HIGH VOLUME CONCRETE TECHNOLOGY FLY ASH. STATUS SUMMARY REPORT In INDIA

Transcription

1 HIGH VOLUME FLY ASH CONCRETE TECHNOLOGY FLY ASH STATUS SUMMARY REPORT In INDIA 1

2 TABLE OF CONTENTS Objective 7 Background...7 Source Of Fly ash In India Present Scenario on Fly ash in India..11 Ash Collection..12 Source of Fly Ash.. 13 Ash Content in Indian Control..13 Fly Ash.. 13 Fly Ash Transportation..15 Dry. 16 Conditioned..16 Stockpiled..16 Lagoon Current Fly Ash Generation In India 17 Current 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...21 Conclusion & Recommendation.21 Annexure 23 Ministry of Environment & Forest 23 Notification of Fly Ash. 23 Amendments List of Major Thermal Plants 28 Fly Ash Suppliers India.32 Tanveer Enterprises 33 Ash Tech..34 Fly Ash Fact Sheets 35 Tamil Nadu Maharashtra 38 Andhra Pradesh.. 44 Uttar Pradesh.49 Gujarat..55 2

3 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. 3

4 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. 4

5 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 was about MW and hydropower generation was 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) 1R Badarpur R I.P. Station Million KWH per day(mu) 5

6 3R Rajghat R Faridabad R Panipat R Bhatinda R Lehra R Ropar R Kota R Suratgarh# P Anpara R Harduagang R Dadri R Obra R Panki R Paricha P Rihand P Singrauli R Tanda R Unchahar Kutch% R Sabarmati# Dhurvaran R Gandhi Nagar R Sikka R Ukai R Wanakbori R Bhusawal R Chandrapur R Dahanu R Khaper Kheda R Koradi R Nasik R Paras Trombay R Parli P Amarkantak R Sanjay Gandhi P Korba Ii&Iii P Korba West P Korba Stps R Satpura P Vindhyachal R Kothagudem R Rayalseema R Nellore R Ramagundam P Rgundam(Stps) R Vijayawada I Ennore I Mettur

7 53I North Madras I Tuticorin R Raichur R Barauni R Muzaffarpur R Patratu R Tenughat P Kahalgaon R Bokaro A&B R Chandrapura R Mejia R Durgapur-Dvc R Bandel R Calcutta New Cossipore R S.Gen Station R Durgapur -Dpl R Kolaghat Bakreshwar* R Santaldih R Titagarh R Budgebudge* P Farakka P Talcher-Ntpc P Talcher-Stps Ib Valley Tps R Bongaigaon Chandrapur(Assam) Namrup TOT AL All India * Kg/KWH are the average for the Eastern region # Kg/KWH are the average for the western Lignite is used as the fuel Based on monthly average R Rail feed plant P Pit-head plant I Inter modal Note: 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: Ropar Kota Annapara Dadri Rihand Singrauli Unchahar Chandrapur Dahanu Trombay Vindyanchal Raichur Ramagundam Korba 7

8 PRESENT SCENARIO ON FLY ASH IN INDIA Over 75% of the total installed power generation is coal-based 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 categories Dry Fly Ash Dry 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 Ash Bottom 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 Ash Conditioned 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%. 8

9 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. 9

10 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 SiO Al2O Fe2O CaO MgO K2O Na2O SO LOI TiO <1 <1 As per ASTM Standards Indian 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 10

11 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 11

12 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, 12

13 but have long service of years without much maintenance in comparison to WBM and Bituminous Macadam roads. HCC Projects Development 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: 13

14 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. 14

15 ANNEXURE MINISTRY OF ENVIRONMENT AND FORESTS Notification on Fly Ash New Delhi, the 27th August 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 14 th September, 1999 (hereinafter referred to as the said notification) which the Central Government proposes to make under sub-section (1) and clause (v) of subsection (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 6 th November, 2002 vide S.O (E), dated the 5 th 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 27 th 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: - AMENDMENTS 1. 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: - 15

16 "(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 31 st August 2004; (ii) 50 per cent by 31 st August 2005; (iii) 75 per cent by 31 st August, 2006; and (iv) 100 per cent by 31 st August 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 31 st August 2004; (ii) 100 per cent by 31 st August (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 subparagraph (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 16

17 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 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. 17

18 (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 lowlying 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 byelaws, regulations and specifications laid down by the authorities mentioned in subparagraph (3) of paragraph 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 1 st day of September, 2003 make provisions for 18

19 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 1 st 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

20 List of Major Thermal Power Plants Plant Owner Location City State Fuel TAMIL NADU Mettur Tamil Nadu SEB Mettur Tamil Nadu Coal 840 North Chennai Tamil Nadu SEB Chennai Tamil Nadu Coal 630 Ennore Tamil Nadu SEB Ennore Tamil Nadu Coal 450 Neyveli Zero CMS India Ltd. Neyveli Tamil Nadu Coal 250 MAHARASHTRA Chandrapur Maharashtra SEB Durgapur Maharashtra Coal 2,340 Trombay (coalfired Tata Power Co. Ltd. Mumbai Maharashtra Coal;Nat 1150 section) ural Gas, Koradi Maharashtra SEB Koradi Maharashtra Coal 1,100 Nasik Maharashtra SEB Nasik Maharashtra Coal Khaperkheda Maharashtra SEB Khaperkheda Maharashtra Coal 840 Parli Maharashtra SEB Parli Vaijnath Maharashtra Coal 690 Dahanu BSES Ltd. Thane Dist. Maharashtra Coal 500 Bhusawal Maharashtra SEB Jalgaon Maharashtra Coal 483 ANDHRA PRADESH Ramagundam NTPC Karimnagar Andhra Coal 2,100 Dist. Pradesh 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 Coal 1,000 Pradesh Rayalaseema Andhra Pradesh, Cuddapah Andhra Coal 420 Power Generation Corp. Dist. Pradesh Vizag Steel Rashtriya Ispat Visakhapat Andhra Coal 236 Works * Nigam Ltd. nam Pradesh ORISSA Talcher NTPC Angul Orissa Coal 1,970 Angul Smelter National Aluminum Corp. Ltd. Angul Orissa Coal 720 Ib Valley OPGC; AES Barhanpalli Orissa Coal 420 Rourkela Works Steel Authority of Rourkela Orissa Coal 269 * India Ltd. Choudwar Indian ChargeChrome Ltd. (ICCL) Choudwar Orissa Coal 108 Total Capacity (MW) 20

21 KARNATAKA Raichur KPCL Raichur Karnataka Coal 1,470 Dist. Torangallu Works * Jindal Tractebel, Power Co. Ltd. Torangallu Karnataka Blast Furnace 260 Gas;Coal MADHYA PRADESH Vindhyachal NTPC Sidhi Madhya Pradesh Coal 2,260 Satpura Madhya Pradesh SEB Betual Dist. Madhya Pradesh Coal 1,143 Sanjay Gandhi Madhya Pradesh SEB Umaria Madhya Coal 840 Dist. Pradesh Amarkantak Madhya Pradesh SEB Shahdal Madhya Pradesh Coal 300 NTPC BALCO NTPC Korba Madhya Coal 270 Pradesh Raigarh Works * Jindal Steel & Power Raigarh Madhya Coal 112 Ltd. Pradesh Nagda Works * Melodeon Exports Nagda Madhya Pradesh Coal 106 CHHATTISGARH Korba STPS NTPC Bilaspur Chattisgarh Coal 2,100 Korba West Chattisgarh SEB Bilaspur Chattisgarh Coal 840 Korba East Chattisgarh SEB Bilaspur Chattisgarh Coal 400 WEST BENGAL Farakka NTPC Murshidabad West Bengal Coal 1,630 Kolaghat West Bengal Power Medinipurt West Bengal Coal 1260 Development Corp. Dist. Bakreshwar West Bengal Power Birbhum Dist. West Bengal Coal 630 Development Corp. Mejia DVC Durlavpur West Bengal Coal 630 Bandel West Bengal SEB Hooghly West Bengal Coal 530 Budge Budge CESC Ltd. Calcutta West Bengal Coal 500 Santaldih West Bengal SEB Santaldih West Bengal Coal 480 Durgapur West Bengal SEB Burdwan West Bengal Coal 405 Durgapur DVC DVC Waria West Bengal Coal 350 Titagarh CESC Ltd. Titagarh West Bengal Coal 240 Cossipore CESC Ltd. Calcutta West Bengal Coal 225 Mulajore CESC Ltd. Shyamnagar West Bengal Coal 150 Durgapur Works Steel Authority of Durgapur West Bengal Coal 140 * India Ltd. Southern CESC Ltd. Calcutta West Bengal Coal 135 UTTAR PRADESH Singrauli NTPC Sonebhadra Uttar Pradesh Coal 2,050 21

22 Dist. Anpara UPRVUNL Mirzapur Uttar Pradesh Coal 1,630 Dist. Obra UPRVUNL Obra Dist. Uttar Pradesh Coal 1,550 Rihand NTPC Sonebhadra Uttar Pradesh Coal 1,000 Dist. Dadri (coal-fired NTPC Dadri Uttar Pradesh Coal 840 section) Unchahar NTPC Rai Bareilli Uttar Pradesh Coal 840 Renusagar * Hindalco Industries Ltd. Renukoot Uttar Pradesh Coal 619 Harduaganj UPRVUNL Harduaganj Uttar Pradesh Coal 440 Tanda NTPC Faizabad Uttar Pradesh Coal 440 Panki UPRVUNL Panki Uttar Pradesh Coal 279 Paricha UPRVUNL Jhansi Uttar Pradesh Coal 220 GUJARAT Wanakbori Gujarat SEB Sevalia Gujarat Coal 1,470 Gandhi Nagar Gujarat SEB Gandhi Gujarat Coal 870 Nagar Ukai Gujarat SEB Ukai Dam Gujarat Coal 850 Dhuvaran Gujarat SEB Anand Gujarat Coal 534 Sabarmati Ahmedabad Electric Sabarmati Gujarat Coal 450 Co. Ltd. Surat Gujarat Industrial Surat Gujarat Coal 250 Power Corp. Ltd. (GIPCL) Sikka Gujarat SEB Sikka Gujarat Coal 240 Kutch Gujarat SEB Kutch Gujarat Coal 210 BIHAR Kahalgaon NTPC Kahalgaon Bihar Coal 840 Barauni Bihar SEB Hazaribagh Bihar Coal 310 Dist. Jamshedpur Works * Tata Iron & Steel Co. Jamshedpur Bihar Coal 238 Muzaffarpur Bihar SEB Kanti Bihar Coal 220 JHARKHAND Bokaro DVC Bokaro Jharkhand Coal 805 Patratu Jharkhand SEB Patratu Jharkhand Coal 770 Chandrapura DVC Chandrapura Jharkhand Coal 750 Tenughat Jharkhand SEB Bokaro Dist. Jharkhand Coal 420 Bokaro Works * Steel Authority of Bokaro Jharkhand Coal 287 India Ltd. PUNJAB Ropar Punjab SEB Ropar Punjab Coal 1,260 Guru Hargobind Punjab SEB Bhatinda Punjab Coal

23 HARYANA Tau Devi Lal Haryana Power Panipat Haryana Coal 860 Generation Corp. Ltd. Faridabad Faradibad Power Systems Ltd. Faridabad Haryana Coal 165 RAJASTHAN Suratgarh Rajasthan RV Suratgarh Rajasthan Coal 1,000 Utpadan Nigam Kota Rajasthan RV Kota Rajasthan Coal 850 Utpadan Nigam DELHI Badarpur NTPC New Delhi Delhi Territory Coal 720 Indraprastha Indraprastha Power New Delhi Delhi Territory Coal 248 Generating Co. Ltd. Rajghat Delhi Transco Ltd. New Delhi Delhi Territory Coal 135 ASSAM 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

24 L-10,First Floor, Kailash Colony NEW DELHI , India Tel. No.: , Tele. Fax: Web Site: 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

25 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 Floor Kailash Colony New Delhi , INDIA Tel No.: , TeleFax: Web: ashtech@touchtelindia.net FLY ASH FACT SHEET State: Tamil Nadu Tamil Nadu is the fourth largest State of the country. It has a population of 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

26 2. Total number of thermal power plants 3. Major thermal power plants I. Mettur Tamil Nadu SEB Mettur II. North Chennai Tamil Nadu SEB Chennai III. Ennore Tamil Nadu SEB Ennore IV. Neyveli CMS India Ltd. Neyveli 840 MW 630 MW 450 MW 250 MW 26

27 Name of plant Neyveli Lignite Corporation Limited CMS india ltd. Chennai Tamil Nadu State Electricity Board North Chennai Quantity of fly ash generation Total Dry Wet Ash collection system Silos are used. Pressurized dense Fly ash conveying system with PLC & silos. Current fly ash use Quantity Application used 1.2% of fly ash being used 26.58% 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. 2.42% of Fly Ash(Dry) used in Bricks and blocks % of Fly Ash used in Cement industries. 1.68% of Fly Ash used in Concrete Mortar. Current user Transportation data Other fly ash utilization activities Madras Cement Ltd Dalmia cements Barath Limited Gracim Industries Limited The India Cements sankari works The indian cements Daiavoi Works Vijay Cements Pvt Ltd Mode of transport & distance km Ash dipper / bulker Ash dipper / bulker Ash dipper / bulker Ash dipper / bulker Ash dipper / bulker Ash dipper / bulker L &T Tanker 125 Madras Cement Ltd Tanker 275 Inbdia Cement Tanker 275 Small Scale Industry Tanker 25 Trans portat ion cost Projects Cement producti on (PPC)

28 FLY ASH FACT SHEET State: 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 3. Major thermal power plants I. Chandrapur Maharashtra SEB Durgapur II. Trombay (coal-fired section) Tata Power Co. Ltd. Mumbai III. Koradi Maharashtra SEB Koradi IV. Nasik Maharashtra SEB Nasik V. Khaperkheda Maharashtra SEB Khaperkheda VI. VII. VIII. Parli Maharashtra SEB Parli Vaijnath Dahanu BSES Ltd. Thane Dist. Bhusawal Maharashtra SEB Jalgaon 2,340 MW 1150 MW 1,100 MW 840 MW 690 MW 500 MW 483 MW

29 Name of plant Quantity of fly ash generation Ash collection system Current fly ash use Current user Transportati on data Other fly ash utilization activities Jalagaon Maharashtra SEB Bhusawal Total Tons Dry Tons Wet Tons Both wet and dry. Ash is converted to slurry form by mixing water through hydroejector & 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. Quantity used 47 %of the fly ash used. Application 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 Mode of transport & distance (km) Truck Truck and Tractor Truck and Tractor Transp ortatio n cost Projects Bircks, blocks Cemen t produc tion (PPC) Cement industry

30 Parli Vaijnath Maharashtra SEB Parli Thane District BSES Dahanu Dry fly ash from all units is being collected in jumbo bags except first row. Manually operated wet system 29 %of the fly ash used. 20% of the fly ash used 1.9 %of both the fly ash used in FA bricks and blocks. 6.61%of both the fly ash used in cement industry %of the wet fly ash used in agriculture %of the wet fly ash used in land development. 0.14% of the fly ash (dry) used in FA bricks and blocks. 0.58% of the fly ash (wet) used in Brick Kiln % of the fly ash (dry) used in agriculture. 0.06% of the fly ash (dry) used in land development. M/s Birla Truck 220 Super Cement Sholapur M/s Visaka Truck 325 Cement Ind. Ltd. Pune M/s New Truck 300 Sahyadri Ind. Ltd. Pune M/s Swastik Truck 370 Ind. Chinchwad Pune M/s Shakti Truck 350 Roofing Pvt Ltd. Pune M/s Everest Truck 380 Industries Ltd. Nashik M/s Jai Truck 370 Bilidicon Products Ltd. Pune M/s Proctor & Truck 370 Walker Pune M/s Ash Crete Truck 370 Pune M/s Ambica Bricks Parli -V Truck 15 Hemant Bafna 14 Manchar Irani 8 M/s Satish Carriers Plastichem Distributors Ashtech India Pvt. Ltd.

31 Durgapur Maharashtra SEB Chandrapur 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

32 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 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 Pradesh 2. Total number of major thermal power plants Major thermal power plants I. Ramagundam NTPC Karimnagar Dist. II. Vijayawada Andhra Pradesh, Power Generation Corp. Krishna III. Kothagudem Andhra Pradesh, Power Generation Corp. Paloncha IV. Simhadri NTPC Paravade V. Rayalaseema Andhra Pradesh, Power Generation Corp. Cuddapah Dist. 2,100 MW 1260 MW 1180 MW 1,000 MW 420 MW

33 VI. Vizag Steel Works Rashtriya Ispat Nigam Ltd. Visakhapatnam 236 MW

34 Name of plant Kadapa/ Cuddapah District Andhra Pradesh Power Generation Corp. Rayalseema Paravade NTPC Simhadri Quantity of fly ash generation Total Tons Dry Tons Wet Tons Ash collection system 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. Three silos 150 T each. Current fly ash use Quantit Application y used 51 %of the fly ash used % of the fly ash (dry) used in FA bricks and blocks (2.11wet and dry) % of the fly ash used in cement industry. 2.56% of the fly ash used in other purposes. Fly ash brick and blocks. Current user 50 current users in Vishakha patnam. L&T using for RMC plant. Transportation data Mode of transport and distance from plant Transp ortatio n cost Other fly ash utilization activities Projects Cemen t produc tion (PPC) Bricks and Blocks. Steel Plant Slag

35 Name of plant Kadapa/ Cuddapah District Andhra Pradesh Power Generation Corp. Rayalseema Paravade NTPC Simhadri Quantity of fly ash generation Tot al Ton s Dry Ton s Wet Ton s Ash collection system 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. Three silos 150 T each. FLY ASH FACT SHEET Current fly ash use Quant Applicatio ity n used 51 %of the fly ash used % of the fly ash (dry) used in FA bricks and blocks (2.11wet and dry) % of the fly ash used in cement industry. 2.56% of the fly ash used in other purposes. Fly ash brick and blocks. State: Uttar Pradesh Current user 50 current users in Vishakha patnam. L&T using for RMC plant. Transportation data Mode of transpo rt and distanc e from plant Trans portat ion cost Other fly ash utilization activities Projec ts Bricks and Blocks. Ceme nt produ ction (PPC) Steel Plant Slag 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

36 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 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 2. Total number of thermal power plants 3. Major thermal power plants I. Singrauli NTPC Sonebhadra Dist. II. Anpara UPRVUNL Mirzapur Dist. III. Obra UPRVUNL Obra Dist. IV. Rihand NTPC Sonebhadra Dist. V. Dadri NTPC Dadri VI. Unchahar NTPC Rai Bareilli VII. Renusagar Hindalco Industries Ltd. Renukoot VIII. Harduaganj UPRVUNL Harduaganj 2,050 MW 1,630 MW 1,550 MW 1,000 MW 840 MW 840 MW 619 MW 440 MW

37 IX. Tanda NTPC Faizabad X. Panki UPRVUNL Panki XI. Paricha UPRVUNL Jhansi 440 MW 279 MW 220 MW

38 Name of plant Renukoot Hindalco Industries Ltd. Renusagar Sohnebhadra District NTPC Rihand Faizabad NTPC Tanda Quantity of fly ash generation Total Dry Wet Ash collection system Both wet and dry. Dry ash collection Have to install. Current fly ash use Quantit y used 48 %of fly ash used. 35 %of fly ash used. Application 0.6 % dry FA used as FA bricks. 8.5 % dry FA used in cement industry % dry FA used in land development. 25.0% dry FA used in raise of ash dyke 2.0% dry FA used as FA bricks. 1.3% dry FA used in cement industry % dry FA used in land development. 25.0% dry FA used in raise of ash dyke Current user M/s Prism Cement Limited, Satna (M.P.) Transportation data Mode of transport & distance from plant Closed Bulkers 225 Km.. Trans porta tion cost Other fly ash utilization activities Project s Bricks. raise of ash dyke Discharged in pond. Nil In process Cement product ion (PPC) cement industry

39 Harduaganj UPRVUNL Harduaganj 25 trucks Slurry collection system Used in Ash pond. Fly ash bricks. Rai Barelli NTPC Unchahar 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 Prakash Nepal

40 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.

41 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 km when survey last conducted for 31st march, 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: