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Ash Utilization in Private Power Plants

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Private power plants Ash utilization

MoEF Notification (3rd Nov 2009) on Fly Ash Utilisation has instructed Operating Coal/Lignite based Power Plants to Achieve the Target for 100% Coal Ash Utilisation

S. No. Percentage Utilisation of Coal Ash Generation Target Date from the Date of issue of this Notification
1. At least 50% One Year
2. At least 60% Two Years
3. At least 75% Three Years
4. At least 90% Four Years
5. 100% Five Years

A. TATA POWER

Trombay, Jojobera and Maithon thermal power plants achieved 100% fly ash utilization whereas CGPL achieved 25% in its first year of full operation, which is in line with regulatory requirements.

Innovations
1. Ultra-Thin White Topping technology: CTTL, a wholly owned subsidiary of Tata Power, in association with BASF, has developed a concrete mix which can help replacing 40% of cement with Fly Ash. The polyheed admixture developed for Trombay Thermal Station Fly Ash has been used in a demonstration project. A demonstration road stretch of 3.5 m x 100 m has been laid. This road has lower absorption of solar energy (higher reflectivity) and is expected to have a longer service life.

2. Bottom ash based brick making: Bottom ash based bricks were manufactured successfully. A patent on the same has been filed.

Technologies Being Reviewed / Adopted
Fly ash based plaster sand: Additives are added into fly ash and mixture is processed to manufacture ceramic sand through an already patented process. This sand is well graded and meets the standard IS specifications for sand. This helps in utilization of fly ash from thermal power station in environmental friendly manner. This plaster sand is then mixed with cement and some more additives in the required proportion for a ready mix plaster. This ready mix can be used for making internal and external wall plaster by adding required proportion of water in it. Tata Power is in the process of putting up a demo plant for the manufacturing of the same. [5]

Plant-wise Fly Ash utilization details

Jojobera unit 1 to 5 Total quantity MT/year
Achieved 100% of ash utilization FY14 FY15
Ash produced from process 1129168 1194404
Ash recycled within the unit for making PPC Lafarge, railways transport to other cement plants, Bricks, pigments and ready mix industries 690162 675175
Sold Nil Nil
Utilized as land filling 439007 475223
Source: Jojobera Plant Environmental Statement for the FY 14-15

Trombay Total quantity MT/year
Achieved 100% of ash utilization FY14 FY15
Ash produced from process 64144.82 44314.85
Quantity recycled or reused within the unit Nil Nil
Sold Nil Nil
Recycled/Utilized 54523.10 37667.62
Source: Trombay Plant Environmental Statement for the FY 14-15
During the year 37667.62 MT was given to ready mix manufacturers and 888.72 was given for other use. Total 44314.85 MT was recycled/reused as per MoEF guidelines and achieved 100% of ash utilization
Maithon
Total quantity MT/year FY14 FY15
Ash from pollution control facilities 1763393 1641888
Quantity recycled or reused within the unit Nil Nil
Sold Nil Nil
Recycled/Utilized • Back filling in abandoned mines: 1981477 MT
• Cement/Other industries 7086 MT
• Total 1988563 MT • Back filling in abandoned mines: 2181227 MT
• Cement/Other industries 18994 MT
• Total 2200221 MT
Source: Maithon Plant Environmental Statement for the FY 14-15
Fly ash was utilized by cement/brick manufacturer as well in the construction of road by NHAI. Fly ash and bottom was utilized in back filling of abandoned mines allotted by ECL.

Coastal Gujrat power limited Total quantity MT/year FY14 FY15
Ash produced from process 532093 MT 648134 MT
Quantity recycled or reused within the unit Nil Nil
Sold Nil Nil
Recycled/Utilized 133470 180560
Source: CGPL Plant Environmental Statement for the FY 14-15

B. JINDAL CONSTRUCTION MATERIALS

JSPL is offering a wide range of construction materials, products and solutions. Some of its key products are fly-ash bricks and Light Weight Aggregates (LWA). The Company’s strong technical team offers customized solution through Light Gauge Structure (LGS), Speedfloor, Expanded polystyrene (EPS) and Jindal Global Road Stabiliser (JGRS). The bricks and LWA are made from its plant by-product fly-ash, hence are green in the truest sense. During the year, the highest ever production and dispatch of bricks in a year (2.33 crore and 2.20 crore units) was registered. The division also achieved a breakthrough with the Odisha Power Transmission Company Ltd. after being shortlisted as a supplier for many categories of new technologies. Speedfloor and LGS have also obtained Performance Appraisal Certificate (PAC) from the Building Materials & Technology Promotion Council (BMTPC), a government body engaged in promoting new technologies. Market opportunities have been explored in the Middle East. In addition, a factory is being set up for manufacturing structural insulated panels at Punjipatra, which would open up new markets. The LWA plant is also under trials, and is expected to start production very soon.

Un-utilised ash is being used for backfilling, along with the overburdening of mined areas in coal mines.

JSPL, Angul(Orissa)

Recycling fly ash in form of Light Weight Aggregate for using in ongoing construction work.
Use of special fly ash brick in place of conventional coal tar and pitch to build roads at township area.

State MSME Minister Jogendra Behera visited JSPL’s Odisha MSME Trade Fair–2015 showcasing innovative methodology and material for construction activities in the the stall and appreciated the Green initiatives of the company of fly ash green bricks.
JSPL displayed sample materials of Fly-Ash Bricks, Pavers, Kerb Stones made from its German Technology based Fly-Ash Brick Plant at Angul.

JSPL, Raigarh (CG)
Utilization of variety of Fly Ashes available at M/S) for developing Cementitious LSA (Ligno-Silico- Aluminous) Material for Non-Structural Applications.
14,26,600 bricks have been manufactured at Tamnar plant using fly ash. Only bricks made of fly ash are being used in construction activities at the colony near the plant.

Fly ash utilization: - A captive brick plant has been established to produce around 4.0 lakh brick products/day for manufacturing of fly ash bricks. All construction activities of the company are done through these fly ash bricks. Measures have already been taken to achieve a level of 100% utilisation of fly ash. The ash is partly used for brick making, ash dyke rising, road and embankment construction, cement manufacturing. [11]

C. ADANI POWER
The company, with a total generation capacity of 7,920 mw, currently recycles fly ash by using it as a source for plant nutrients in agriculture; in addition to its utilisation in the production of cement concrete, construction of roads, bricks and structural filling.

Company did a pilot project vermicomposting -- use of earthworms to convert organic waste into fertiliser -- unit at its 4,620 mw power project in Mundra in Gujarat. [2]

The Mundra TPP is researching the expanded usage of the fly ash it generates, as a liming material and as a feedstock for vermicomposting (converting organic waste into fertilizer). Most of the fly ash is conveyed to three 3,000-m3 silos. From there, trucks dispatch it to makers of bricks, ceramics, cement and roads; it also is packed in 1.4-mt bags for shipment to the Middle East. [4]

Adani has planned to replicate the same vermicomposting model at other two projects in Maharashtra and Rajasthan also.
Future plan: Given the quantity of fly ash that will be generated as a by-product, Adani is planning to set up a cement plant in Kutch. [3]

Companies offering total ash management

JAYCEE
JAYCEE in conjunction with BMI offers 'total ash management' solutions to coal-fired thermal power stations across India to help them recycle and utilize all by-products such as FlyAsh, Furnace Bottom Ash and Pond Ash. With a partnership driven value-sharing approach, we offer a number of solutions based on successful global benchmarks:
• Designing, engineering, operating and maintaining ash collection and handling systems as well as storage infrastructure
• Managing health, safety and environmental compliance, including landfill and ash-pond management
• Developing ash beneficiation systems and technologies
• New product development
• Product testing and analysis, quality control and assurance services
• Marketing and sales of ash and ash-based products
• Local and export logistics
• Managing man power and training

Jaycee’s Fly Ash Operations Across India
• JSW Energy Ltd. – Jaigad TPS, Ratnagiri, Maharashtra
• Adani Power Ltd. – Mundra TPP, Gujarat
• Tata Power CGPL – Mundra TPP, Gujarat
• Tata Power – Trombay TPP, Maharashtra
• GSECL – Wanakbori TPS, Gujarat
• GSECL – Gandhinagar TPS, Gujarat
• GSECL – Ukai TPS, Gujarat
• GNFC TPP, Gujarat
• Uttam Galva Steels Ltd. TPS, Maharashtra
Jaycee is having sourcing arrangements at Mahagenco – Nashik TPS, Bhusawal TPS and
Nagpur TPS, Maharashtra and NTPC – Simhadri TPS, Visakhapatnam, Andhra Pradesh

References
1. JSPL, Annual Report 2014
2. http://www.adani.com/Common/Uploads/NewsTemplate/105_NzParaImg_The%20Times%20of%20India_Adani%20Power_Ahm_210314_PG-13.pdf
3. http://epaper.timesofindia.com/Default/Layout/Includes/TOINEW/ArtWin.asp?From=Archive&Source=Page&Skin=TOINEW&BaseHref=TOIA%2F2010%2F08%2F10&ViewMode=HTML&GZ=T&PageLabel=1&EntityId=Ar00100&AppName=1
4. http://www.powermag.com/mundra-thermal-power-plant-mundra-gujarat-india-owneroperator-adani-power-ltd/?pagenum=4
5. Tata Power company, Annual Report 2014
6. https://www.tatapower.com/sustainability/pdf/Env-Statement-jojobera-FY14-15.pdf
7. https://www.tatapower.com/sustainability/pdf/Trombay-Env-Statement-FY14-15.pdf
8. https://www.tatapower.com/sustainability/pdf/Env-Statement-jojobera-FY14-15.pdf
9. https://www.tatapower.com/sustainability/pdf/Maithon-Env-Statement-FY14-15.pdf
10. https://www.tatapower.com/sustainability/pdf/CGPL-Env-Statement-2014-15.pdf
11. http://www.jindalsteelpower.com/sustainabilities/solid-waste-management.html
12. http://jaycee.in/cementitious-fly-ash.php

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