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1
PRESENTATION ONPRESENTATION ON
FLY ASH UTILISATIONFLY ASH UTILISATION
A SUCCESS STORY OF Dr. NARLA A SUCCESS STORY OF Dr. NARLA TATA RAO THERMAL POWER TATA RAO THERMAL POWER
STATIONSTATION
2
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
FORMATION OF APGENCO
3
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
4
INSTALLED CAPACITY AT Dr.NTTPS
Station Unit Capacity (MW)
Date of 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
5
AWARDS WON BY Dr.NTTPS
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
Medal ReceivedAward Received
Economic
Operation Award
( Rs Lakhs)
Productivity
Award
( Rs lakhs )
Year
VTPS qualified for meritorious productivity award for 19th
consecutive year since 1983-84. VTPS stood No.1 in India during 1997-98 and 2001-02 for achieving highest PLF.
6
FLY ASH UTILISATION AT
Dr.NTTPS DURING 1998-99 TO 2007-08
76.6183232423914342007-08
51.9115017622164722006-07
52.6111244421165382005-06
49.6103849220955692004-05
40.584009520758302003-04
20.746491522457922002-03
14.733353622693222001-02
15.336429723838352000-01
9.923082623220061999-00
5.713400623521681998-99
% Fly ash
Utilization
Fly Ash UtilizedFly Ash GeneratedYear
7
ASH UTILISATION AT
Dr.NTTPS DURING 1998-99 TO 2007-08
67.5201897429892932007-08
62.3172653527705902006-07
56.7150054726456732005-06
46.1120781426194612004-05
36.995703925947882003-04
19.153899028072402002-03
11.833353628366532001-02
18.254089729797942000-01
7.923082629025071999-00
4.613400629402101998-99
% ash UtilizationAsh UtilizedAsh GeneratedYear
8
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..
9
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..
10
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.
11
ORIGINAL DRY FLY ASH SYSTEMS INSTALLED
ALONG WITH MAIN EQUIPMENT
100%Vacuum + Pressure6
100%Vacuum + Pressure5
30%Vacuum - Hydrovector4
30%Vacuum - Hydrovector3
30%Vacuum - Hydrovector2
30%Vacuum - Hydrovector1
Efficiency of the
System
Method of CollectionUnit No.
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.
12
BETTER QUALITY OF FLY ASH The fly ash collected from field wise and got tested. The field wise
characteristics are as follows.
Around 26001st Field
Around 32002nd Field
Around 45003rd Field
Around 46004th Field
Around 60005th Field
Around 64006th Field
Specific surface area cm2/gmField
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.
Cenospheres are also issued from the ash ponds of other stations
13
USE OF FLY ASH FOR PPC COMPLIANCE OF IS-SPECIFICATIONS
1.5 max-Alkalies as Na2O
12.0 max0.29Loss on Ignition (LOI)
Above figures in percentage by mass
2.75 max1.24Total sulphur as SO3
Dr. NTTPS
5.0 max1.65MgO
70.0 min90.1SiO2 + Al2O3 +Fe2O3
35.0 min72.3SiO2
IS 3812 requirement
Test resultsConstituent
CHEMICAL PARAMETERS OF FLY ASH
14
USE OF FLY ASH FOR PPC
COMPLIANCE OF IS-SPECIFICATIONS
Contd..
Dr. NTTPS
0.15 max0.008Drying shrinkage %
0.80 max0.015Autoclave expansion %
3200 min3700Fineness cm2/gm
4.0 min5.3Lime Reactivity N/mm2
IS 3812 & IS 1489
requirement
Test value Property
PHYSICAL PARAMETERS OF FLY ASH
15
CEMENT PLANTS NEARER TO Dr.NTTPS
1.10 M/s Rain Commodities Ltd
0.85M/s NCL Industries Ltd
1.00M/s Penna Cement Industries Ltd
1.02 M/s Andhra Cements Ltd
2.00 M/s Madras Cements Ltd
2.16M/s Sri Vishnu Cements Ltd
2.76M/s My Home Industries Ltd
4.80M/s The India Cements Ltd
Installed
Capacity
(MTPA)
Name of the Cement Plant
Contd..
16
CEMENT PLANTS NEARER TO Dr.NTTPS
18.64Total
0.89Others
0.54 M/s Parasakti Cement Ind. Ltd
0.72M/s Ckoramandal Cements Ltd
0.80 M/s Deccan Cements
Installed
Capacity
(MTPA)
Name of the Cement Plant
17
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 incorporatefly 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.
18
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.
19
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.
20
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.
USE OF ASH FOR AGRICULTURE
11.75 lakhs10002004-053
15 lakhs 10002003-042
75 lakhs 50002002-031
Amount subsidy (Rs.)
No. of PlotsYearSl.No
The field studies indicate increase of yield but final results are yet to be received.
21
Research studies through 4 research stations of Acharya N.G. RangaAgricultural University, Hyderabad are taken up for different crops.
RESEARCH STUDIES THROUGH ANGRAU
RTSRiceRARS, Jagtial4
RTPPMaizeARS, Utukur3
KTPSMangoARS, Ashwaraopet2
VTPSa) Sugarcane
b) Rice
ARS, Vuyyuru1
TPS coveredCropsResearch StationSl.No
22
Increase of yield in tons/Ha is reported as follows.
RESEARCH STUDIES THROUGH ANGRAU Contd..
7.358.113.652) FP + Fly ash at RD
7.36.462.731) Farmers practice (FP)
Rice at Vuyyuru
Rice at Jagtial
Maize at Utukur
Treatments
FP: Farmers Practice – NPK 130 : 50 : 0
RD: Recommended Dose of fly ash
Rice : 10 tons/Ha
Maize : 15 tons/Ha
23
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
RESEARCH STUDIES THROUGH ANGRAU Contd..
24
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.
25
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 cementcompanies 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.
26
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
EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-1,3&4
Contd..
27
• Necessary valves, bends, laterals, couplings, breakers, pipes, bag filters, fluidising blowers and other accessories
• Civil structures, MCC and PLC control room etc
EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-1,3&4
28
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
EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-2
Contd..
29
• Necessary valves, bends, laterals, couplings, breakers, pipes, bag filters and other accessories
• Civil structures, MCC and PLC control room etc
EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-2
30
PERFORMANCE AFTER UPGRADATION
93%M/s India Cements Ltd4
93%a) Sri Vishnu Cements
b) Visaka Industries Ltd
c) Hyderaba Industries Ltd
d) Sagar Cements
3
84%a) Home Industries Ltd
b) Rain Commodities
c) NCL Industries
2
84%a) India Cements Ltd
b) Sri Vishnu Cements Ltd
c) Andhra Cements
1
Fly ash extraction Up-gradation completed byUnit No.
31
PRESENT ASH UTILISATION DURING
2008-09
6
5
4
3
2
1
Sl.
No.
Sep-2008
Aug-2008
July-2008
June-2008
May-2008
April-2008
Month
83.4158984190709
84.2166403197630
85.6176684206427
93.9189342201600
82.0155328189329
82.0163646199447
% Fly ash
Utilization
Fly ash
Utilization in
MT
Fly Ash
Generation in
MT
32
33
Fly Ash Utilization at other stations of
APGENCO
--13.05%% Utilised
--162044Ash Utilised
13240199349512410781999-2000Ash Produced
--1.07%% Utilised
--12385Ash Utilised
108165115971311627441998-1999Ash Produced
--0.5%% Utilised
--4952Ash Utilised
107253104340910060401997-1998Ash Produced
62.5 MW500 MW420 MWInstalled capacity
RTS ‘B’KTPS VRTPPYear
34
RTS ‘B’KTPS VRTPPYear
20.9%3.7%32.3%% Utilised
2349544721315310Ash Utilised
1122371220469976302
2002-2003 Ash Produced
2%1.6%18.8%% Utilised
252517023188896Ash Utilised
12752410852361005552
2001-2002 Ash Produced
1.50%-10.73%% Utilised
2400-126193Ash Utilised
1396057969401176004
2000-2001Ash Produced
35
RTS ‘B’KTPS VRTPPYear
67.4%18.9%63.9%% Utilised
71943169207385588Ash Utilised
106770895778603205
2005-2006 Ash Produced
47.9%22.4%%54.2%% Utilised
52400238483445131Ash Utilised
1094001064937821224
2004-2005Ash Produced
18.0%27.2%41.4%% Utilised
23249296164369355Ash Utilised
1291801087354892345
2003-2004Ash Produced
36
RTS ‘B’KTPS VRTPPYear
79.05%41.87%57.52%% Utilised
102234451142845354Ash Utilised
12931710773121469548
2007-2008 Ash Produced
67.09%29.68%57.92%% Utilised
62391356154521459Ash Utilised
930001199861900307
2006-2007 Ash Produced
37
Status of fly ash utilization at NTPC Limited
81.062.713.3435.269.471600Farakka
90.721.471.6235.734.54840Dadri
60.870.641.0639.072.70440Tanda
100.002.392.3940.135.951050Unchar
32.711.183.6132.0011.052000Singrauli
61.101.863.0428.9010.512000Rihand
98.401.041.0638.002.79460Talchar(TPS)
17.621.206.8237.1116.383000Talchar(KAN)
37.831.906.0230.2316.603260Vindhyachal
81.101.081.3332.584.09705Badarpur
61.443.034.9439.5712.472100Korba
37.090.631.8833.985.431340Kahalgoan
71.471.832.2738.945.841000Simhadri
61.642.884.6738.7613.052400Ramagundam
%
Utilization
Fly Ash
utilization
In mtpa
Fly ash
Generation
In mtpa
Ash
Content in
%
Coal
Consumption
In mtpa
Installed
Capacity in
MW
Name of
TPS
Recommended