FLY ASH GENERATION

AND UTILIZATION

DURING 2016-17

Fly Ash

• MoEF&CC dated 3rd November,2009 notification stipulates: “Fly ash "means and includes all the coal or lignite ash generated at thermal power plant, such as ESP ash, dry fly ash, bottom ash, pond ash and mound ash for the purpose of utilization.

Fly Ash Generation

1. As per the National Power Portal the installed capacity of Coal based Thermal Power Plant is about 193.8 GW.

2. The report of CEA for 2016-17 on fly ash generation/utilization states the following:

• Nos of TPPs 155

• Installed Capacity 157.4 GW

• Coal Consumed 509.46 MT

• Fly Ash Generation 169.25 MT

• Fly Ash Utilization 107.10 MT

• Fly Ash utilization in percentage 63.28

MT-Million Tonne

MoEF Notifications for Ash Utilization

Ministry of Environment & Forests and Climate Change (MoEF&CC) has issued Notification dated 14th September,1999 and following amendments on fly ash utilization:

i) 27th August, 2003 ii) 03rd November, 2009, and iii) 25th January, 2016 There is a Monitoring Committee under Additional Secretary, MoEF&CC with members from various Departments such as Ministry of Coal, Ministry of Mines, Ministry of Power, Central Pollution Control Board, Central Electricity Authority, Department of Science and Technology, and Building Material Technology Promotion Council for management and gainful utilization of fly ash.

Continued…..

• MoP/CEA has been tasked with collection and compilation

of data on fly ash generation /utilization pertaining to

coal/lignite based thermal power stations installed in the

country.

• MoP/CEA in pursuance of the same has been compiling

since 1996 the data to prepare report on yearly/half yearly

basis. The progressive fly ash generation and utilization

from 1996-97 to 2016-17 is encapsulated as below:

5

PROGRESSIVE FLY ASH GENERATION AND ITS UTILIZATION (DURING THE PERIOD FROM 1996-97 TO 2016-17)

Sl. No.20

Year Fly Ash Generation (Million-ton))

Fly Ash Utilization (Million-ton)

Fly Ash Utilization in

% age

(1) (2) (3) (4) (5) 1 1996-97 68.88 6.64 9.63

2 1997-98 78.06 8.43 10.80

3 1998-99 78.99 9.22 11.68

4 1999-2000 74.03 8.91 12.03

5 2000-01 86.29 13.54 15.70

6 2001-02 82.81 15.57 18.80

7 2002-03 91.65 20.79 22.68

8 2003-04 96.28 28.29 29.39

9 2004-05 98.57 37.49 38.04

10 2005-06 98.97 45.22 45.69

11 2006-07 108.15 55.01 50.86

12 2007-08 116.94 61.98 53.00

13 2008-09 116.69 66.64 57.11

14 2009-10 123.54 77.33 62.60

15 2010-11 131.09 73.13 55.79

16 2011-12 145.41 85.05 58.48

17 2012-13 163.56 100.37 61.37

18 2013-14 172.87 99.62 57.63

19 2014-15 184.14 102.54 55.69

20 2015-16 176.74 107.77 60.97

21 2016-17 169.25 107.10 63.28

It is seen that the fly ash generation has been fluctuating while utilization has been steadily increasing.

7

UTILIZATION TARGET FOR FLY ASH FOR THERMAL POWER STATIONS

• The MoEF&CC had set target of 100% utilization by

November,2014 which however could not be achieved and

therefore MoEF&CC subsequently set target for 100% fly

ash utilization by 31st December,2017 vide notification

dated 25th January, 2016. The said notification of

January,2016 has enlarged scope with a view to increasing

the utilization. The gist of the same is noted below:

Continued..

The transportation cost of fly ash to be borne by the thermal power station within 100 km and from 100 km to up to 300 km equally by both the user as well as the Thermal Power Plants(TPPs)

Restriction to provide 20% of dry ESP fly ash shall not apply to plants utilizing 100% fly ash

Coal based TPPs to upload the details of Ash Stock within 3 months from the date of notification i.e. dated 25th January,2016 and monthly update Ash Stock position.

Continued….. Installation of dedicated dry ash silos having separate access roads

to ease the delivery of fly ash.

TPPs shall promote, adopt and setup the ash based manufacturing facilities within or nearby their premises to reduce the transportation of fly ash.

TPPs shall also assist in setting up of manufacturing unit in the vicinity of their plant.

To ensure that the contractor of road construction utilizes the ash in the road, the Authority concerned for road construction shall link the Payment of Contractor with the Certification of Ash supply from the TPPs.

Entire cost of transportation under Pradhan Mantri Gram Sadak Yojana(PMGSY) and government’s asset creation programmes within a radius of 300 km to be borne by TPPs.

TPPs located in coastal distt. shall engage into construction of shore line protection measures.

10

Continued…. • The state authorities shall amend the Building Bye Laws

of the cities so as to ensure the mandatory use of ash bricks.

• It shall be the responsibility of the State Authorities approving construction projects to ensure that Memorandum of Understanding(MoU) for using fly ash is made between TPPs and the construction agency or contractor.

• The concerned authority shall ensure mandatory use of Ash based brick or products in all Govt. Scheme e.g. Mahatma Gandhi National Rural Employment Guarantee Act,2005(MGNREGA), SWACHH BHARAT ABHIYAN, Urban and Rural Housing Scheme wherein built up area is more than 1000 square feet.

• The Ministry of Agriculture may consider the promotion of ash utilization in agriculture as soil conditioner.

11

MODES OF FLY ASH UTILIZATION DURING THE YEAR 2016-17

Sl. No.

Mode of utilization Quantity of Fly Ash utilized in the mode of utilization

Million-ton Percentage (%)

(1) (2) (3) (4)

1 Cement 40.5869 23.98

2 Mine filling 11.7827 6.96

3 Bricks & Tiles 14.9110 8.81

4 Reclamation of low lying area

11.0392 6.52

5 Ash Dyke Raising 11.8888 7.02

6 Roads & flyovers 6.1942 3.66

7 Agriculture 1.9243 1.14

8 Concrete 0.7647 0.45

9 Hydro Power Sector 0.0197 0.01

10 Others 7.9840 4.72

11 Unutilized Fly Ash 62.1577 36.72

Total 169.2534 100.00

12

13

STATE WISE FLY ASH GENERATION AND ITS UTILIZATION

DURING THE YEAR 2016-17

14

Sl. No.

Name of State Nos. of TPS

Installed Capacity

(MW)

Fly Ash Generation

(Million-tonne)

Fly Ash Utilization (Million-tonne)

Percentage Utilization %

1 2 3 4 5 6 7

1 UTTAR PRADESH 18 19104.00 28.2732 13.2480 46.86

2 CHHATTISGARH 20 17740.00 25.1658 10.8393 43.07

3 AANDHRA PRADESH 10 10972.50 17.8322 12.6832 71.13

4 WEST BENGAL 17 14142.00 16.7039 13.7837 82.52

5 MAHARASHTRA 20 21556.00 16.4984 11.7649 71.31

6 ODISHA 5 5188.00 11.4560 6.3975 55.84

7 MADHYA PREDESH 7 10640.00 11.4186 4.1064 35.96

8 BIHAR 4 4100.00 7.3916 2.3929 32.37

9 RAJASTHAN 8 7840.00 6.7657 6.4489 95.32

10 JHARKHAND 7 5612.50 6.7453 7.2876 108.04

11 TAMIL NADU 10 8430.00 6.1763 4.6297 74.96

12 HARYANA 5 5550.00 4.1413 5.2922 127.79

13 GUJARAT 11 15472.00 3.4842 3.5465 101.79

14 KARNATAKA 4 5480.00 3.0739 1.7080 55.56

15 TELANGANA 3 1820.00 2.6751 0.9652 36.08

16 PUNJAB 3 2640.00 0.8799 1.4296 162.47

17 DELHI 2 840.00 0.3650 0.5720 156.71

18 ASSAM 1 250.00 0.2070 0.0000 00.00

GRAND TOTAL 155 157377.00 169.2533 107.0956 63.2754

STATE WISE FLY ASH GENERATION AND ITS UTILIZATION DURING THE YEAR 2016-17

15

Initiatives of Govt. as advised by NITI AAYOG to increase utilization of fly ash

• Operationalised Web based Monitoring System for monthly updation of Fly Ash Stock available With TPPs.

• Workshop and two Video Conferences conducted in CEA/NTPC to explain operation of the web page to power utilities.

• Launching of Mobile App “Ash Track” on 09.02.2018 with a view to have interface between generator and utilizer of fly ash. The Mobile App includes the following information on:

Consumer

Power Stations

Ash Utilization 16

POTENTIAL AREAS OF UTILIZATION OF FLY ASH

1. Cement manufacturing and in concrete as admixtures

2. Construction of the roads and embankments- Issues involved-Distance & Transportation

3. Construction of Bricks, Block & Tiles

4. Construction of buildings , Fly Overs, etc.

5. Back filling and Stowing of Mines- Issues Involved-Safety Mines & Abandoned Mines

6. Agriculture, Forestry, waste land development, etc.

7. Reclamation of low lying areas

8. Raising of ash dyke, etc.

9. Other areas e.g. Light weight aggregate, Polymers, Light weight Blocks, etc.

CONCLUSIONS & RECOMMENDATIONS

1. Because of higher ash content in Indian Coal, the fly ash generation is on higher side but the quality of fly ash is very good.

2. There is huge scope of fly ash utilization in Highway/ Railway tracks. However, Fly Ash is not being used in Railway tracks in India and concerned/ relevant issues need to be addressed.

3. The highest level of fly ash utilization of about 63.28% was achieved in the year 2016-17 .Efforts are required to achieve the target of 100% utilization.

4. Power Utilities need to shift from passive mode to active mode to increase fly ash utilization in the county.

CONCLUSIONS & RECOMMENDATIONS

5. There is scope of increased fly ash utilization in brick manufacturing , light weight blocks, tiles, light weight aggregates, etc.

6. In order to reduce ash content in coal washeries may be set up at appropriate location.

19