam SEB Salakati Dist.

Assam Coal 240

Fly Ash Suppliers-India

Tanveer Enterprises

Tanveer Enterprises, with its corporate headquarters in Delhi, India, has recycled 12,50,000 tons approx. of fly ash in India during the last 10 years. With Four distribution terminals (NTPC- DADRI, NTPC-BARDARPUR, NTPC-RIHAND & PANIPAT THERMAL POWER STATION-HARYANA, MSEB Khaparkheda Maharashtra) Tanveer Enterprises (TE) is one of the major fly ash suppliers to Industries like Ready Mix Concrete, Cement Plants, Asbestos Sheet, Bricks, Blocks, Interlock Blocks & Pavers, and Building Contractors etc.

Dry Graded Fly Ash from ESP, Silos can be supplied. TE has their own fleet of trucks, & highly trained staff for quality maintenance & round the clock operations. TE has installed its own state of art equipment for collection of Fly Ash from ESP's (Electro Static Precipitators) at the power plants.

Address

23


L-10,First Floor,Kailash Colony NEW DELHI – 110048,India Tel. No.: 91-11- 55656805, 51622968Tele. Fax: 91-11-51622968E-mail: [email protected] Site: www.iflyash.com

AshTech AshTech, with its corporate headquarters in Delhi, India, has recycled 12,50,000 tons approx. of fly ash in India during the last 10 years.AshTech is one of the major fly ash suppliers to Industries like Ready Mix Concrete, Cement Plants, Larsen & Toubro / KSHI for Prestigious Delhi Metro Rail Corporation, Asbestos Sheet, Bricks, Blocks, Interlock Blocks & Pavers, and Building Contractors etc.

Fly ash from ESP, Silos, Ash Mounds, and Wet Ponds Ash can be supplied. AshTech has their own fleet

24

http://www.iflyash.com/

http://www.iflyash.com/

mailto:[email protected]


of trucks, & trained staff for quality maintenance & round the clock operations. AshTech has installed its own state of art equipment for collection of Fly ash from ESP's (Electro Static Precipitators) at the power plants. AshTech can supply fly ash of different quality and properties as per your specification at very competitive rates, in bulk carriers, or packed in HDPE bags (40 kgs).

AshTech has its own fleet of pneumatic tank trailers for hauling bulk materials & trucks to deliver material to the Ready Mix Concrete, Construction, Asbestos, brick/block & paving industries.

L-10, First FloorKailash ColonyNew Delhi-110048, INDIA Tel No.: 91-11- 55656805, 51622968TeleFax: 91-11-51622968Web: http://www.ashtechindia.comE-mail : [email protected]

FLY ASH FACT SHEET State: Tamil Nadu

Tamil Nadu is the fourth largest State of the country. It has a population of 62.11 million, about 6.05 per cent of the total Indian population, and 30 administrative districts. Agriculture is the mainstay of the economy, with most of the population dependent upon it for their livelihood. Nevertheless, Tamil Nadu is among the most industrialised States and ranks next to Maharashtra in terms of the contribution made by the manufacturing sector to net state domestic product. Per capita income was below the national average during the 1980s but crossed the national average since the 1990s.

There are four major coal based thermal power plants in the state with a capacity of

around 2200 MW.

1. State Tamil Nadu

25

mailto:[email protected]

http://www.ashtechindia.com/


2. Total number of thermal power plants

3. Major thermal power plants

I. MetturTamil Nadu SEBMettur

840 MW

II. North ChennaiTamil Nadu SEBChennai

630 MW

III. EnnoreTamil Nadu SEBEnnore

450 MW

IV. Neyveli CMS India Ltd.Neyveli

250 MW

26

Name of plant Quantity of fly ash generationTotal Dry Wet

Ash collection system

Current fly ash useQuantity used

ApplicationCurrent user Transportation data Other fly ash

utilization activities

Mode of transport & distance km

Transportation cost

Projects Cement production (PPC)

Neyveli Lignite Corporation LimitedCMS india ltd. 13

5729

8

1139

975

2173

23 Silos are used.

1.2% of fly ash being used

0.2% of Fly Ash used in Bricks and blocks.1.1% of Fly Ash used in Cement industries.0.08% of Fly Ash used in Earth filling.0.1% of Fly Ash used in NLC Precasting yard.

Madras Cement Ltd

Ash dipper / bulker

45

Dalmia cements Barath Limited

Ash dipper / bulker

125

Gracim Industries Limited

Ash dipper / bulker

95

The India Cements sankari works

Ash dipper / bulker

200

The indian cements Daiavoi Works

Ash dipper / bulker

48

Vijay Cements Pvt Ltd

Ash dipper / bulker

90

ChennaiTamil Nadu State Electricity BoardNorth Chennai

1319

860

9239

02

3959

58 Pressurized dense Fly ash conveying system with PLC & silos.

26.58% of fly ash being used

2.42% of Fly Ash(Dry) used in Bricks and blocks.22.48% of Fly Ash used in Cement industries.1.68% of Fly Ash used in Concrete Mortar.

L &T Tanker 125

Madras Cement Ltd

Tanker 275

Inbdia Cement Tanker 275

Small Scale Industry

Tanker 25

FLY ASH FACT SHEETState: Maharashtra

Maharashtra is the second most populous State in the country, where per capita income is 40 per cent higher than the all India average. Maharashtra is located on the west coast along the Arabian Sea and is among the richer States of the country. It has an uneven natural resource endowment. Maharashtra’s 35 districts are divided into 6 revenue divisions. Being more urbanised than most States in the country, almost 43 per cent of its population, much of it migrant, lives in towns and cities.

There are around eight major coal based thermal power plants in the state with a capacity of around 7500 MW. Most of these power plants are owned by the state government.

1. State Maharashtra

2. Total number of major thermal power plants


I. ChandrapurMaharashtra SEBDurgapur

2,340 MW

II. Trombay (coal-fired section)Tata Power Co. Ltd.Mumbai

1150 MW

III. KoradiMaharashtra SEBKoradi

1,100 MW

IV. NasikMaharashtra SEBNasik

V. KhaperkhedaMaharashtra SEBKhaperkheda

840 MW

VI. ParliMaharashtra SEBParli Vaijnath

690 MW

VII. DahanuBSES Ltd.Thane Dist.

500 MW

VIII. BhusawalMaharashtra SEBJalgaon

483 MW

Name of plant

Quantity of fly ash generation

Total Tons

Dry Tons

Wet Tons


Current fly ash use

Quantity used

Application

Current user Transportation data

Other fly ash utilization activities

Mode of transport & distance (km)

Transportation cost


JalagaonMaharashtra SEBBhusawal

7733

71

6186

97

1546

74 Both wet and dry.Ash is converted to slurry form by mixing water through hydro-ejector & then pumped to Ash bund from where ash is collected. Provision is made to the outlet of ESP hoppers to collect dry fly ash by user manually.

47 %of the fly ash used.

30 %of the fly ash used in FA bricks and blocks.4%of the fly ash used in cement industry. 13 %of the fly ash used in agriculture.

Orient Cement

Brick Manufacturing

Agriculture

Truck

Truck and Tractor

Truck and Tractor

25

100

50

Bircks, blocks

Cement industry

Parli VaijnathMaharashtra SEBParli

1146

260

9170

00

2336

00 Dry fly ash from all units is being collected in jumbo bags except first row.


1.9 %of both the fly ash used in FA bricks and blocks.6.61%of both the fly ash used in cement industry. 0.50 %of the wet fly ash used in agriculture.19.92 %of the wet fly ash used in land development.

M/s Birla Super Cement Sholapur

Truck 220

M/s Visaka Cement Ind. Ltd. Pune

Truck 325

M/s New Sahyadri Ind. Ltd. Pune

Truck 300

M/s Swastik Ind. Chinchwad Pune

Truck 370

M/s Shakti Roofing Pvt Ltd. Pune

Truck 350

M/s Everest Industries Ltd. Nashik

Truck 380

M/s Jai Bilidicon Products Ltd. Pune

Truck 370

M/s Proctor & Walker Pune

Truck 370

M/s Ash Crete Pune

Truck 370

M/s Ambica Bricks Parli -V

Truck 15

Thane District BSESDahanu

5659

17

5735

0

1085

67 Manually operated wet system

20% of the fly ash used

0.14% of the fly ash (dry) used in FA bricks and blocks.0.58% of the fly ash (wet) used in Brick Kiln. 0.008% of the fly ash (dry) used in agriculture.0.06% of the fly ash (dry) used in land development.

Hemant Bafna 14

Manchar Irani 8

M/s Satish Carriers

Plastichem Distributors

Ashtech India Pvt. Ltd.

Durgapur Maharashtra SEBChandrapur

4990

022

3742

517

1247

505 Nil ? 0.79% of the fly

ash (dry) used in FA bricks and blocks.1.42% of the fly ash (dry) used in Cement Industry. 0.05% of the fly ash (wet) used in stowing in mines.1.72% of the fly ash (wet) used in cement (pond ash). O.05% of fly ash (wet) used for other purposes.

Nil

FLY ASH FACT SHEET State: Andhra Pradesh

In the recent past, Andhra Pradesh has emerged on the forefront of economic development of the country. The state has taken rapid strides in industrialization and now enjoys leadership status in knowledge industry sectors like IT, Biotech, Drugs and Pharmaceuticals etc. The state forms an integral part of the growth powerhouse” of the Southern Region.

The average annual growth rate of Andhra Pradesh during the last three years was around 7 %. The State of Andhra Pradesh is ranked third in terms of investments received since liberalisation of Industrial Policy in 1991. According to official sources Andhra Pradesh is ranked fourth, with total industrial investment of 1,54,129 crores from 335 projects and is ranked first in terms of foreign industrial investment with 56,966 crores from 32 projects. Since liberalization in 1991, 3279 new proposals with investment worth Rs. 1, 10,109 crores were received in the state. Out of these, 1386 projects with an investment of Rs. 15,365 crores have gone into production.

There are around six major coal based thermal power plants with a total capacity of around 6200 MW. Most of the major thermal power plants in the state are government owned and are efficient in operation.

1. State Andhra

Pradesh2. Total number of major thermal power plants 06


I. RamagundamNTPCKarimnagar Dist.

2,100 MW

II. VijayawadaAndhra Pradesh, Power Generation Corp.Krishna

1260 MW

III. KothagudemAndhra Pradesh, Power Generation Corp.Paloncha

1180 MW

IV. SimhadriNTPCParavade

1,000 MW

V. RayalaseemaAndhra Pradesh, Power Generation Corp.Cuddapah Dist.

420 MW

VI. Vizag Steel Works Rashtriya Ispat Nigam Ltd.

Visakhapatnam

236 MW

Name of plant Quantity of fly ash generationTotal Tons

Dry Tons

Wet Tons



ApplicationCurrent user Transportation

dataOther fly ash utilization activities

Mode of transport and distance from plant

Transportation cost


Kadapa/ Cuddapah DistrictAndhra Pradesh Power Generation Corp.Rayalseema

8930

63

4464

00

5253

08 Wet : ash is mixed with water and pumped to ash pond.Dry : ash is collected in two RCC silos of 360 MT capacity each and issued to cement factories and brick manufaturers.


22.45% of the fly ash (dry) used in FA bricks and blocks.74.99 (2.11wet and 76.22 dry) % of the fly ash used in cement industry. 2.56% of the fly ash used in other purposes.

ParavadeNTPCSimhadri

2000

0

1000

0

1000

0 Three silos 150 T each.

Fly ash brick and blocks.

50 current users in Vishakha patnam.L&T using for RMC plant.

Bricks and Blocks.

Steel Plant Slag

FLY ASH FACT SHEET

State: Uttar Pradesh

Uttar Pradesh is the most populous state in the country accounting for 16.4 per cent of the country’s population. It is one of the largest state in geographical area covering 9.0 per cent of the country’s geographical area, encompassing 2,94,411 square kilometres and comprising of 83 districts

The structure of state income shows that the contribution of primary sector has declined to 41 percent of the state income though the sector still sustain 73 percent of the total working force. The share of secondary sector, on the other hand, has gone up to 20 percent of the total state income, which now employ 9 percent of the total workers in the state. U.P.'s growth has been more capital intensive than labour intensive, more urban based than rural based and the shift income from primary to other sectors is not accompanied by corresponding change in employment pattern.

Distinguishing feature of Uttar Pradesh's economy is its regional imbalances. In terms of economic indicators like agricultural productivity, infrastructural facilities, industrial

Name of plant Quantity of fly ash generationTotal Tons

Dry Tons

Wet Tons



Application

Current user

Transportation data


Mode of transport and distance from plant

Transportation cost

Projects

Cement production (PPC)

Kadapa/ Cuddapah DistrictAndhra Pradesh

Power Generation

Corp.

Rayalseema

8930

63

4464

00

5253

08 Wet : ash is mixed with water and pumped to ash pond.Dry : ash is collected in two RCC silos of 360 MT capacity each and issued to cement factories and brick manufaturers.


22.45% of the fly ash (dry) used in FA bricks and blocks.74.99 (2.11wet and 76.22 dry) % of the fly ash used in cement industry. 2.56% of the fly ash used in other purposes.

ParavadeNTPCSimhadri

2000

0

1000

0

1000

0 Three silos 150 T each.

Fly ash brick and blocks.

50 current users in Vishakha patnam.L&T using for RMC plant.

Bricks and Blocks.

Steel Plant Slag

growth, the Uttar Pradesh's economy can be categorise into five regions; Western, Eastern, Central, Ruhelkhand and Hill. The Western Uttar Pradesh is agriculturally prosperous. It is relatively industrialized and has seen greater degree of urbanization.

There are around 11 major thermal power plants in the state with a totatal capacity of around 10000 MW. Most of the larger thermal power plants in the state are either owned by NTPC or the state government’s Rajya Vidyut Utpadan Nigam Limited. In general, the thermal power plants in the state are modernized and produce good quality of fly ash.

1. State Uttar Pradesh



I. SingrauliNTPCSonebhadra Dist.

2,050 MW

II. AnparaUPRVUNLMirzapur Dist.

1,630 MW

III. ObraUPRVUNLObra Dist.

1,550 MW

IV. RihandNTPCSonebhadra Dist.

1,000 MW

V. Dadri NTPCDadri

840 MW

VI. UnchaharNTPCRai Bareilli

840 MW

VII. RenusagarHindalco Industries Ltd.Renukoot

619 MW

VIII. HarduaganjUPRVUNLHarduaganj

440 MW

IX. TandaNTPCFaizabad

440 MW

X. PankiUPRVUNLPanki

279 MW

XI. ParichaUPRVUNLJhansi

220 MW

Name of plant Quantity of fly ash generation

Total Dry Wet


Current fly ash useQuantity used Application

Current user

Transportation data


Mode of transport & distance from plant

Transportation cost

Projects

Cement production (PPC)

Renukoot Hindalco Industries Ltd.Renusagar

1689

320

8446

60

8446

60 Both wet and dry.

48 %of fly ash used.

0.6 % dry FA used as FA bricks.8.5 % dry FA used in cement industry.13.90% dry FA used in land development.25.0% dry FA used in raise of ash dyke

M/s Prism Cement Limited, Satna (M.P.)

Closed Bulkers

225 Km..

Bricks.raise of ash dyke

cement industry

Sohnebhadra DistrictNTPCRihand

13.2

2

10.5

8

2.64 Dry ash

collection 35 %of fly ash used.

2.0% dry FA used as FA bricks.1.3% dry FA used in cement industry.96.13.90% dry FA used in land development.25.0% dry FA used in raise of ash dyke

FaizabadNTPCTanda 10

5000

0

8400

00

2100

00 Have to install.

Discharged in pond. Nil In process

HarduaganjUPRVUNLHarduaganj 25

truc

ks Slurry collection system

Used in Ash pond. Fly ash bricks.

Rai BarelliNTPCUnchahar 20

5000

0 Dry ash collection Silo two in number 350 MT each.4

50 % of Fly Ash used inCement Industries.Fly ash bricks.Roads.

NHAI

ACC

Birla Corporate

Prism cements

Jai PrakashNepal

FLY ASH FACT SHEET State: Gujarat

Gujarat is situated in the west coast of India. The state is bounded by the Arabian sea on the west, Pakistan and Rajasthan in the north and north-east respectively, Madhya Pradesh in the south-east and Maharashtra in the south. The state covers an area of 196,024 sq km.

One of India's most industrialized states, Gujarat maintains a variety of industries, the principal ones being general and electrical engineering and the manufacture of textiles, vegetable oils, chemicals, soda ash, and cement. New industries include the production of fertilizers and petrochemicals. Petroleum production began in 1960, and an oil refinery is located at Vadodara.

There are around eight major thermal power stations in Gujarat. Most of the thermal plants are quite old and are in the process of phase-wise up-gradation to increase their efficiency and ash collection system. At present, the major portion of usable fly ash is collected by the cement companies and only a small portion is available for other application like concrete and other real estate applications.

The state has witnessed large infrastructure grown over the past few years. It has a total road length of 72950 km when survey last conducted for 31st march, 1999. Its National Highways constitute about 4.5 per cent of the total length of National Highways in India. The major ongoing infrastructure projects in the state include roads and other construction projects. However, there is very limited use of fly ash in high volume fly ash concrete technology in the state. A brief profile of the state is presented below:

4. State Gujarat



V. Sabarmati Thermal Power PlantAhmedabad Electric Co. Ltd.Sabarmati

450 MW

VI. Kutch Thermal Power PlantGujarat SEBKutch

210 MW

VII. Ukai Thermal Power PlantGujarat SEBUkai Dam

850 MW

VIII. Wanakbori Thermal Power PlantGujarat SEBSevalia

1,470 MW

IX.Gandhi Nagar Thermal Power PlantGujarat SEB

Gandhi Nagar

870 MW

X. Dhuvaran Thermal Power PlantGujarat SEBAnand

534 MW

XI. Surat Thermal Power PlantGujarat Industrial Power Corp. Ltd. (GIPCL)Surat

250 MW

XII. Sikka Thermal Power PlantGujarat SEBSikka

240 MW

Fly ash detailsName of plant Quantity of fly ash

generationTotal Tons

DryTons

WetTons



ApplicationCurrent user Transportation data Other fly ash

utilization activitiesMode of transport & distance (km)

Transportation cost


Sabarmati Thermal Power PlantAhmedabad Electric Co. Ltd.Sabarmati

2625

02

2231

27

3937

5 Major portions of ash is ollected in dry forms and bottom ash clinkers are deposited by wet system.In case of an outage in dry system, it is collected through wet system.

100% of the fly ash used

70% of the fly ash used for bricks/blocks, cement and concrete.30% used for other application

AEC Cement Truck 35

Gujarat Ambuja Cement

Truck 200

Binani Cement

Tanker 300

JK Corporation

Tanker 300

Ultratech Cemco

Truck 200

Gujarat Composite

Tanker 5

Tata Chemicals

Tanker 500

--- Housing projects,Construction of road dividers

PPC, Bricks and Cement sheets

Kutch Thermal Power PlantGujarat SEBKutch

Ukai Thermal Power PlantGujarat SEBUkai Dam

Wanakbori Thermal Power PlantGujarat SEBSevalia

Gandhi Nagar Thermal Power PlantGujarat SEB

Gandhi Nagar

Dhuvaran Thermal Power PlantGujarat SEBAnand

Surat Thermal Power PlantGujarat Industrial Power Corp. Ltd. (GIPCL)Surat

Sikka Thermal Power PlantGujarat SEBSikka

summary report flyash

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