NTPC EFFORTS TO

ENHANCE
ASH UTILIZATION

V. K. MATHUR
AGM / NTPC
 Power Generation Scenario in India
Present Installed Capacity (31-09-08)
• Total Installed Capacity : 1,45,555 MW
• Coal Based Capacity : 76,989 MW (53%)
• Hydro Power Capacity : 36,348 MW
• Gas & Diesel based Capacity : 15,904 MW
• Nuclear & Renewable Energy Sources : 16,315 MW
• Capacity addition target by 2012 : 60,000 MW
(coal based capacity)

• Ash Generation during 2007-08 : 130 Million Tonne

• Estimated Ash Generation By 2012 ~ 210 Million Tonne
• Ash Utilization during 2007-08 : 70 Million Tonne (54%)

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

• Ash Utilization in NTPC (2007-08) : 23.7 Million Tonne (55%)
 Ash Generation at NTPC Stations-as on March 2008
Station Total Ash Production Lakh Tonne / Year MW Capacity

Dadri 16.22 840

Badarpur 13.31 705

Singrauli 36.08 2000

Rihand 30.37 2000

Unchahar 23.86 1050

Tanda 10.55 440

Korba 49.35 2100

Vindhyachal 50.19 3260

Ramagundam 46.65 2600

Simhadri 22.74 1000

Farakka 33.39 1600

Kahalgaon 18.46 1340

Talcher -Thermal 10.60 460

Talcher-Kaniha 68.21 3000

Total 430.05 22395

 Qty in Million tonne
19
91

0
5
10
15
20
25
19 -92
92
-
19 93
93

0.33 0.47
19 -94
94

1.05
-
19 95
95

1.79
19 -96

2
96
19 -97
97
-
19 98
98
19 -99
99
20 -00
00
2.2 2.25 2.44 2.74

Year
20 01
01
3.04
Year wise Ash Utilization

20 -02
02
3.76

-
20 03
03
5.67
ASH UTILIZATION IN NTPC

20 -04
04
7.52

20 -05
05
12.7

-
20 06
06
16.7

20 -07
07
20.8

-0
8
23.7
 NTPC EFFORTS
• Dry Ash Evacuation System (DAES)

• Building Products

• Agriculture

• Roads

• Mine Filling

• Research Studies

• Awareness Measures
Dry Ash Evacuation system
(DAES)
Dry Ash Evacuation system (DAES)

• 100 % DAES in all new

Plants and expansion units
• 20% DAES in all existing
Plants. Further
augmentation depending
upon requirement
• Long Term Agreements
signed with Cement
industries for 29.5 Lakh M/T
fly ash at four stations.
• New agreements with
cement industries being
signed through NVVN
Dry Ash Evacuation system (DAES)

• 52500 M/T Fly Ash

exported through
NVVN.

• JV’s being entered

through NVVN.

• 950 M/T Cenospheres

exported through
NVVN
 Ash Utilization in NTPC

Increase in Issue of Fly Ash to Industries

10.00
8.70
9.00
Q t y . in M illio n T o n n e

8.00 7.45

7.00
5.67
6.00
4.60
5.00
4.00 3.10
3.00 2.163
1.69
2.00 1.20 1.21
0.74 0.91 0.89
0.40 0.56
1.00 0.04 0.05 0.11
0.00
1991- 1992- 1993- 1994- 1995- 1996- 1997- 1998- 1999- 2000- 2001- 2002- 2003- 2004- 2005- 2006- 2007-
92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08

Year
Fly Ash bricks
• All NTPC Stations
Have Fly ash bricks
making plants for
demonstration
purposes to
encourage private
enterprenuers to set
up their plants
• Bricks being made for
inhouse consumption.
 Fly Ash bricks
• In 2007-08, NTPC
produced 7 crores fly ash
bricks.
• This is being increased to
12 crore bricks by setting
up 3 more brick plants at
Sipat, Vindhyachal and
Dadri.
• At Ramagundam, High
Volume Clay-ash bricks
are being made.
• About 5.2 lakh cum pond
ash was utilized for these
bricks during 2007-08.
Vibro Press
 Agriculture
• Show case projects on use
of fly ash in Agriculture
being taken up at Simhadri,
Unchahar, Singrauli, Dadri &
Talcher-Thermal Stations
involving nearby farmers
and Agriculture university.

• Results at Simhadri are very

encouraging. Initially only 5
farmers came forward for
the study, the number has
now gone to 25 farmers
within one year.
View of Paddy crop on ash
mix plot at Simhadri
 Road Embankment
• Allahabad bypass road
embankment construction
utilized 67 Lac Cum Pond
Ash from Unchahar.

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

• Low lying areas in NTPC

being filled with Pond ash

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

• Efforts are on to take up Random

filling of ash along with over
burden of an operating mine as a
pilot study.

• Ministry of Coal has agreed for

such study and asked coal
companies to identify mines for the
same.

• A documentary film on use of fly

South Balanda Mine ash in mine filling is under
production.
STUDIES / DEMONSTRATION
PROJECTS
 Studies / Demonstration Projects
• NTPC & RDSO have signed an MoU for the study of
suitability of coal ash in Railway Embankment –
07.09.07
A study for design of the embankment has been
awarded to CRRI.
To validate the design of Rail
Embankment,another study has been awarded to
IIT Bombay for conducting Centrifuge model tests.
Kahalgaon MGR -10 km has been selected for
pilot study.
MGR extension / Railway siding at Talcher-Kaniha
are also planned to be taken up as part of study
 Studies / Demonstration Projects
• Fly ash based concrete road are being
constructed at Dadri and Farakka –study by
CRRI.
• Roller compacted concrete pavement is being
constructed at Ramagundam-study by CRRI.
• High volume fly ash- clay bricks / tiles using flux
bonded technology taken up in association with
National Institute of Inter Disciplinary Science &
Technology, Trivandrum at Ramagundam
• Cold Setting Structural Bricks / Blocks with high
volume fly ash in association with RRL
Bhubaneshwar
 Studies / Demonstration Projects
• Use of fly ash in Bituminous Road Surfacing
taken up through CRRI.
Demonstration stretch shall be constructed
at NTPC Dadri.
• Use of fly ash in Railway Concrete Sleepers
is being taken up in association with IIT,
Kanpur.
• Use of Bottom ash in concrete block making is
being taken up in association with National
Council for Cement & Building material,
Ballabhgarh at NTPC Unchahar.
AWARENESS MEASURES
 AWARENESS MEASURES
• Documentary Films

• Workshops

• Advertisements in News papers

• Exhibitions

• Distribution of Booklets, Pamphelets etc

 AWARENESS MEASURES
DOCUMENTARY FILMS
1. Coal Ash –as Fill Material –2001
2. Use of Fly Ash in Concrete & RMC
Plants-(2004-05)
3. Clay Fly Ash Bricks --(2005-06)
4. Fly Ash Bricks --(2006-07)
5. High Volume Ash Clay Bricks –(2007-
08)
6. Use of fly ash in mine filling –(Under
preparation)
 AWARENESS MEASURES
Workshops organized by NTPC:
1. Delhi PWD
2. Delhi Development Authority
3. Ghaziabad development Authority
4. Noida Authority
5. Greater Noida Authority
6. Municipal Corporation of Delhi (MCD)
7. New Delhi Municipal Council (NDMC)
8. Hyderabad Urban Development Authority
9. NHAI
10. Research Designs & Standards Organization (RDSO),
Lucknow
11. M/S CES Delhi / Kolkata
12. M/S ICT Consultant
13. RITES
14. World Bank
15. Asian Development Bank
 AWARENESS MEASURES
Advertisements
• Advertisements are being published on all
India basis on frequent intervals

• Advertisements are theme based

--Various applications of fly ash
--Specific usage of fly ash-Cement &
Concrete, Building products, Roads and
Embankments, Agriculture, Mine filling etc
2006-072 2006-07
2006-07
2006-07
2007-08
2007-08