Winners of NTPC Grand Challenge for Ash Utilization Ideas....Click here.
FlyAsh produced at Coal based ThermalPowerPlant, is a resource material for Cement industry and building products manufacturing units. It is also being used as one of construction material in Road and Fly over embankment construction and thus helping to save earth and degradation of good agricultural land. Sustainable FlyAshutilization is one of the thrust areas of its activities at all NTPCs Coal based PowerPlants. To give momentum for FlyAsh utilization, separate Ash Utilization Group was set up in 1991. Now, at all Coal based stations are having dedicated group responsible for Ash utilization activities and the group strives to achieve 100% Ash utilization on sustainable basis.
1.0 Efforts for Maximizing FlyAsh Utilization:
1.1 Supply of FlyAsh to Cement Industry:
To make dry FlyAsh available to users, suitable dry FlyAsh extraction and storage silos have been installed at all Coal based ThermalPowerPlants (TPPs) of NTPC. Further, to facilitate bulk transportation of FlyAsh through Railway wagons, which is presently cheapest option for bulk transportation, Rail loading facilities have been developed at Kahalgaon, Ramagundam, Rihand, Mouda, Simhadriand Korba TPS. Such system is also under installation at Sipat, Vindhyachal, Talcher-Kaniha, Solapur, Kudgi, Meja, Khargone, Lara, Darlipalli and Gadarwara TPS.
Bulk transportation of FlyAsh through Railway: To start bulk transportation of FlyAsh in closed and environment friendly manner through Railway wagons, NTPC has signed an agreement with Indian Railway under SFTO (Special Freight Train Operator) scheme andpurchasedthree BTAP wagon rakes. Now, FlyAsh supply in BTAP rakes has been started from Rihand to CementPlant located in Maihar region. FlyAsh is also being brought to demand centre like NTPC-Dadri through BTAP wagon rakes from Rihand for supply to Cement industry. NTPC Kahlgaon and Ramagundam are supplyingFlyAsh through Railway wagon rakes on regular basis to Cement industries located in North East States and Gulbarga region respectively. NTPC Mouda has dispatched FlyAsh in BCFC/ BCCW wagon rakes to CementPlant located in Gulbarga Region. Recently, FlyAsh transportation has been started in bags from Vindhyachal and Barauni TPPs also. NTPC Rihand, Mouda and Simhadri TPPs have also dispatched FlyAsh in BOXN wagons on trial basis to CementPlants and efforts are being made to start supply from these stations on regular basis.
1.2 Use of FlyAsh bricks:
To promote use of FlyAsh bricks in building construction, NTPC has set up FlyAsh brick manufacturing Plants at its Coal based ThermalPowerPlants and FlyAsh bricks are being manufactured on regular basis. These bricks are being utilized in Plant as well as township construction activities exclusively. On an average total about 60 million FlyAsh bricks are being manufactured annually by NTPCs own FlyAsh brick Plants.
As per the MoEF&CC directives, NTPC stations are keeping at least 20% of total FlyAsh produced in reserve for issue toFlyAsh brick/ blocks/ tiles manufacturers and issuing FlyAsh free of cost to them. About 9% of total FlyAsh produced in NTPCs stations, is being utilized by FlyAsh bricks/ blocks and tiles manufacturing units annually.
1.3 Supply of pond Ash for Road/ Fly over construction projects:
Ministry of Environment, Forests and Climate Changes (MoEF&CC), Govt. of India vide its Gazette Notification dated 25-01-2016, stipulates that the cost of transportation of Ash for Road construction projects within a radius of 100/ 300 km shall be borne/ shared by TPPs. The said notification also mandates that TPPsshall within a radius of 300 km bear the entire cost of transportation of Ash to the site of Road construction projects under asset creation program of Government. NTPC stations are complying to this mandate and large quantity is being supplied to NHAI/ State government Road projects through MoU route with NHAI/ State government Road construction department as well as supplying by engaging own Ash transporter through the transparent bidding procedure.
In the year 2019-20 more than 12.9 million ton Ash was supplied to various Road&Highway construction projects of NHAI/ State Governments. In the year 2020-21, 15 NTPCs station are supplying Ashto variousRoad projects and Ash utilization is expected to cross by 20 million ton.
1.4 Use of Ash in reclamation of Mine Voids:
Reclamation of Mine voids using Ash is one of the area where large quantity of Ashcan be utilized on sustainable basis and reclaimed area can be developed into green land through afforestation. Reclamation of Mine void filling at NTPC Talcher-ThermalPower station has been carried out since 2005 onwards after getting due clearances from Odisha State Pollution Control Board and subsequently from Expert Committee of MoEF& CC. Station has also carried out environmental studies as directed by Expert Committee of MoEF&CC and based on the results of all studies, Committee as well as National Green Tribunal has expressed that reclamation of Mine voids can be one of the permissible avenue for sustainable utilization of Ash.
NTPC is also doing Mine void filling with Ash from its Korba TPP to ManikpurMine voids on regular basis. Further, Bottom Ash is being utilized in stowing of Surakachar underground Mine in Korba area. This activity is helping Minecompany to extract more Coal from underground Mine. At Ramagundam, Bottom Ash is being issued to Singareni Collieries Company Limited for stowing of Srirampur underground Mine. NTPC Talcher-Kaniha has also been allocated JaganathMine voids and necessary infrastructure & pipeline laying is being carried to start MineAsh filling in the voids. NTPC Vindhyachal has been allocatedGorbiMine voids for Ash filling. Environmental studies and development of infrastructure are being carried out for taking up Ash filling in this Mine void.
Ash filling along with Overburden material in Operating DulangaMine:
MoEF&CC Gazette Notification mandates for use of atleast 25% FlyAsh on volume to volume basis along with overburden material in external dump as well as upper benches of backfilling of open cast Mine. To demonstrate the use of Ash in this area, NTPC Darlipalli and NTPCs DulangaCoalMine have taken up project in association with Central Institute for Mine and Fuel Research (CIMFR), Dhanbad. Ash filling along with over burden material has been started now.
1.5 New initiatives for FlyAsh utilization
(i) FlyAsh based Geo-Polymer concrete Road:
NTPC has successfully developed FlyAsh based Geo-PolymerRoadconstruction technique and Roads were constructed at Ramagundam, Rihand, Kahlagoan, Farakka TPS for its demonstration. These Road stretches are performing well. Now, Township and CSR Road will be constructed at NTPC stations through this FlyAsh based technology forlarge scale promotion and confidence building.
(ii) To promote use of FlyAsh in Agriculture, NTPC in association with Indian Institute of Soil Science (IISS), Bhopal has taken up long term project titled “Use of FlyAsh in Agriculture for Sustainable Crop Production and Environment Protection”. The results of this study will help to remove doubts amongst agriculturist for safe and beneficial use of FlyAsh in this sector.
(iii) Setting up of Light Weight Aggregate Plant at Sipat is under progress.
(iv) Research and Development (R&D) of FlyAsh based aggregates for concrete in association with VNIT, Nagpur and SVNIT, Surat.
(v) R&D for use of FlyAsh in Gypsum Vermiculate Plaster (GVP) for internal plastering work in association with CBRI, Roorkee.
(vi) NTPC had conducted National level contest on “Grand Challenge on Ash Utilization Ideas” in the year 2018. The first winner’s idea of this contest on FlyAsh based Nano Concrete Aggregate (NACA) - a good substitute for Natural Stone Aggregate (NSA)was demonstrated by constructing 1-BHK 2-storeyed residential building at NTPC Simhadri.
1.6 Awareness and interactive meets with FlyAsh user
NTPC stations are organizing awareness program on FlyAsh utilization as well as interactive meets with FlyAsh users/ customers on regular basis for increasing FlyAsh utilization. Some of the examples are:
- In order to share information’s on various activities being carried out in NTPC as well as other Power utilities, a webinar was organized by Corporate Ash Management Group on 16-10-2020, which was participated by representatives from MoEF&CC, CEA, DVC, Tata Power, MAHAGENCO and Research Institutes like CBRI, Roorkee and VNIT, Nagpuretc.
- NTPC Barh has organized Ash users meet on 20-01-2021, which was participated by representatives from Brick/ Blocks and Cement manufacturers and officials of Road project construction department.
- NTPC Darlipalli has organized Ash users meet on 2nd Feb., 2021 to promote Ash utilizationin and around Sundergarh&Jharsuguda district of Odisha. The invitees of the Ash user meet were representatives of FlyAshBrick manufacturers of the nearby areas and Cement/ Refractory Plants of Sundergarh, Jharsuguda& nearby districts. District Industrial Centre In-charges of Sundergarh.
1.7 Ash Utilization progress at NTPC
The last five years Ash utilization status at NTPC are as under:
Awareness/Training programme/Workshop organised by NTPC stations for spreading awareness in the adjoining area of 100 Kms distance of Power plants for promoting Usage of Fly Ash Bricks in the Construction Sector
In compliance with NITI Aayog directive, workshop/training programmes were conducted in the adjoining rural areas up to 100 Kms distance of the Power Plant, as per following details.
|S.No.||Name of NTPC station||Workshop/Training Venue||Date|
|1||NTPC Sipat||RatanPur ,Dist Bilapur (C.G.)|
|2||NTPC Tanda||Dist. Head quarter ,Basti (U.P.)||29.06.2017|
|3||NTPC Talcher-Kaniha||Odash Stadium ,Khamar.Distt .Angul ( Odisha)||17.07.2017|
|4||NTPC Mouda||At EDC NTPC Mouda||25.07.2017|
|5||NTPC Rihand||At Sirsoti Village|
Distt : Sonebhadra (U.P.)
At Mayur Pur
|6||NTPC Korba||Samudayik Bhawan, Dhanras village, Korba(CG||29.07.2017|
|7||NTPC-Vindyachal||At NTPC Vindyachal Training Center||31.07.2017|
|8||Ramagundam||At Training Centre Ramagundam||26.08.2017|
|9||NTPC Unchahar||At Unchahar||29.08.2017|
|10||NTPC Farakka||Planned on 13.09.2017|
Awareness /Training Programme organized by NTPC Sipat on 28.03.2017 & 31.07.2017
In line with MoEF notification on fly ash utilization-2009 and as amended in 2016,with a view to promote ash utilization in brick manufacturing in surrounding area, a workshop organised by NTPC Sipat at Ratanpur,Distt Bilaspur on 28.03.2017 and at Kawarda (C.G) on 31.07.2017 and was attended 50 participants mainly brick manufactures and Pollution control board authorities. Advantage of fly ash bricks over red bricks were explained in the workshop and methodology of making fly ash bricks were explained. Literature containing information on use of ash in fly ash bricks, high volume ash clay bricks, road embankments, cement concrete and agriculture were distributed among the participants. Workshop was attended by Brick manufacturers and local people along with Distt pollution Control Board authorities.
Approx. 50 participants attended the Workshop at Kawardha from brick manufacturing Units and Local entrepreneurs. In the Workshop, participants demanded compulsory use of fly ash bricks in all Construction activities including Government Construction activities were discussed. Workshop was chaired by Collector Kawardha(C.G.) and transportation of fly ash at brick manufacturing site by Thermal Power stations. NTPC informed that such guidelines for transportation of fly ash to brick units have been finalized by NTPC. NTPC informed that fly ash is available “free of any Charge ” at NTPC stations.
Awareness/Training Workshop at Dist Head quarter Basti ( U.P.) –Organised by NTPC Tanda
A one day workshop on “Ash Brick Manufacturing” was organized on 29th June 2017 by NTPC, Tanda at District Headquarter Basti (U.P.) . The workshop aimed at creating awareness among entrepreneurs/local villagers about various fly ash brick technologies and motivating new entrepreneurs to set up ash brick plants. The workshop was also conducted to bring together different manufacturers involved on a common platform to discuss problems and their probable solutions .The workshop was attended by more than 50 participants including ash brick manufacturers, new entrepreneurs etc. In workshop brick manufacturing methodology was explained and stressed over making quality bricks . NTPC informed that fly ash is available “free of any Charge ” at NTPC stations.
Awareness /Training Workshop organised by NTPC Talcher –Kaniha on 17.07.2017
An awareness programme on Fly Ash Brick was organized by NTPC Talcher Kaniha at Odash Stadium, Khamar on 17.07.2017.The programme was chaired by Suman Minz, Addnl. Tahasildar Pallahara in presence of Smt. Rashmita Priyadarsini, SPCB Official, Angul Regional Office and Shri A.K.Kamilla, AGM(EMG/AU),NTPC Kaniha.
The programme was attended by fly ash brick manufacturers, brick users as well as masonry workers. About 120 persons participated in the programme.
Participants who have used fly ash bricks shared their views on their experience. Participants queries were clarified by the guests regarding the longevity of the ash brick as well as its strength. Addnl. Tahasildar, Pallahara Suman Minz, speaking on this occasion shared the benefits of use of fly ash brick and impact of clay bricks on environment. In his brief talk, he emphasized on the use of fly ash brick in construction activities.
Dy. Engr, Odisha State Pollution Control Board, Angul Regional Office, Smt. Rashmita Priyadarsini, elaborated on the advantages of fly ash brick in respect of its cost effectiveness and quality. She stressed on manufacturing bricks according to BIS in order to maintain quality of the bricks and to gain confidence of the users to opt for ash bricks instead of clay bricks. NTPC informed that fly ash is available “free of any Charge” at NTPC stations.
Awareness /training workshop at EDC Mouda –Organised by NTPC Mouda on 25.07.2017
A one day workshop on “Ash Brick Manufacturing” was organized on 25th July 2017 by NTPC, Mouda, at Training Center. The workshop aimed at creating awareness among entrepreneurs about various fly ash brick technologies and motivating new entrepreneurs to set up ash brick plants . The workshop was also conducted to bring together different manufacturers involved on a common platform to discuss problems and their probable solutions .The workshop was attended by more than 40 participants including ash brick manufacturers, new entrepreneurs etc.
The workshop was inaugurated by Mr. A.K.Nanda, GGM, NTPC -Mouda welcoming all the participants and faculty members. AGM, Ash Utilization, delivering the welcome address, highlighted on the various uses of fly ash thereby transforming a waste into a profitable resource, if used judiciously. Workshop was also addressed by GM (O&M), NTPC MOUDA, Mr K.S.RAO who emphasized for ash use in manufacture of cement, concrete, concrete products, bricks/ tiles etc. as well as for construction of roads, embankments, dams, dykes or for any other construction activity. GM(O), NTPC Mouda while addressing the participants briefed about the advantages of joining this business and assured for all kind of support for entrepreneurs interested to use fly ash for brick manufacturing purpose. NTPC informed that fly ash is available “free of any Charge” at NTPC stations
Awareness /Training workshop organised by NTPC Rihand on 28.07.2017 & 09.08.2017
A one day workshop on “Ash Brick Manufacturing” was organized on 28th July 2017 by NTPC, Rihand at Sirsoti, Distt Sonebhadra (U.P.) and on 09.08.2017 at Mayurpur Block of Distt Sonebhadra(U.P.) The workshop aimed at creating awareness among entrepreneurs about various fly ash brick technologies and motivating new entrepreneurs to set up ash brick plants The workshop was also conducted to bring together different manufacturers involved on a common platform to discuss problems and their probable solutions .The workshop was attended by more than 50 participants including ash brick manufacturers, new entrepreneurs ,local villagers etc.
Advantage of fly ash bricks over red bricks were explained in the workshop and methodology of making fly ash bricks were explained. Literature containing information on use of ash in fly ash bricks, high volume ash clay bricks, road embankments, cement concrete and agriculture were distributed among the participants. Workshop was attended by Brick manufacturers and local people along with Distt pollution Control Board authorities. NTPC informed that fly ash is available “free of any Charge” at NTPC stations.
Awareness /TrainingWorkshop organized by NTPC Vindyachal on 31.07.2017
Awareness workshop on manufacturing and use of fly ash bricks has been organized at NTPC Vindhyachal on 31.07.2017. Total 57 participants have participated in above workshop on 31.07.2017.
In the open house, NTPC Vindhyachal has described in detail regarding best practices of fly ash brick manufacturing, ideal raw mix design etc. for production of good quality bricks so that it may be well accepted by the community at large. Additionally, case studies have been discussed by various ash brick manufacturers on the following topics:
- Problem faced by them during ash brick manufacturing process and modification made by them in their raw mix design and manufacturing process.
- Testing of their fly ash brick samples.
- Method adopted by them regarding marketing of their ash bricks.
- Cost of ash brick production.
- Ideal practices to be followed while handling of ash bricks to avoid breakage.
- Practices to be adopted while constructing a wall with ash bricks.
- Photographs of the houses constructed with only fly ash bricks have also shown in the workshop along with the screening of NTPC video of fly ash bricks. NTPC informed that fly ash is available “free of any Charge” at NTPC stations.
The awareness program of NTPC/Korba regarding ash brick was held on 29.07.2017 at Samudayik Bhawan, Dhanras village, Korba(CG). In this program representative of CECB, Korba Shri Manik Chandel and Ex. Sarpanch Shri Chhatrapal Singh Kanwar along with around 50 villagers participated. Shri S.K. Sanbad, Shri Sudhir Kumar Agarwal and Shri V.R. Thakur from NTPC side were present in this awareness program, where in the details of ash brick manufacturing, its utility, better quality/strength over red brick and its price were discussed. An effort was also made to motivate the people to manufacture ash brick & use the same and make a source of earning. Shri Manik Chandel and Shri Chhatrapal Singh Kanwar also expressed their view about quality ash brick being manufactured by NTPC/Korba and to make extensive use of them. NTPC informed that fly ash is available “free of any Charge” at NTPC stations.
AWARENESS /TRAINING WORKSHOP AT NTPC Ramagundam on 26.08.2017
Awareness programme organised by NTPC Ramagundam on 26.08.2017 at Training centre at Ramagundam. Approx. 50 participants from clay brick manufacturers and fly ash brick manufacturing units attended the programme. The methodology of making quality bricks was explained in the workshop and participants were informed that fly ash is available “free of any Charge ” at NTPC Ramagundam.
AWARENESS /TRAINING WORKSHOP AT NTPC UNCHAHAR on 29.08.2017
Awareness /Training workshop organised by NTPC Unchahar on 29.08.2017 at Unchahar/ Approx. 50 participants from clay brick manufacturers and fly ash brick manufacturing units attended the programme. The methodology of making quality bricks was explained in the workshop and participants were informed that fly ash is available “free of any Charge” at NTPC Unchahar.
The Ministry of Environment & Forests (MoEF), Govt. of India vide its notification (amendment) dated 3rd Nov 2009 has made it mandatory:
Major Projects where fly ash has been utilised
Within 100 Km radius of a Thermal Power Plant
- To use fly ash based building products such as cement or concrete, fly ash bricks, blocks, tiles etc. in all construction projects
- To use fly ash in road or flyover embankment construction
- To use fly ash in reclamation of low lying areas
Within 50 Km radius of a Thermal Power Plant (By Road)
- To use fly ash in back filling of underground and open cast mines
Financial institutions to include a clause in their loan documents for compliance of this notification
Road Embankment Construction & Filling Works:
- 67 lakh Cubic Meters (Cu.M) of pond ash from NTPC Unchahar Station has been utilised in Allahabad By-pass Road executed by NHAI.
- 20 lakh Cu.M of pond ash from NTPC Badarpur Station has been used in Noida - Greater Noida Expressway
- About 1.5 lakh Cu.M of pond ash from Indraprastha thermal power station has been utilised in 2nd Nizammudin approach road embankment
- About 5.0 lakh Cu.M of pond ash from NTPC Badarpur Station has been utilised in Yamuna Expressway & Badarpur Flyover
- More than 15 lakh Cu.M of pond ash has been used by Delhi Metro Rail Corporation (DMRC) in their Shastri Park rail car depot from NTPC Badarpur Station.
- Fly ash from NTPC Dadri Station is being utilised in all underground concrete works by DMRC for its metro projects in Delhi.
- Fly ash is being utilised by all Ready Mix Concrete (RMC) Plants
- Fly ash used by ACC Ltd. in concrete road at its RMC Plant in Greater Noida
- Fly ash used in concrete road construction from Dehra Jhal to NTPC Dadri
Building Construction Works:
- Administrative Building of Greater Noida Industrial Development Authority (GNIDA) constructed with fly ash bricks.
- NTPC’s own Buildings constructed with fly ash bricks
- NETRA office at Greater Noida
- 'D' Type residential quarters at Noida Township
- Northern Region Headquarter building at Lucknow
- All Projects and Township construction
- Private real estate developers in various metro cities viz. Pune, Visakhapatnam & NCR areas use fly ash bricks for construction of residential complexes.
- South Balanda Mine being filled with ash from NTPC Talcher-Thermal Station.
NTPC is constantly looking at innovative and new ways to utilise the ash generated. Following research studies have been / are being conducted for development of new segments having long term potential of ash utilisation:
To demonstrate use of ash in construction of railway embankment, research study was carried out in association with the Central Road Research Institute (CRRI), New Delhi. The design of railway embankment developed by CRRI was validated by conducting Centrifuge Model Tests at IIT Bombay. Construction of railway embankment for NTPC’s Merry Go-Round (MGR) rail track for coal transportation is planned at NTPC Kahalgaon and NTPC Talcher-Kaniha.
- Feasibility study is being conducted at Talcher-Kaniha by M/s Desien for finalising the techno economically optimum mode of transporting ash from power plant to mines on long term basis. Infrastructure shall be created accordingly for filling of mines with fly ash from NTPC Talcher- Kaniha.
- Research study is being done by the Central Institute of Mining & Fuel Research (CIMFR), Dhanbad for taking up technology demonstration project for random filling of ash from NTPC Ramagundam with Mine over Burden (MOB) at Medapalli Mines.
Pre-stressed Railway Concrete Sleepers:
Use of fly ash in the manufacture of pre-stressed railway concrete sleepers demonstrated in association with IIT Kanpur.
Ash based Bituminous Road:
Demonstration project for construction of fly ash based bituminous roads have been taken up in association with CRRI at NTPC Badarpur and Dadri.
Flux bonded Bricks/Tiles:
Research study for use of fly ash in flux bonded bricks/tiles has been conducted at NTPC Ramagundam, in association with NIIST Trivandrum.
Use of fly ash in manufacturing of HDPE products taken up by Vindhyachal through IIT Delhi.
Showcase Projects on use of Ash in Agriculture:
Use of fly ash in agriculture, as a soil modifier and source of micro and macro nutrients, has been successfully demonstrated through “Show case projects” in collaboration with the local farmers under the direct guidance of reputed agriculture institutions/universities.
- At NTPC Simhadri in association with Annamalai University
- At NTPC Unchahar in association with N.D University of Agriculture & Technology, Faizabad (U.P)
- At NTPC Talcher – Thermal in association with Annamalai University
- At NTPC Vindhyachal in association with Annamalai University
- At NTPC Dadri in association with Annamalai University
Various crops have been grown and harvested in varying agro-climatic conditions and different soil-crop combinations and following increase in crops yield has been successfully demonstrated:
|S.No.||Name of Crop||Increase in Yields|
|1||Wheat||16 - 22%|
|2||Paddy||10 - 15%|
|3||Sugarcane||20 - 25%|
|4||Banana||25 - 30%|
|5||Maize||More than 30%|
|6||Vegetables||10 - 15%|
The AUD is constantly at work to promote and popularise multifaceted utilisation of fly ash as a resource material in various segments and to create awareness among the prospective users & entrepreneurs for the use of ash. It organises regular workshops and lecture series for potential users.
Here are some of the campaigns undertaken by them in the recent past:
- NTPC Guide for Users of Coal Ash
- Fly Ash Bricks – Modern Building Material; Towards Cleaner Environment
- Fly Ash for Cement Concrete – A Resource for High Strength and Durability of Structure at Lower Cost
For awareness creation advertisements in National dailies are released from time to time on various application of fly ash such as: