ASH UTILISATION IN NTPC DADRI

Submitted in partial fulfilment for the degree of

Bachelors of Business Administration
Under guidance of
Mrs Renu

SUBMITTED BY:
Ruchi Verma
0281341706

IDEAL INSTITUTE OF MANAGEMENT AND

TECHNOLOGY,DELHI
ACADEMIC YEAR: 2006-2009
CERTIFICATE

This is to certify that Ruchi Verma of BBA has done this project under my
supervision. She has taken interest and shown sincerity in completion of her
project file of “ASH UTILIZATION IN NTPC DADRI” to my full satisfaction.

Mrs. RENU

INTRODUCTION :
From time immemorial ,great Indian philosophers , thinkers
& saints have emphasized the need for conserving natural
resources & using them wisely . But , with the leaps that
science has taken in the modern times , and coupled with
man’s greed for power , prosperity and prestige , man has
done untold damage to the environment. He has used
development as a means to exploit nature to its maximum ,
not caring a bit for the damage it has done & is doing to the
humanity. The damage that has been done to the
ecosystem & biological diversity is impossible to assess .
Fortunately , it is now being realized all over the world that
man’s greatest need at this hour is to save the planet & it’s
inhabitants . People have now realized that progress in
science & technology should keep pace with sustainable
development. Emphasis should be laid on minimum
consumption so that we leave a healthy & joyful life for our
future generations .
Industrial discharges are important cause of pollution as the
pollutants introduced by the industries are at such high
levels that the ecosystem cannot dissipate them or
decompose them .
Industries thus have a paramount role in rethinking their
processes , evaluating the impact on the environment &
coming up with innovative techniques to mitigate the
damage being made .
OBJECTIVE :

Amongst the various type of industries operating , thermal

power plants are considered to be a major source of
environment hazard .
In our country , NTPC Ltd. is the biggest power major , thus
with this view in mind , it was decided to carry out our study
at NTPC , to assess

• The environment issues / challenges being confronted

• The existence of a well defined environment policy

• The implementation of it’s strategies to achieve the

desired environmental goals .

To carry out the study , a visit was made to Dadri plant of

NTPC , which is treated as a model plant as far as
environment management is considered . During the visit
attention was concentrated on ASH as a pollutant and thus
primarily focussing on the ash generation , its collection ,
disposal & other utilization practices .
 ENVIRONMENT MANAGEMENT

Harmony between man and environment is the essence of healthy

life and growth. Therefore, maintenance of ecological balance and a
pristine environment has been of utmost importance to the Union
Ministry of Power (MoP). NTPC being the leading organization under
the ministry in the areas of power generation, has been taking
various measures discussed below for mitigation of environment
pollution due to power generation.

Environment Policy & Environment Management System

Driven by its commitment for sustainable growth of power, NTPC has

evolved a well defined environment management policy and sound
environment practices for minimising environmental impact arising
out of setting up of power plants and preserving the natural ecology.

National Environment Policy: At the national level, the Ministry of

Environment and Forests had prepared a draft Environment Policy
(NEP) and the Ministry of Power along with NTPC actively participated
in the deliberations of the draft NEP.

The NEP 2006 has since been approved by the Union Cabinet in May
2006.
NTPC Environment Policy: As early as in November 1995, NTPC
brought out a comprehensive document entitled "NTPC Environment
Policy and Environment Management System". Amongst the guiding
principles adopted in the document are company's proactive
approach to environment, optimum utilisation of equipment,
adoption of latest technologies and continual environment
improvement. The policy also envisages efficient utilisation of
resources, thereby minimising waste, maximising ash utilisation and
providing green belt all around the plant for maintaining ecological
balance.

Environment Management, Occupational Health and Safety

Systems:

NTPC has actively gone for adoption of best international practices

on environment, occupational health and safety areas. The
organization has pursued the Environmental Management System
(EMS) ISO 14001 and the Occupational Health and Safety
Assessment System OHSAS 18001 at its different establishments. As
a result of pursuing these practices, all NTPC power stations have
been certified for ISO 14001 & OHSAS 18001 by reputed national and
international Certifying Agencies.

Pollution Control Systems

While deciding the appropriate technology for its projects, NTPC

integrates many environmental provisions into the plant design. In
order to ensure that NTPC comply with all the stipulated environment
norms, various state-of-the-art pollution control systems / devices as
discussed below have been installed to control air and water
pollution.
Electrostatic Precipitators: The ash left behind after combustion
of coal is arrested in high efficiency Electrostatic Precipitators (ESPs)
and particulate mission is controlled well within the stipulated norms.
The ash collected in the ESPs is disposed to Ash Ponds in slurry form.

Flue Gas Stacks: Tall Flue Gas Stacks have been provided for wide
dispersion of the gaseous emissions (SOX, NOX etc) into the
atmosphere.

Low-NOX Burners: In gas based NTPC power stations, NOx

emissions are

controlled by provision of Low-NOx Burners (dry or wet type) and in

coal fired stations, by adopting best combustion practices.

Neutralisation Pits: Neutralisation pits have been provided in the

Water

Treatment Plant (WTP) for pH correction of the effluents before

discharge into Effluent Treatment Plant (ETP) for further treatment
and use.

Coal Settling Pits / Oil Settling Pits: In these Pits, coal dust and
oil are removed from the effluents emanating from the Coal Handling
Plant (CHP), coal yard and Fuel Oil Handling areas before discharge
into ETP.

DE & DS Systems: Dust Extraction (DE) and Dust Suppression (DS)

systems have been installed in all coal fired power stations in NTPC
to contain and extract the fugitive dust released in the Coal Handling
Plant (CHP).
Cooling Towers: Cooling Towers have been provided for cooling the
hot Condenser cooling water in closed cycle Condenser Cooling
Water (CCW) Systems. This helps in reduction in thermal pollution
and conservation of fresh water.

Ash Dykes & Ash Disposal Systems: Ash ponds have been
provided at all coal based stations except Dadri where Dry Ash
Disposal System has been provided.

Ash Ponds have been divided into lagoons and provided with
garlanding

arrangements for change over of the ash slurry feed points for even
filling of the pond and for effective settlement of the ash particles.

Ash in slurry form is discharged into the lagoons where ash particles
get settled from the slurry and clear effluent water is discharged
from the ash pond. The discharged effluents conform to standards
specified by CPCB and the same is regularly monitored.

At its Dadri Power Station, NTPC has set up a unique system for dry
ash collection and disposal facility with Ash Mound formation. This
has been envisaged for the first time in Asia which has resulted in
progressive development of green belt besides far less requirement
of land and less water requirement as compared to the wet ash
disposal system.

Ash Water Recycling System: Further, in a number of NTPC

stations, as a proactive measure, Ash Water Recycling System
(AWRS) has been provided. In the AWRS, the effluent from ash pond
is circulated back to the station for further ash sluicing to the ash
pond. This helps in savings of fresh water requirements for
transportation of ash from the plant.

The ash water recycling system has already been installed and is in
operation at Ramagundam, Simhadri, Rihand, Talcher Kaniha,
Talcher Thermal, Kahalgaon, Korba and Vindhyachal. The scheme
has helped stations to save huge quantity of fresh water required as
make-up water for disposal of ash.

Dry Ash Extraction System (DAES): Dry ash has much higher
utilization

potential in ash based products (such as bricks, aerated autoclaved

concrete blocks, concrete, Portland pozzolana cement, etc.). DAES
has been installed at Unchahar, Dadri, Simhadri, Ramagundam,
Singrauli, Kahalgaon, Farakka, Talcher Thermal, Korba, Vindhyachal,
Talcher Kaniha and BTPS.

Liquid Waste Treatment Plants & Management System: The

objective of industrial liquid effluent treatment plant (ETP) is to
discharge lesser and cleaner effluent from the power plants to meet
environmental regulations. After primary treatment at the source of
their generation, the effluents are sent to the ETP for further
treatment. The composite liquid effluent treatment plant has been
designed to treat all liquid effluents which originate within the power
station e.g. Water Treatment Plant (WTP), Condensate Polishing Unit
(CPU) effluent, Coal Handling Plant (CHP) effluent, floor washings,
service water drains etc. The scheme

involves collection of various effluents and their appropriate

treatment centrally and re-circulation of the treated effluent for
various plant uses.

NTPC has implemented such systems in a number of its power

stations such as Ramagundam, Simhadri, Kayamkulam, Singrauli,
Rihand, Vindhyachal, Korba, Jhanor Gandhar, Faridabad, Farakka,
Kahalgaon and Talcher Kaniha. These plants have helped to control
quality and quantity of the effluents discharged from the

stations.
Sewage Treatment Plants & Facilities: Sewage Treatment Plants
(STPs) sewage treatment facilities have been provided at all NTPC
stations to take care of Sewage Effluent from Plant and township
areas. In a number of NTPC projects modern type STPs with
Clarifloculators, Mechanical Agitators, sludge drying beds, Gas
Collection Chambers etc have been provided to improve the effluent
quality. The effluent quality is monitored regularly and treated
effluent conforming to the prescribed limit is discharged from the
station. At several stations, treated effluents of STPs are being used
for horticulture purpose.

Environmental Institutional Set-up

Realizing the importance of protection of the environment with

speedy development of the power sector, the company has
constituted different groups at project, regional and Corporate
Centre level to carry out specific environment related functions. The
Environment Management Group, Ash Utilisation Group and Centre
for Power Efficiency & Environment Protection (CENPEEP) function
from the Corporate Centre and initiate measures to mitigate the
impact of power project implementation on the environment and
preserve ecology in the vicinity of the projects. Environment
Management and Ash Utilisation Groups established at each station,
look after various environmental issues of the individual station.

Environment Management During Operation Phase

NTPC's environment friendly approach to power has already begun to

show results in conservation of natural resources such as water and
fuel (coal, oil & gas) as well as control of environmental pollution. As
already mentioned earlier, NTPC has chalked out a set of well defined
activities that are envisaged right from the project conceptualisation
stage so that during the entire life cycle of the power plant, NTPC is
fully compliant with various environment regulations and a pristine
environment and ecological balance is maintained in and around its
power station and

townships. Following is brief description of some of the measures

taken during the operation phase of the stations. Performance
enhancement and up-gradation measures are undertaken by the
organisation during the post operational stage of the stations. These
activities have greatly helped to minimise the impact on
environment and preserve the ecology in and around its power
projects. These measures have been enumerated as follows.

Monitoring of Environmental Parameters: A broad based

Environment Monitoring Programme has been formulated and
implemented in NTPC. All pollutants discharged from the power plant
such as stack emission, ash pond effluent, main plant effluent,
domestic effluent and Condenser Cooling Water (CCW) effluent are
monitored at

the stipulated frequency at the source itself and at the points of

discharge. In addition to the above, ambient air, surface water and
ground water quality in and around NTPC plants are regularly
monitored to assess any adverse impacts as a result of operation of
the power plant.

On-Line Data Base Management: In order to have better control

on pollution and to achieve effective environment management in
and around NTPC stations, it is imperative to have an on-line, reliable
and efficient environment information system on the plant
operational and environmental performance parameters at all three
levels i.e generating Stations, Regional Headquarters and Corporate
Centre. In consideration of the above, a computerized programme,
namely "Paryavaran Monitoring System" - PMS, which could provide
reliable storage, prompt and accurate flow of information on
environmental performance of Stations was developed and installed
in NTPC. This software facilitates direct transfer of environment
reports and other environment related information from stations to
the Regional Headquarters and Corporate Centre. The PMS has
already been

implemented at Corporate Centre, the Regional Headquarters and

most of the Stations. This system has helped in achieving continuous
improvement in NTPC’s environment performance through improved
monitoring and reporting system by using the trend analysis and
advanced data management techniques.

Environment Reviews: To maintain constant vigil on

environmental compliance, Environmental Reviews are carried out at
all operating stations and remedial measures have been taken
wherever necessary. As a feedback and follow-up of these
Environmental Reviews, a number of retrofit and up-gradation
measures have been undertaken at different stations.

Such periodic Environmental Reviews and extensive monitoring of

the facilities carried out at all stations have helped in compliance
with the environmental norms and timely renewal of the Air and
Water Consents.

Upgradation & Retrofitting of Pollution Control Systems: In

order to keep pace with the changing norms and ensure compliance
with statutory requirements in the field of pollution control, NTPC
keeps an open mind for Renovation and Modernisation (R & M) and
Retrofitting and Upgradation of pollution monitoring and control
facilities in its existing stations. It is important to mention that such
modifications/retrofit programs not only helped in betterment of
environment but also in resource conservation.
High efficiency Electro-Static Precipitators (ESPs) of the order of
99.5% and above have been provided at NTPC stations for control of
stack particulate emissions. However, the ESPs of a number of
stations were built prior to the promulgation of the Environment
(Protection) Act, 1986 and notification of emission control standards
under this Act. Remedial measures have already been taken up and
implemented to improve the efficiency of the existing ESPs at various
NTPC stations. ESP performance enhancement programme by
adopting advanced microprocessor based Electrostatic Precipitator
Management System (EPMS) was installed at its power stations at
Singrauli, Ramagundam, Korba, Farakka, Rihand, Vindhyachal and
Unchahar. Additional ESPs were retrofitted in the older power
stations, namely at Badarpur and Talcher Thermal. As a result of the
above retrofits, the emission of Suspended Particulate Matter (SPM)
has been brought down appreciably at the above stations and is
maintained within the present statutory limit of 150 mg/Nm3. In new
projects, the ESPs have been designed for a

maximum permissible outlet dust emission of 50 mg/Nm3 to meet

the likely stringent emission norms in the near future.

Resources Conservation

With better awareness and appreciation towards ecology and

environment, the organization is continually looking for innovative
and cost effective solutions to conserve natural resources and reduce
wastes. Some of the measures include:

__ Reduction in land requirements for main plant and ash disposal

areas in

newer units.

__ Capacity addition in old plants, within existing land.

__ Reduction in water requirement for main plant and ash disposal
areas

through recycle and reuse of water.

__ Efficient use of Fuel (Coal, Natural gas and Fuel oil) and

__ Reduction in fuel requirement through more efficient combustion

and

adoption of state-of-the-art technologies such as super critical boilers

Waste Management

Various types of wastes such as domestic wastes, hazardous wastes,

Bio-Medical wastes get generated in power plant areas, plant

hospital and the townships of projects. The wastes generated are a
number of solid and hazardous wastes like used oils & waste oils,
grease, lead acid batteries, other lead bearing wastes (such as
garkets etc.), oil & clarifier sludge, used resin, used photochemicals,
asbestos packing, e-waste, metal scrap, C&I wastes, electricial scrap,
empty cylinders (refillable), paper, rubber products, canteen (bio-
degradable) wastes, buidling material wastes, silica gel, glass wool,
fused lamps & tubes, fire resistant fluids etc. These wastes fall either
under hazardous wastes category or non-hazardous wastes category
as per classification given in Government of India’s notification on
Hazardous Wastes (Management and Handling) Rules 1989 (as
amended on 06.01.2000 & 20.05.2003). Handling and management
of these wastes in NTPC stations have been discussed below.

Municipal Waste Management: Domestic or municipal waste is

generated in households at townships. This waste is segregated into
bio-degradable and non biodegradable wastes at source itself in
different colored containers and thereafter the two types are
disposed separately. Bio-degradable waste is spread uniformly in
identified low lying areas and thereafter it is covered with soil for use
later as manure after composting. The segregated non bio-
degradable waste is disposed off separately in other identified low
lying areas and is spread out

uniformly.

Hazardous Waste Management: NTPC being a proactive

organization, the

handling and disposal of hazardous wastes are done as per the

Hazardous Wastes (Management & Handling) Rules 1989 (as
amended in 2003) guidelines issued by Government of India for the
treatment, storage and disposal of hazardous wastes.

Scientific study on management and handling of hazardous wastes

was carried out at a few NTPC stations to adopt the best practices so
that there is a complete compliance with statutory requirements. In
NTPC sataione, the Hazardous Wastes (Recyclable) are sold /
auctioned to registered recyclers / refiners. The other hazardous
wastes such as the activated carbon resins, used drums (hazardous)
chromium (Cr-III electrolytes, used petro-chemicals, asbestos
packings, used torch

batteries, ribbon, toners / cartridges, mixed wastes (waste oil, water

& cotton) filters, earth contaminated with synthetic oil (FQF) glass
used & sodium silicate, lamps & tubes etc. fall under the category of
Hazardous Wastes (Non-Recyalable).

These wastes are small in quantity and are stored in properly

identified locations.

As per the notification, hazardous wastes (non-recyalable) are to be

sent to State Pollution Control Board (SPCB) approved common
treatment storage and disposal facility (TSDF).
Bio-Medical Waste Management:

Hospital (or Bio-medical) wastes get generated from hospitals and

they include urine bags, human anatomical wastes, plaster of paris
waste, empty plastic bottles of water & glucose, blood & chemical
mixed cotton, blood & urines tubes etc. these wastes are segregated
and are placed in buckets of different colors as per the notification
for Bio-Medical Waste (Management & Handling) Rules. The
segregated bio-medical wastes are either disposed through the SPCB
approved agency or they are treated in autoclaves before disposal
into bio-medical waste disposal pits. The treated bio-medical waste is
spread uniformly and covered with 10 cm thick soil in bio-medical
waste disposal

pits.

Land Use / Bio-diversity

As a policy, NTPC lays special emphasis on land use and Bio-diversity

by way of development of green belts, energy plantations,
reclamation ofabandoned Ash Ponds and EIA and ecological
monitoring in the project areas and its surroundings.

Reclamation of Abandoned Ash ponds: The reclamation of

abandoned ash pond sites is a challenging task. NTPC has reclaimed
temporary ash disposal areas at some of its projects namely
Ramagundam, Talcher Thermal, Rihand, Singrauli and Unchahar
through plantation and converted these sites into lush green
environments. Extensive plantations have also been undertaken on
dry ash mound at NTPC-Dadri. It is planned to reclaim all the
abandoned ash disposal areas by plantation.

Green Belts, Afforestation & Energy Plantations: What’s more,

in a concerted bid to counter the growing ecological threat, NTPC is
undertaking afforestation programmes covering vast areas of land in
and around its projects. Appropriate afforestation programmes for
plant, township and green belt areas of the project have been
implemented at all projects.

In order to enhance green cover in the areas around our projects, as

a responsible corporate citizen, NTPC till date has planted more than
18 million trees at its projects throughout the country. The
afforestation has not only contributed to the aesthetics but also has
been serving as a 'sink' for the pollutants released from the station
and thereby protecting the quality of ecology and environment in
and around the projects. Thrust has also been given to bio-diesel
plantation and around 4.8 lakh energy plants including Pongamia and
Jatropha have already been planted. A pilot project for extraction of
seeds from these bio-diesel plants has also been set

up.

Ecological Monitoring & Scientific Studies

NTPC has been a leader in the industrial sector of India in

undertaking scientific studies related to thermal power generation.
NTPC has pioneered several scientific studies in collaboration with
national/ international institutions to develop an environmental
databank e.g. Detailed Geohydrological Studies to understand the
impact of ash pond leachate on ground water and Ecological Impacts
Monitoring through Remote Sensing Data have been carried out at its
operating stations as

discussed below.

Environment Impact Asssement Studies: Environmental Impact

Assessment (EIA) Studies are inevitably undertaken to evaluate
potential negative impacts as well as to formulate Environmental
Management Plans to overcome the identified impacts. Based on the
recommendations of Environmental Impact Assessment Study and
Environmental Management Plan (EMP) and the conditions stipulated
in the clearances from Ministry of Environment and Forests and State
Pollution Control Boards,

These studies consists of impact assessment in the area of the land

use, water use, socio-economic aspects, soil, hydrology, water
quality, meteorology, air quality, terrestrial and aquatic ecology and
noise. These studies are conducted before starting the construction
as well as after operation of the plant and gives comprehensive
status of the environment as existed before construction as well as in
the post operational stages of the project. The EIA involves stage-by-
stage evaluation of various parameters which affect the
environment. Based on EIA study, wherever required, specific
scientific studies are also conducted to scientifically assess the likely
impact of the pollutants on the sensitive flora and fauna in the
surroundings, as also, to take preventive and mitigatory measures,
wherever required.

Apart from project specific EIA studies, Regional Environmental

Assessment studies have been conducted for Integrated
Development of Singrauli, Korba and Ramagundam areas. Such
studies are of first of their kind in India and probably very few such
studies have been undertaken in other countries.

Socio-economic Studies: Detailed socio-economic studies are

undertaken to establish the socio-economic status of project affected
persons and rehabilitation and resettlement plans are drawn in
consultation with the state government.

Rehabilitation and resettlement options include land for land (subject

to
availability), limited jobs with NTPC and contractors and self
employment schemes.

In addition, NTPC also undertakes community development activities

in the

surrounding villages.

Ecological Monitoring Programme: NTPC has undertaken a

comprehensive

Ecological Monitoring Programme through Satellite Imagery Studies

covering an area of about 25 Kms radius around some of its major
plants. The studies have been conducted through National Remote
Sensing Agency (NRSA), Hyderabad at its power stations at
Ramagundam, Farakka, Korba, Vindhyachal, Rihand and Singrauli.

These studies have revealed significant environmental gains in the

vicinity areas of the project as a result of pursuing sound
environment management practices. Some of these important gains
which have been noticed are increase in dense forest area, increase
in agriculture area, increase in average rainfall, decrease in waste
land etc.

In general, the studies, as such, have revealed that there is no

significant adverse impact on the ecology due to the project
activities in any of these stations. Such studies conducted from time
to time around a power project have established comprehensive
environment status at various post operational stages of the project.

Geo-hydrological Studies: NTPC has conducted several geo

hydrological studies of the ash disposal areas at its projects
(Singrauli, Rihand, Vindhyachal, Korba, Farakka and Talcher) through
reputed institutions like Indian Institutes of Technology, Roorkee;
Indian Institutes of Technology, Mumbai, Centre for Studies on Man
and Environment, Calcutta. All these studies conclude that the
leaching of heavy metals from ash occurs only under pH 4 or below.
In practice, the pH of the

ash water is either neutral or alkaline (7 or above) and hence the

leaching of heavy metals is highly unlikely.

Use of Waste Products & Services -Ash Utilization

Ash is the main solid waste which is put into use for various products
and services.

NTPC has adopted user friendly policy guidelines on ash utilisation.

In order to motivate entrepreneurs to come forward with ash

utilisation schemes, NTPC offers several facilities and incentives.
These include free issue of all types of ash viz. Dry Fly Ash / Pond Ash
/ Bottom Ash and infrastructure facilities, wherever feasible.
Necessary help and assistance is also offered to facilitate
procurement of land, supply of electricity etc from Government
Authorities.

Necessary techno-managerial assistance is given wherever

considered necessary.

Besides, NTPC uses only ash based bricks and Fly Ash portland
pozzolana cement (FAPPC) in most of its construction activities.
Demonstration projects are taken up

in areas of Agriculture, Building materials, Mine filling etc. The

utilisation of ash and ash based products is progressively increasing
as a result of the concrete efforts of these groups.

Advanced / Eco-friendly Technologies

NTPC has gained expertise in operation and management of 200 MW
and 500 MW

Units installed at different Stations all over the country and is looking
ahead for higher capacity Unit sizes with super critical steam
parameters for higher efficiencies and for associated environmental
gains. At Sipat, higher capacity Units of size of 660 MW and
advanced Steam Generators employing super critical steam
parameters have already been implemented as a green field project.

Higher efficiency Combined Cycle Gas Power Plants are already

under operation at all gas-based power projects in NTPC. Advanced
clean coal technologies such as Integrated Gasification Combined
Cycle (IGCC) have higher efficiencies of the order of 45% as
compared to about 38% for conventional plants. NTPC has initiated a
techno-economic study under USDOE / USAID for setting up a
commercial scale demonstration power plant by using IGCC
technology. These plants can use low grade coals and have higher
efficiency as compared to conventional plants.

With the massive expansion of power generation, there is also

growing awareness among all concerned to keep the pollution under
control and preserve the health and quality of the natural
environment in the vicinity of the power stations. NTPC is committed
to provide affordable and sustainable power in increasingly larger
quantity. NTPC is conscious of its role in the national endeavour of
mitigating energy poverty, heralding economic prosperity and
thereby contributing towardsIndia’s emergence as a major global
economy. ASH UTILISATION SCENARIO OF INDIA

 65% of the total installed power generation is coal-based

 230 - 250 million MT coal is being used every year

 High ash contents varying from 30 to 50%

 95 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

Ash utilisation is one of the key concerns at NTPC. The Ash

Utilisation Division, set up in 1991, strives to derive maximum usage
from the vast quantities of ash produced at its coal-based stations.
The division proactively formulates policy, plans and programme for
ash utilisation. It further monitors the progress in these areas and
works at developing new fields of ash utilisation.

The quality of ash produced conforms to the requirements of IS

3812. The fly ash generated at NTPC stations is ideal for use in
cement, concrete, concrete products, cellular concrete, lightweight
aggregates, bricks/blocks/tiles etc. This is attributed to its very low
loss on ignition value. To facilitate availability of dry ash to end-
users all new units of NTPC are provided with the facility of dry ash
collection system. Partial dry ash collection systems have also been
set up at the existing stations where these facilities did not exist
earlier. Augmentation of these systems to 100% capacity is
presently in progress.

As the emphasis on gainful utilization of ash grew, the usage over

the years also increased. From 0.3 million tons in 1991-1992, the
level of utilization during 2007-08 stood at over 23.686 million tons.

The various channels of ash utilization currently include use by a

number of Cement, Asbestos-Cement products & Concrete
manufacturing Industries, Land Development, Roads & Embankments,
Ash Dyke Raising, and Building Products.
Area wise break-up of utilisation for the year 2007-08 is as
under:

Quantity (in Million

Area of Utilisation
Tons)
Land Development6.935
Cement & Concrete8.694
Roads/Embankments
2.277
Ash Dyke Raising 3.886
Bricks 0.140
Mine Filling 0.946
Others 0.808
Total 23.686

NTPC has adopted user friendly policy guidelines on ash utilisation.

These include actions identified for:

 Ash Collection & Storage System

 Facilities & Incentives to Users

 Direct Department Activities

 Administrative & Financial
Aspects.

Major Initiatives Taken By NTPC Towards Ash Utilisation

NTPC continually strives to evolve innovative and diverse means of Ash

Utilisation to further broaden the scope. Prominent among the methods
devised so far are:

 Dry Flyash Extraction Systems

 Use in cement & concrete

 Use in Ash based products including setting up of

 Ash Technology Park

 Land Development/Wasteland Development, Roads &

Embankments, Raising Ash Dykes'

 Mine filling / Stowing

 Agriculture
 Fly Ash Mission Activities

NTPC Guide For Users Of Coal Ash

NTPC, Ash Utilisation Division has brought out a booklet titled 'NTPC
Guide for users of coal ash for distribution amongst prospective
entrepreneurs and users of ash.
Other Promotional literature printed for distribution includes brochures
titled:

 Ash a Resource

 Eco-Friendly Bricks for new Millennium

 Fly ash based Portland Pozzolana Cement

 Coal ash Environment friendly material for fills, Embankments and

Road pavement construction
TYPES OF COAL ASH

Three categories of ash available from thermal power stations.

• Dry Fly Ash : Collected from different rows of Electro-Static-

Precipitators in dry form. Used for manufacture Portland Pozzolana
Cement, Cement concrete & Mortar, Lime fly ash bricks, Building blocks,
Aerated Concrete Blocks, etc.

• Bottom Ash : Collected at the bottom of boiler furnace

characterized by better geo-technical properties. Good material for fill,
road and embankment construction.

• Pond Ash : Fly ash and Bottom ash are mixed together with water
to form slurry-which is pumped to the Ash Pond Area, ash gets settled
and excess water is decanted. This deposited ash is Pond ash; it’s being
used as filling material including embankment and road construction.
Selected pond ash can be used for manufacture of building products like
lime fly ash bricks/blocks.

USES OF COAL ASH

• Construction of embankments and fills.

• Construction of road in base and sub-base course.

• Manufacture of Portland pozzolana cement.

• Cement concrete and mortar as a partial replacement of cement.

• Manufacture of bricks/blocks, aerated concrete blocks, light weight

aggregate.

• Back filling of open cast mines and stowing of under-ground mines.

• Filling as flowable fill material.

• Agriculture as soil amendment/source of essential plant nutrients.

• Manufacture of alum. Paint, ceramics and other high value items.

Coal Ash in Fills & Embankment

Principal Advantages

• Lower density than earth resulting in lower over burden pressure.

• Lower settlement, lower transportation cost as compared to earth.

• Advantageous in weak/clayey sub-soils.

• Hardly any measureable settlement over time due to low

compressibility.

• Speed of construction is faster as it can be compacted in wide

range of moisture content.

• Work can be taken up even in rainy season due to quick draining

properties of loose ash.

• Assured availability free of cost.

• Eco-friendly since it replaces soil taken from agriculture lands.

Road Construction

• Bottom ash can be used directly in sub-base course.

• Fly ash and pond ash stabilized with soil/lime/cement or with

moorum can be used in sub-base and base course material.

• Fly ash can be used as partial replacement of cement & fine

aggregate in rigid pavement.
• Fly ash is can be used as a filler material bituminous concrete used
in base/wearing course.

Manufacture of Portland Pozzolana Cement

• Fly ash is widely utilized in manufacture of fly ash based Portland

Pozzolana Cement (FAPPC) conforming to IS-1489.

• Portland Pozzolana Cement (FAPPC) is equivalent to 33 grade of

Ordinary Portland Cement (OPC) on the basis of 3, 7 and 28 days
compressive strength.

• FAPPC has following advantages over OPC :-

» Improved workability

» Reduced heat of hydration

» Increased Sulphate resistance

» Reduced Alkali-Aggregate Reaction

» Reduced porosity & uniform matrix structure

» Increased corrosion resistance

» Greater long term strength

Use in Fly ash lime bricks

• Fly ash is utilized in manufacture of fly ash-lime bricks.

• Fly Ash Lime bricks have better crushing strength than clay-bricks.

• Fly Ash Lime bricks are more resistant to salinity and water.

• CPWD has incorporated in their specification for use of these bricks

in all types of constructions.
• These bricks are widely used in NTPC and different parts of the
country.

• Fly Ash Lime bricks are becoming popular in Delhi too.

Use of Fly Ash in Cement Concrete

• Fly ash can be utilized in cement concrete and mortar as an

ingredient/partial replacement of cement and sand.

• Use of fly ash in cement concrete improves the properties of

concrete which inter-alia include:-

» Greater long term strength

» Improves workability

» Increased durability

» Reduction in cost of concrete

• Replacement of Ordinary Portland Cement may vary from 15 to

35% or even higher percentage in mass concrete.

• IS 456 : Code of practice for plain and reinforced concrete allows

the use of fly ash as a partial replacement of Ordinary Portland Cement
and sand.

• In developed countries such as USA, UK etc; Fly ash is extensively

used in manufacture of cement concrete.

• Fly ash has been used in foundations, walls, floors, concrete fire
proofing of Sears Towers, the world’s one of the tallest building in USA
and construction of channel link between England and France.

• Fly ash from NTPC’s power stations has been tested and found
suitable for use in cement concrete and mortar.
Light Weight Aerated Concrete Block

• Fly ash is utilized in manufacture of Light Weight Aerated Concrete

products such as blocks, panels, reinforced slabs, etc.

• The products are much lighter than conventional materials.

• Bulk density of product ranges from 500 kg/m3 to 1800 kg/m3

depending upon requirement.

• The use of the blocks in housing construction can results nearly

40% of dead load reduction, 50% saving in construction time and about
80% saving in consumption of mortars in comparison to conventional
brick work.

• These products provide better thermal insulation and sound

absorption property as compare dto conventional works.

Use in Control Low Strength fill Material (CLSM)

• Large quantity of fly ash (90-95%) and small quantity of Ordinary

Portland Cement (5-10%) is mixed with sufficient quantity of water so as
to make flowable fill material termed as Controlled Low Strength
Material (CLSM).

• CLSM is ideal fill material for use in restricted areas where placing
and compaction is very difficult such as back filling of narrow trenches
utilities structure such as mines, tunnels, tanks and trenches in road
pavement cut for laying of utilities etc. It can also be utilized in control
of undesirable growth of elephant grass.

• CLSM provides various advantages which are :-

» Easy to produce, can be filled with minimal efforts.

» No compaction and no curing required.

» Fill all voids and spaces, no settlement after final set, can be dug
back later when required.

» Different strength can be designed depending upon the

requirement.

» Low unit weight, reduced labour cost and thus cost effective.

Other Areas of Utilization

• Fly ash is used in manufacture of Asbestos cement products.

• Fly ash can be used in large quantity in back filling of open cast
mines and stowing of underground mines.

• It can be utilized in Agriculture as soil amendment to modify pH of

soil, soil conditioner to improve physicochemical properties of soil and
as source of essential plant nutrient.

• It can be utilized in manufacture of Alum, Paints, Ceramics and

other high value items.

ECO BRICK

A new environment friendly building material conforming to the

provisions of IS: 12894 issued by Bureau of Indian Standards.

Process

• Eco-Bricks are made by precision machines with semi-dry mix of

high quality fly ash, sand and lime/cement.
• The excellent pozzolanic property of fly ash in presence of
lime/cement and moisture makes Eco-Brick more strong and durable.

• The brick manufactured in this process keeps on gaining strength

continuously for a long time and ultimately it becomes very strong.

Moulding/ Pressing

Hydraulic presses or vibratory presses are used for moulding ensures

uniform size of all bricks / blocks.

Curing

These moulded bricks/ blocks are dried for about 24-48 hours in
shade and then suitably water/ steam cured.

Dry Shrinkage

The average drying shrinkage does not exceed 0.15 percent which is
within limit as per IS specifications.

Efflorescence

The rating of efflorescence for the Eco-bricks when tested as

prescribed by IS:3495 (Part- 3): 1976 is ‘nil` though as per IS:12894,
it can be ‘moderate`.

Water Absorption

The water absorption of Eco-bricks is less than 20% for bricks of Class
designation 7.5. The water absorption for the Eco-bricks of class
designation 10 or 12.5 is less than 15%.

Availability
 The Eco-bricks are available round the year unlike clay bricks, which
aren’t manufacture during monsoon period.

Advantages of Using ECO- BRICK

• As the size of Eco- bricks is uniform with smooth / plain surfaces,

the requirement of mortar for the brick masonry works is about 25%
less than the requirements for clay brick walls.

• The thickness of plaster required is 6 to 10mm in place of 12 to 18

mm for clay brick walls.

• The external walls made with Eco-bricks having absorption less

than 15% can be left un-plastered thus giving a pleasant look and
savings in plastering cost and yearly maintenance cost of building.

• The Eco-bricks are lighter than clay bricks and thus saves cost of
construction.

• The Eco-bricks are environment friendly bricks as it saves

» Degradation of agriculture land required for clay bricks

» Land required for ash disposal.

SALIENT FEATURES OF NTPC - DADRI (ASH

HANDLING PLANT)
• STATION CAPACITY - 840 MW

• COAL CONSUMPTION - 3.66 Million T / Year

• ASH GENERATION - 1.5 Million T / Year

• ASH DISPOSAL - Dry Ash System

• DRY ASH SYSTEM - Vac. Extraction & Pr.

Transportation

• WATER REQMT. FOR - 20 % By Weight

ASH CONDITIONING

• ASH MOUND AREA - 375 Acres

CHEMICAL COMPOSITION OF FLY ASH

• Silica, SiO2 64.57 %

• Allumina, Al2O3 24.08%

• Ferric Oxide, Fe2O3 6.4%

• CaO 0.84-2 %,

• MgO 0.84%

• P2O5 0.15%

• SO3 0.05%

• Na2O 0.36%

• Potassium Oxide 0.55%

• C 0.05%

• pH 8.10

• Bulk Density 0.81 gm/ml

Salient features of installed system

• Extraction & transportation of fly ash in complete dry form.

• System having provision to store selected grade of ash in separate

Silo (Silo-3).

• Complete re-circulation of water for Bottom ash handling system.

• Unloading & Transportation of conditioned ash from Silos & decanted
bottom ash from Hydro bins on to belt conveyors.

• Construction of Ash Mound in a systematic manner.

 FLY ash system

BASICS OF A THERMAL POWER PLANT

The core components of a thermal power plant cycle are

• Boiler

• Turbine

• Electric Generator
The thermal power plants employ steam turbines to run
the generators. The steam required is obtained from a
boiler . A boiler is a closed vessel in which water is put in
tubes & heated until the water converts into steam at the
required pressure . Coal is burnt in the bottom of the
boiler & its heat is used to convert water into steam . The
steam is passed in the turbine to rotate it & the generator
at required speed & generate power.
Efforts are made to enhance the cycle efficiency by
maximum utilization of heat in the system by installing
components like Economizers , Air pre heaters , Feed
water heaters & Super heaters . The function of an
economizer is to recover some of the heat which is being
carried away in the flue gases through the chimney . The
heat extracted is used to heat the feed water being fed to
the boiler for steam generation , thus economizing the
fuel requirement .
Air Pre heaters (APH)are components placed in the flue
gas path before chimney & are used to further extract
heat from the flue gas to heat the air required for
combustion in the burners of the boiler.
The steam produced in the water tubes is still in the
unsaturated form , which is dangerous for the turbine .
Hence the steam is converted into super heated form in a
superheater , installed in the boiler , by using the heat of
the flue gases .
The combustible products are in the form of
1) bottom ash
2) Flue gas.
The bottom ash is removed through bottom ash system
by adding water & transforming it in slurry form , for ease
to be transported at the desired location .
The flue gas of fly ash is removed from the boiler through
high chimneys. The ash / dust in the flue gas is extracted
through various equipments like Electro static
precipitator(ESP), cyclone separator etc. In an ESP , the
gas contaminated by dust is passed into a chamber ,
where the dust particles are negatively charged & then on
passing through an electric field , the dust particles are
attracted to the positively charged collecting plates , thus
preventing the dust to go out to the atmosphere through
the chimney.

Fly Ash System

• The fly ash is evacuated from fly ash hoppers & transported to Ash
storage silos in two steps:

• From the ESP & APH Hoppers to Buffer Hoppers thro’ VACUUM
SYSTEM.

• From Buffer Hoppers to Ash Storage Silos thro’ PRESSURE

SYSTEM.

FLY ASH REMOVAL SYSTEM

Mixed Fly Ash Evacuation
SILO UNLOADING SYSTEM
SILO UNLOADING SYSTEM
Complete Recirculation of Water
in Bottom Ash Hopper Evacuation System

• LP Water :

 LP Pump taking suction from Surge Tank

» Bottom Ash Hopper make-up

» Seal Trough make-up

» Economizer flashing to Coarse Ash Tank

• Over Flow Pump:

 Recycle the LP water to Settling Tank

• HP Water:

• HP Pump taking suction from Surge Tank

» Evacuate Bottom Ash & Coarse Ash and send to Hydrobin

» Hydrobin overflows to Settling Tank

» Settling Tank overflows to Surge Tank

Ash Management in Ash Mound Area

• Ash can be dumped in three different areas in ash mound depending

upon system availability & weather conditions.

• Ash is dumped in “PERMANENT ASH MOUND AREA” normally.

• During Rainy Season or System Non-Availability Ash is

Dumped in “TEMPORARY ASH STORAGE AREA” from where
it is reclaimed to “Permanent Ash Mound Area” thro’
Reclaimer.

• In case of Non-Availability of Systems for Permanent &

Temporary Ash Mound Areas; Ash is transported to
“EMERGENCY STOCK PILE” from where it is reclaimed with
the help of “MOBILE EQUIPMENTS”.
ZONEWISE CONSTRUCTION SEQUENCE OF
ASH MOUND
MOBILE EQUIPMENTS DEPLOYED FOR
CONSTRUCTION OF ASH MOUND
• DOZER D-355 1 NOS.
• DOZER D-155 3 NOS.

• DOZER D-50 2 NOS.

• MOTOR GRADER 1 NO.

• VIBRATORY COMPACTOR 2 NO.

• PAY LOADER 1 NO.

• HYD. EXCAVATOR 1 NO.

• DUMPERS 2 NOS.

• WATER BOWSERS 3 NOS.

• Art. Dump truck 2 Nos.

• Vacuum Truck 1 No.

• Fork Lifter 1 No.

• Hydra 1 No.

• Two Tonne Dumper 1 No.

• Pipe layer(for conv. shifting) 1 No.

• Tractors 2 Nos.

• Omega crane 1 No.

WORKSHOP M/Cs AT ASH MOUND

• Lathe 1 No.

• Shearing M/c 1 No.

• Radial Drilling M/c 1 No.

• Pillar Drilling M/c 2 No.

• Hydraulic Press 1 No.

• Hack Saw M/c 1 No.

SPECIES OF SHRUBS & TREES PLANTED ON

ASH MOUND
• SHRUBS - BOUGAINVILLAEA, GUDHAL , PILI KANER
,JHOUN , INDIGO (Neel) , DEDONIA

• TREES - DALBERGIA - SISOO , BOTTLE-BRUSH, CASURINA ,

SHOO-BABOOL , RAMASAN, KACHNAR , RUBBER , FICUS-
BENJAMINA , GULLAR , PILKHAN , BARGAD , PIPAL , BOMBAX,
SIRUS , TICTONA-GRANDES (TEAK ) , POPELUS ,JAMUN , AMLA,
IMLI, CAMPHAR

Salient Features of Ash Mound

• Total Land Area 500 Acres.(Approx.)

• Actual Ash Mound Area 375 Acres.(Approx.)

• Finished Area at Mound Top 140 Acres.(Approx.)

• Final Height of Ash Mound 55Meters.

• Ash Volume 530 Lakh CuM.

• Drainage Blanket Thickness 1.0 Meters.

• Gradient of Slide Slopes 1:4 & 1:4.5

• Capacity of Temp. Stock Yd. 1,90,000 CuM.

• Capacity of Emergency Yd. 10,500 CuM.

Ash Utilization
ADVANTAGE OF DRY ASH DISPOSAL SYSTEM
• LESS REQUIREMENT OF LAND

• LESS WATER REQUIREMENT

• ELIMINATES UNDERGROUND WATER AND SURROUNDING

WATERWAYS POLLUTION

• FACILITATE LARGE SCALE UTILISATION OF ASH

• PROGRESSIVE RESTORATION OF ASH DISPOSAL SITE AS

USEFUL LAND

CONCLUSION