PRESENTATION ON

FLY ASH UTILISATION

A SUCCESS STORY OF Dr. NARLA
TATA RAO THERMAL POWER
STATION
1
 FORMATION OF APGENCO

ANDHRA PRADESH POWER GENERATION CORPORATION

LIMITED (APGENCO) WAS FORMED FROM ERSTWHILE

APSEB UNDER ANDHRA PRADESH ELECTRICITY

REFORM ACT 1998 ON 01-02-1999 WITH THE
PRINCIPAL OBJECTIVE OF ENGAGING IN THE BUSINESS
OF GENERATION OF ELECTRICITY IN ANDHRA PRADESH

2
 ROLE OF APGENCO

• Responsible for
– Operation and Maintenance of all existing
generating stations and those under construction
by APGENCO
– Setting up new thermal and hydro power stations
– Refurbishment, renovation and modernization of
Existing Thermal Power Stations

3
INSTALLED CAPACITY AT Dr.NTTPS

Station Unit Capacity Date of

(MW) Commissioning
VTPS Stage-I 1 210 01.11.1979
2 210 10.10.1980
Stage-II 3 210 05.10.1989
4 210 23.08.1990
Stage-III 5 210 31.03.1994
6 210 24.02.1995
Stage-IV 7 500 Under Construction
and programmed for
commissioning
during March 2009

4
 AWARDS WON BY Dr.NTTPS
Productivity Economic
Year Award Operation Award Award Received Medal Received
( Rs lakhs ) ( Rs Lakhs)

1994-95 11.99 13.73 Productivity Award Gold

1995-96 12.14 13.73 Productivity Award Gold
1996-97 13.00 13.55 Productivity Award Gold
1997-98 10.40 9.18 Productivity Award Gold
1998-99 9.37 4.97 Productivity Award Gold
1999-00 11.72 6.01 Productivity Award Gold
2000-01 21.15 12.50 Productivity Award Gold
2001-02 21.15 12.50 Productivity Award Gold

VTPS qualified for meritorious productivity award for 19th

consecutive year since 1983-84. VTPS stood No.1 in India during
5
1997-98 and 2001-02 for achieving highest PLF.
 FLY ASH UTILISATION AT
Dr.NTTPS DURING 1998-99 TO 2007-08

Year Fly Ash Generated Fly Ash Utilized % Fly ash

Utilization
1998-99 2352168 134006 5.7
1999-00 2322006 230826 9.9
2000-01 2383835 364297 15.3
2001-02 2269322 333536 14.7
2002-03 2245792 464915 20.7
2003-04 2075830 840095 40.5
2004-05 2095569 1038492 49.6
2005-06 2116538 1112444 52.6
2006-07 2216472 1150176 51.9
2007-08 2391434 1832324 76.6
6
 ASH UTILISATION AT
Dr.NTTPS DURING 1998-99 TO 2007-08

Year Ash Generated Ash Utilized % ash Utilization

1998-99 2940210 134006 4.6
1999-00 2902507 230826 7.9
2000-01 2979794 540897 18.2
2001-02 2836653 333536 11.8
2002-03 2807240 538990 19.1
2003-04 2594788 957039 36.9
2004-05 2619461 1207814 46.1
2005-06 2645673 1500547 56.7
2006-07 2770590 1726535 62.3
2007-08 2989293 2018974 67.5
7
 MAIN FACTORS FOR SUCCESS

• Dry fly ash collection, storage and delivery systems are

installed along with main equipment.
• Better quality of fly ash from VTPS strengthened initial
confidence among users.
a) Proper grinding of coal is ensured
b) Optimum combustion of coal in furnace is ensured by
continuously monitoring the air flow, fire ball etc. This has
resulted low un-burnt carbon in the fly ash
• Availability of Cement plants of installed capacity 18.64 million
tons per annum nearer to the project.
• Arranged the staff in shifts round the clock.

Contd.. 8
 MAIN FACTORS FOR SUCCESS

• Early understanding of advantages of fly ash.

• Best efforts in dissemination of technical and financial
benefits of fly ash among users
(Through Press, Seminars, Circulation of material, IS
codes etc.).
• Practical demonstration of fly ash products (By
installing fly ash brick plants, using fly ash for roads,
studies on fly ash for agriculture through ANGRAU).
• MOUs with cement plants for up-gradation of dry
ash handling systems.

Contd.. 9
 MAIN FACTORS FOR SUCCESS

• Encouraging brick manufacturing units by providing certain

priorities. In addition to this, Government housing schemes
encouraged the brick manufacturing units to utilize more
quantity of ash.
• There is considerable demand from several eco-friendly
housing schemes.
• As the demand for fly ash is more than the availability, some
cement companies are lifting pond ash also for manufacturing
PPC.
• Cement companies are insisted to carry fly ash in closed
tankers instead of open tankers to minimize the ash pollution.

10
ORIGINAL DRY FLY ASH SYSTEMS INSTALLED
ALONG WITH MAIN EQUIPMENT
Unit No. Method of Collection Efficiency of the
System
1 Vacuum - Hydrovector 30%
2 Vacuum - Hydrovector 30%
3 Vacuum - Hydrovector 30%
4 Vacuum - Hydrovector 30%
5 Vacuum + Pressure 100%
6 Vacuum + Pressure 100%

Due to availability of dry ash handling facilities ash utilization

started from beginning but quantity of utilization was less. It
picked up gradually due to various other measures.
11
 BETTER QUALITY OF FLY ASH
The fly ash collected from field wise and got tested. The field wise
characteristics are as follows.
Field Specific surface area cm2/gm

1st Field Around 2600

2nd Field Around 3200
3rd Field Around 4500
4th Field Around 4600
5th Field Around 6000
6th Field Around 6400

The Cement Companies & Asbestos Industries started using fly ash from
2nd & 3rd fields for manufacturing PPC and Asbestos sheets respectively.
The demand from brick units was less.
12
Cenospheres are also issued from the ash ponds of other stations
 USE OF FLY ASH FOR PPC
COMPLIANCE OF IS-SPECIFICATIONS
CHEMICAL PARAMETERS OF FLY ASH
Constituent Test results IS 3812
Dr. NTTPS requirement
SiO2 72.3 35.0 min
SiO2 + Al2O3 + Fe2O3 90.1 70.0 min
MgO 1.65 5.0 max
Total sulphur as SO3 1.24 2.75 max
Alkalies as Na2O - 1.5 max
Loss on Ignition (LOI) 0.29 12.0 max

Above figures in percentage by mass

13
 USE OF FLY ASH FOR PPC
COMPLIANCE OF IS-SPECIFICATIONS
Contd..
PHYSICAL PARAMETERS OF FLY ASH
Property Test value IS 3812 & IS
Dr. NTTPS 1489
requirement
Fineness cm2/gm 3700 3200 min
Lime Reactivity N/mm2 5.3 4.0 min
Drying shrinkage % 0.008 0.15 max
Autoclave expansion % 0.015 0.80 max

14
CEMENT PLANTS NEARER TO Dr.NTTPS
Name of the Cement Plant Installed
Capacity
(MTPA)
M/s The India Cements Ltd 4.80
M/s My Home Industries Ltd 2.76
M/s Sri Vishnu Cements Ltd 2.16
M/s Madras Cements Ltd 2.00
M/s Rain Commodities Ltd 1.10
M/s Andhra Cements Ltd 1.02
M/s Penna Cement Industries Ltd 1.00
M/s NCL Industries Ltd 0.85
15
Contd..
 CEMENT PLANTS NEARER TO Dr.NTTPS

Name of the Cement Plant Installed

Capacity
(MTPA)
M/s Deccan Cements 0.80
M/s Ckoramandal Cements Ltd 0.72
M/s Parasakti Cement Ind. Ltd 0.54
Others 0.89
Total 18.64

16
 DISSEMINATION OF TECHNICAL
INFORMATION
Information on Technical and financial benefits of fly ash was
disseminated through following means
• Press notifications
• Seminars
• Circulation of IS codes and technical information to various
Govt departments like R&B, PR, Irrigation, Public Health,
NHAI and other organizations. Requests made to incorporate
fly ash based material and rates in the SSRs.
• Exhibitions
• Electronic media
• Appeals made to Govt. & APPCB to give directions to use fly
ash based materials.
• APGENCO succeeded in bringing GO from GOAP regarding
use of PPC and fly ash based materials by all departments.
17
 IS CODES ON FLYASH

• IS codes on flyash and flyash based materials such as

IS 1489 (Part 1), IS 3812-1981, IS 12330-1988 IS
1727-1967 etc are collected and communicated to all
Govt departments for implementation.

18
PRACTICAL DEMONSTRATION OF FLYASH
BASED PRODUCTS
• Guidelines to all stations under APGENCO to use fly ash for in-house
consumption.

• High volume fly ash concrete roads are laid.

• Mix proportions are communicated to use fly ash for various concrete &
brick works

• Fly ash brick plants are installed at all the Thermal plants to infuse
confidence among private brick manufacturers.

• Studies on fly ash for agriculture were done through ANGRAU.

19
 USE OF ASH FOR AGRICULTURE
Field tests using fly ash was conducted in 10 districts in Andhra
Pradesh during last 3 years to establish the increase of yield and
other benefits using fly ash transport subsidy given by Agriculture
Department, Andhra Pradesh.

Sl.No Year No. of Plots Amount subsidy

(Rs.)
1 2002-03 5000 75 lakhs
2 2003-04 1000 15 lakhs
3 2004-05 1000 11.75 lakhs

The field studies indicate increase of yield but final results are yet
to be received.

20
 RESEARCH STUDIES THROUGH ANGRAU
Research studies through 4 research stations of Acharya N.G. Ranga
Agricultural University, Hyderabad are taken up for different crops.

Sl.No Research Station Crops TPS covered

1 ARS, Vuyyuru a) Sugarcane VTPS
b) Rice
2 ARS, Ashwaraopet Mango KTPS
3 ARS, Utukur Maize RTPP
4 RARS, Jagtial Rice RTS

21
 RESEARCH STUDIES THROUGH ANGRAU
Contd..
Increase of yield in tons/Ha is reported as follows.
Treatments Maize at Rice at Rice at
Utukur Jagtial Vuyyuru
1) Farmers practice (FP) 2.73 6.46 7.3
2) FP + Fly ash at RD 3.65 8.11 7.35

FP: Farmers Practice – NPK 130 : 50 : 0

RD: Recommended Dose of fly ash

Rice : 10 tons/Ha
Maize : 15 tons/Ha

22
 RESEARCH STUDIES THROUGH ANGRAU
Contd..
Results

Application of fly ash to Maize at Utukur increased yield by about

1 ton/Ha over farmers practice

At Jagtial, increase of paddy yield is recorded as 1.65

tons/Ha over farmers practice

At Vuyyuru there is no increase of yield over farmers practice

ANGRAU recommended for long term studies for consistent

results

23
 YEAR 2002 – A TURNING POINT

• Till 2002, major bottleneck in utilization of flyash was

non-utilization of 1st field ash which is significant in
coal based TPS. Utilization of 1st field ash for PPC
started at RTPP by M/s Zuari Cements Ltd,
Yerraguntla and then onwards it got popularized
widely.
• Ash utilization picked up after utilization of 1st field
ash at VTPS.
• Demand has steadily increased.
24
 MOUs FOR UPGRADATION OF EXISTING
DRYASH HANDLING SYSTEMS
• The demand for fly ash was extremely high.
• APGENCO proposed to upgrade the existing systems through
cement companies with the following terms:
a) 80% of flyash extracted from each unit was allocated to cement
companies having MOU with APGENCO for that unit.
b) 100% investment by cement companies
c) MOU period is 10 years
d) After 10 years cement companies will not have any
right on Plant & Equipment installed by them.
By doing so APGENCO saved considerable time in upgradation.

25
 EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-1,3&4
Following equipment installed for each unit

• 48 Nos transfer vessels

• 2 Nos transport air blowers of capacity 28 m3/min with
160 KW motors
• 1 No vent filter of capacity 12000 m3/hr
• PLCC panel
• 2 Nos instrument air compressors of 2 Cum/Min @ 7
kg/cm2

Contd.. 26
 EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-1,3&4

• Necessary valves, bends, laterals, couplings, breakers,

pipes, bag filters, fluidising blowers and other
accessories
• Civil structures, MCC and PLC control room etc

27
 EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-2
Following equipment installed for each unit
3 Nos (2 W+1 S) Mechanical exhausters with guaranteed
capacity of 2800 m3/hr with motor rating 75 KW
• 2 Nos Intermediate transfer tanks
• 2 Nos transport air blowers of capacity 2900 m3/hr with
132 KW motors
• 1 No vent filter of capacity 12000 m3/hr
• PLCC panel with manual operation
• 2 Nos instrument air compressors of 3 Cum/Min @ 7
kg/cm2

Contd.. 28
 EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-2

• Necessary valves, bends, laterals, couplings, breakers,

pipes, bag filters and other accessories
• Civil structures, MCC and PLC control room etc

29
 PERFORMANCE AFTER UPGRADATION
Unit No. Up-gradation completed by Fly ash extraction

1 a) India Cements Ltd 84%

b) Sri Vishnu Cements Ltd
c) Andhra Cements
2 a) Home Industries Ltd 84%
b) Rain Commodities
c) NCL Industries
3 a) Sri Vishnu Cements 93%
b) Visaka Industries Ltd
c) Hyderaba Industries Ltd
d) Sagar Cements
4 M/s India Cements Ltd 93%
30
 PRESENT ASH UTILISATION DURING
2008-09

Sl. Month Fly Ash Fly ash % Fly ash

No. Generation in Utilization in Utilization
MT MT
1 April-2008 199447 163646 82.0
2 May-2008 189329 155328 82.0
3 June-2008 201600 189342 93.9
4 July-2008 206427 176684 85.6
5 Aug-2008 197630 166403 84.2
6 Sep-2008 190709 158984 83.4

31
32
 Fly Ash Utilization at other stations of
APGENCO
Year RTPP KTPS V RTS ‘B’
Installed capacity 420 MW 500 MW 62.5 MW
1997-1998 1006040 1043409 107253
Ash Produced
Ash Utilised 4952 - -
% Utilised 0.5% - -
1998-1999 1162744 1159713 108165
Ash Produced
Ash Utilised 12385 - -
% Utilised 1.07% - -
1999-2000 1241078 993495 132401
Ash Produced
Ash Utilised 162044 - -
% Utilised 13.05% - - 33
 Year RTPP KTPS V RTS ‘B’

2000-2001
Ash Produced 1176004 796940 139605
Ash Utilised 126193 - 2400
% Utilised 10.73% - 1.50%
2001-2002
Ash Produced 1005552 1085236 127524
Ash Utilised 188896 17023 2525
% Utilised 18.8% 1.6% 2%
2002-2003
Ash Produced 976302 1220469 112237
Ash Utilised 315310 44721 23495
% Utilised 32.3% 3.7% 20.9%
34
 Year RTPP KTPS V RTS ‘B’
2003-2004
Ash Produced 892345 1087354 129180
Ash Utilised 369355 296164 23249
% Utilised 41.4% 27.2% 18.0%
2004-2005
Ash Produced 821224 1064937 109400
Ash Utilised 445131 238483 52400
% Utilised 54.2% 22.4%% 47.9%
2005-2006
Ash Produced 603205 895778 106770
Ash Utilised 385588 169207 71943
% Utilised 63.9% 18.9% 67.4%

35
 Year RTPP KTPS V RTS ‘B’

2006-2007
Ash Produced 900307 1199861 93000
Ash Utilised 521459 356154 62391
% Utilised 57.92% 29.68% 67.09%

2007-2008
Ash Produced 1469548 1077312 129317
Ash Utilised 845354 451142 102234
% Utilised 57.52% 41.87% 79.05%

36
 Status of fly ash utilization at NTPC Limited
Name of Installed Coal Ash Fly ash Fly Ash %
TPS Capacity in Consumption Content in Generation utilization Utilization
MW In mtpa % In mtpa In mtpa
Ramagunda 2400 13.05 38.76 4.67 2.88 61.64
m
Simhadri 1000 5.84 38.94 2.27 1.83 71.47
Kahalgoan 1340 5.43 33.98 1.88 0.63 37.09
Korba 2100 12.47 39.57 4.94 3.03 61.44
Badarpur 705 4.09 32.58 1.33 1.08 81.10
Vindhyacha 3260 16.60 30.23 6.02 1.90 37.83
l
Talchar(KA 3000 16.38 37.11 6.82 1.20 17.62
N)
Talchar 460 2.79 38.00 1.06 1.04 98.40
(TPS)
Rihand 2000 10.51 28.90 3.04 1.86 61.10
Singrauli 2000 11.05 32.00 3.61 1.18 32.71
Unchar 1050 5.95 40.13 2.39 2.39 100.00
Tanda 440 2.70 39.07 1.06 0.64 60.87
Dadri 840 4.54 35.73 1.62 1.47 90.72
Farakka 1600 9.47 35.26 3.34 2.71 81.06 37