Fly Ash Utilisation in Odisha

Fly Ash Utilisation Conference, Delhi 15th, March, 2018

Dr. D.K. Behera

Sr. Env. Scientist

State Pollution Control Board, Odisha

Bhubaneswar

Setting up of Fly Ash Resource Centre

(FARC) in SPCB, Odisha (Decision of High Power Committee Chaired by Chief

Secretary, Odisha, July, 2013)

To enhance fly ash utilization in Odisha

To coordinate with TPPs with various sectoral

users

To create awareness for popularization of

FA based construction materials

To promote research and development

Objectives

Growth of Thermal Power in Odisha

Present generation of thermal power

(Coal) 15, 895MW

About 33237 MW different

stages of clearance/

construction.

Power plants are mostly

located near coal mines of Talcher and

Ib Valley

Total capacity

including

pipeline

projected:

49,132MW

Ash Generation from TPPs

Power grade coal in Odisha contains about 35 – 48% of ash.

Specific ash generation is 7-9 MT/day/MW.

Annual ash generation in Odisha is about 32 MTPA

Ash generation likely to increase to about 100 MTPA after commissioning of proposed power plants.

Land Requirement for Ash Disposal

Sl. Disposal method Area in

Ac/ MW

1. Lean slurry disposal with complete recirculation of

water for 25 years life

1.5

2. High density disposal with no utilization for 25 years life 1.0

3. High density disposal with 100% ash utilization by end

of 9th year

0.5

4. High density disposal with 100% ash utilization by end

of 9th year, using washed coal (34% ash)

0.3

5. High density disposal with 100% ash utilization by end

of 5th year

0.25

6. High density disposal with 100% ash utilization by end

of 5th year, using washed coal (34% ash)

0.15

Year Installed Capacity (MW)

Fly ash Generated (Million TPA)

Fly Ash Utilised (Million TPA)

Fly Ash % Utilisation

2005-06 5415.9 11.0 3.1 28.2 2006-07 5655.9 12.16 3.38 27.8 2007-08 5784.2 13.62 3.34 24.5 2008-09 7073.5 15.44 5.41 35.0 2009-10 7742 19.23 8.45 43.93 2010-11 9685 21.18 10.68 50.42 2011-12 11400 23.57 12.77 54.19 2012-13 11980 24.67 14.62 59.29 2013-14 11969 24.44 15.17 62

2014-15 14512 24.69 12.99 52.57

2015-16 15742 27.90 16.39 58.51

2016-17 15895 32.56 22.08 67.66

Till Jan’18 15895 25.51 18.67 73.18

Year wise Thermal Power and Fly Ash Generation in Odisha

Installed Capacity (MW) of Thermal Power in Odisha

0

5

10

15

20

25

30

35

2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

QU

QN

TIT

Y IN

MT

PA

YEAR

Fly Ash Generation, Utilisation & Accumulation in Odisha

Fly ash Generated (Million TPA)

Fly Ash Utilised In (Million TPA)

Unutilized / Accumulation (Million TPA)

Thermal Power Plants in Odisha (2016-17)

Capacity in MW

No of TPPs Total Power Generation in

MW

FA Generation in Million

tonne

% FA

10-50 11 270 1.02 3.13

50-100 10 770 3.66 11.24

100-500 11 3090 6.79 20.89

500-1000 2 1710 2.41 7.4

1000-3000 6 10065 18.67 57.35

Total 40 15895 32.55 100

Fly Ash Generation & Utilisation, Odisha

2012-13

Tons

2013-14

Tons

2014-15

Tons

2015-16

Tons

2016-17 2017-18,

TillJanuary’18

Fly Ash

Generated 246,71158 244,42381 246,95551 279,09495 325,60377 255,19888

Total Ash

Utilisation 146,28506 151,69590 129,91470 163,90911 220,83824 186,76501

% of

Utilisation 59.29 % 62 % 52.61 % 58.73% 67.82 %

73.18 %

979,572 956,871

1,371,993

2,236,318

3,267,858

2,827,006

0

500,000

1,000,000

1,500,000

2,000,000

2,500,000

3,000,000

3,500,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18(Till

Jan'18)

Fly

Ash

Uti

lisat

ion

in

MT

Year

Brick Manufacturing

2012-13

MT

2013-14

MT

2014-15

MT

2015-16 2016-17 2017-18,

Till January’18

9,79572

3.97 %

9,56871

3.91 %

13,71993

5.56 %

22,36318

8.01 %

32,67858

10.04 %

28,27006

11.08 %

Brick Manufacturing

881,449 916,555797,996

1,159,555

1,496,944

1,016,654

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

1,600,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18

(TillJan,18)

Fly

Ash

Uti

lisat

ion

in M

T

Year

Cement

2012-13

MT

2013-14

MT

2014-15

MT

2015-16 2016-17 2017-18,

Till January’18

8,81449

3.57 %

9,16555

3.74 %

7,97996

3.23 %

11,59555

4.15 %

14,96944

4.60 %

10,16654

3.98 %

Cement Manufacturing

33,255

109,935128,775

162,194

124,354

78,487

0

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

180,000

Fly

Ash

Util

isatio

n in

MT

Year

Asbestos

2012-13

MT

2013-14

MT

2014-15

MT

2015-16 2016-17 2017-18,

Till January’18

33255

0.13 %

1,09935

0.45 %

1,28775

0.52 %

1,62194

0.58 %

1,24354

0.38 %

78487

0.31 %

Asbestos Manufacturing

651,955 598,958

1,251,766

1,501,647

2,048,282

1,436,504

0

500,000

1,000,000

1,500,000

2,000,000

2,500,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 (TillJan'18)

Fly

Ash

Uti

lisa

tio

n i

n M

T

Year

Quarry Filling

2012-13

MT

2013-14

MT

2014-15

MT

2015-16 2016-17 2017-18,

Till January’18

6,51955

2.64 %

5,98958

2.45 %

12,51766

5.07 %

15,01647

5.38 %

20,48282

6.29 %

14,36504

5.63 %

Quarry Filling

1,275,8141,245,7041,364,292

1,426,133

1,156,006

1,005,915

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

1,600,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18(Till

Jan'18)

Fly

Ash

Uti

lisat

ion

in M

T

Year

Coal Mine Void Filling

2012-13

MT

2013-14

MT

2014-15

MT

2015-16 2016-17 2017-18,

Till January’18

12,75814

5.17 %

12,45704

5.096 %

13,64292

5.52 %

14,26133

5.11 %

11,56006

3.55 %

10,05915

3.94 %

Coal Mine Void Filling

2012-13

MT

2013-14

MT

2014-15

MT

2015-16 2016-17 2017-18,

Till January’18

25,65309

10.39 %

29,21750

11.95 %

34,35178

13.91 %

59,25198

21.23 %

64,31344

19.75%

56,90853

22.30 %

2,565,3092,921,750

3,435,178

5,925,1986,431,344

5,690,853

0

1,000,000

2,000,000

3,000,000

4,000,000

5,000,000

6,000,000

7,000,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 (TillJan'18)

Fly

Ash

Uti

lisat

ion

in

MT

Year

Dyke Raising

Dyke Raising

2012-13

MT

2013-14

MT

2014-15

MT

2015-16 2016-17 2017-18,

Till

January’18

76,50626

31.01 %

80,13103

32.78 %

44,30075

17.94 %

31,50070

11.29 %

56,58451

17.38 %

48,41305

18.97 %

7,650,6268,013,103

4,430,075

3,150,070

5,658,451

4,841,305

0

1,000,000

2,000,000

3,000,000

4,000,000

5,000,000

6,000,000

7,000,000

8,000,000

9,000,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 (TillJan'18)

Fly

Ash

Uti

lisa

tio

n i

n M

T

Year

Land Development

Land Development

2012-13

MT

2013-14

MT

2014-15

MT

2015-16 2016-17 2017-18,

Till

January’18

5,89126

2.38 %

2,84565

1.16 %

1,96405

0.80 %

7,70569

2.76 %

18,43916

5.67 %

17,77805

6.96 %

589,126

284,565196,405

770,569

1,843,916 1,777,805

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

1,600,000

1,800,000

2,000,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 (TillJan'18)

Fly

Ash

Util

isa

tio

n in

MT

Year

Road Making

Road Making

Locations of TPPs & Blocks within 100 Km

Nos. of Blocks in Odisha – 314

Nos. of Blocks fully covered in 100 Km radius of TPPs – 262

Nos. of Blocks Particially covered in 100 Km radius in TPPs – 27

Initiatives by

Fly Ash Resource Centre (FARC) for utilization of

Fly Ash

Development of Database on Fly Ash generation

and utilization from each TPPs. Composition of FA

from individual TPP w.r.t. IRC Geotechnical

Specifications (SP-58/2001).

Works Dept., Govt. of Odisha has included Fly Ash in

the schedule of rates and tender documents for

road construction.

Coordinate with NHAI, Works dept., CPWD with TPPs

for smooth availability of Fly Ash in road/building

construction Projects.

Cement industries have been requested for enhancing

use of Fly Ash in cement making.

20 Sensitization workshops conducted at different

locations in the State. ( Sector Specific)

TPPs were instructed to supply Fly Ash free of cost to fly

ash based construction material manufacturing units

and for road construction. Further, all thermal power

plants above 100 MW capacity have been instructed to supply fly ash at the user point of road making and

manufacturers of construction materials or provide a

subsidy of Rs.150/- ton of fly ash.

Abandoned mine quarries ,identified by the District

Administrations and TPPs are linked for reclamation.

Third Party Audit of annual Fly Ash Generation and

Utilization by TPP being conducted since 2012-13.

VSSUT, Burla has been engaged to study on the

Environment Impact of Fly Ash disposal sites in

Odisha.

Coordination meetings with TPPs and Concessioner

of NH/SH for smooth availability of fly ash

Simplification of procedure of CTE for land

reclamation

Major Thermal Power Plants have been directed to

construct village / panchayat Road of at least 1 km

using fly ash under CSR activities.

Availability of fly ash (free transportation upto 100 km

or Rs.150/- per tonne) to develop a market. Included in

Consent condition

Proposal for banning clay bricks within 100 km radius

in phased manner.

Exemption of fly ash brick manufacturing units from

Consent Administration

Inclusion of fly ash in tender for road construction

Proposal for Fly Ash Park for construction materials

manufacturing units.

Promotion of use of light weight aggregates and

aerated autoclave blocks. .

Notification (Works Dept.) for use of Fly ash bricks in

in all Govt. construction

Other Promotional Activities

Studies / Report Prepared by FARC- OSPCB

website

Comprehensive Report on Reclamation of Coal

Mine Void with Fly Ash in Odisha

DPR on proposed Fly Ash Park at Angul

Guideline on Fly Ash Utilization in Road

Construction

Guidelines for Reclamation of Low Lying Areas

and Abandoned Quarries with Fly Ash

Guideline on Fly Ash Brick Manufacturing

Guideline on Canal lining

Environmental Impact of Fly ash Ponds/Mounds

FARC- Coordination, Facilitation, Review, Monitoring

and Enforcement

NAVA BHARAT Management of Mine Void / Stone Quarry

Ash Compacting Ash Leveling Ash Dumping

Plantation Top Soil Covering Water Sprinkling

NAVA BHARAT Green Belt at Balanda Mine Void

NAVA BHARAT Park developed at Balanda Mine Void

Lawn Children's Playing Equipment Lawn

Green Lawn Plantation Benches

200 mm thick PCC M-30

100 mm thick PCC M-15

75 mm thick WBM Gr-II + 75 mm thick WBM Gr-III

100 mm thick Granular sub-base

Earth cover MDD=1.94 g/cc

Side

drain

Shoulder

3.75 m 1.0 m 1.0 m

RR Masonry or stone pitching

15 cm 0.6 m

0.6 m

1.0 m

1.0 m

0.5 m

Fly ash or pond ash

Thickness: 1.5/2.0 m

2.0 m

2H:1V

Subgrade

9.95 m

Natural ground level

Demonstration Rural Road Project using Fly

Ash-Vedanta Limited, Jharsuguda , IIT,

Bhubaneswar

=19,875 tonnes

=231.75 tonnes

20,106.75 tonnes

Demonstration Rural Road Project using Fly

Ash-Vedanta Limited, Jharsuguda

Source materia

l

Alkaline

solution AGGREGATES GPC

Final hardened product

NaOH and Na2SiO3

Fine aggregate Coarse aggregate

Fly Ash

Geopolymer Concrete ( IIMT, Bhubaneswar)

40 m Geopolymer Concrete Road, Vedant

Lanjigargh

Light weight aggregates (LWA) made out of fly ash is now a replacement for stone chips.

LWA uses around 90 % of Fly Ash

•Light weight concrete blocks and slabs

•Structural light weight concrete

•Floor and roof slabs

•Highway construction

•Sound proof requirement

Why use Light Weight Aggregate (LWA)

•Reduction in weight - reducing loading

•Improve thermal properties

•Improve fire resistance

•Improve Acoustic Properties

•Improve durability

Indian Standard (IS: 9142 – 1979) Specifies for use of Artificial Light weight

Aggregates for Concrete Masonry Units.

Aerated Autoclaved Fly Ash Blocks (AAC)

AAC is a steam cured manufactured from pulverised fly ash,

Cement, Lime and an Aeration Agent.

High pressure steam curing in Autoclaves helps achieving the

desired physical strength in the Blocks.

These are Light weight Blocks having density of 600kg/M3

75

15

9

1

RAW MATERIAL % BY WEIGHT

FLY ASH

OPC CEMENT

LIME

OTHERS

High usage of Fly Ash

Compliance to the MoEF & CC Notification 2009 as

amended in Jan. 2016 on utilisation of Fly Ash .

Manufacturing of quality fly ash bricks confirming to

BIS specifications.

Fly ash utilization in coal mine void filling.

Fly ash utilization in road construction (SH, NH and

rural roads).

Promotion of utilization of fly ash in other

construction material such as Tile, Concrete mortar

etc.

Issues and Challenges

Promotion of fly ash based construction material

Availability of Fly Ash in scarce area

Availability of quality fly ash- business model

Availability of Technology for manufacturing of Fly

ash based construction materials

Development of market by creating awareness

Project approving authorities to promote use of fly

ash based materials

Manufacturing of quality products

Exploring export potential

Review and monitoring

Way Forward

Thank you