Conference on Fly Ash Utilisation – 8th Edition

An ISO 9001 : 2015 Certified Company

Presentation on Ash Management

Energy Scenario

• About 70% of Power Generation in India is by Coal Fired Power Plants

• In the process of electricity generation large quantity of fly ash gets produced and becomes available as a by-product of coal-based power stations.

59.2

1.8

11.9

15.4

11.7

Generation ( %)

Thermal (2,07,200 MW)Nuclear ( 6,300 MW)Hydro ( 41,650 MW)R.E ( 53,900 MW)Captive >1 MW( 40,950 MW)

Power Generation ( Installed Capacity)

Installed Capacity - 3.50 Lakh MW ( As on 31st Dec -2018)

Actual Power Generation

Generation ( Billion Units )

71.7

2.7

8.9

4.7 12.0

Generation % ( Billion Kwh)

Thermal (951 ) Nuclear ( 38 ) Hydro (122 ) R.E ( 65.8 ) Captive >1 MW(166 )

Power Generation ( 2017-18)

Improvement in Electrical Energy Utilisation

Present Scenario

Power Generation Coal based

( Billion Units )

Coal Consumed ( Million

Tons)

Ash Generated (

Million Tons)

Ash Utilised ( Million

Tons )

Percentage Utilisation

( %)

951 608 200 118 59

Ash Generation Vs Utilisation ( FY 2017-18)

Many Power Utilities Unable to meet MOEF Targets on Ash Utilisation

Air Pollution

EnvironmentalPollution

Land Pollution

Pond Pollution

Storage Problem

Challenges in Ash Management

New Coal/Lignite based Power Plants & Expansion UnitsCommissioned after the notification Dtd 3rd Nov-2009 to achievethe target utilisation as per the table below :

MOEF Notifications – On Ash Management

Sl. No. Fly Ash Utilisation Target

1 50% Fly Ash Generated One Year from Date of Commissioning

2 70% Fly Ash Generated Two Years from Date of Commissioning

3 90% Fly Ash Generated Three Years from Date of Commissioning

4 100% Fly Ash Generated Four Years from Date of Commissioning

- Contd …..

Year of Commissioning 100 % Ash Utilisation by

2010 2014

2011 2015

2012 2016

2013 2017

2014 2018

2015 2019

2016 2020

2017 2021

2018 2022

National Green Tribunal Order on Fly Ash Utilisation

As per the NGT order Dtd: 20th Nov-2018, the Power Stationswhich have not achieved 100% Ash Utilisation as on 31st Dec-2017, to deposit damages to environment restoration as follows:

Sl. No. Capacity of Thermal Power Plant Cost of Damages

1 Up to 500 MW Rs 1 Crore

2 Up to 1000 MW Rs 3 Crores

3 Beyond 1000 MW Rs 5 Crores

- Contd…..

National Green Tribunal Order on Fly Ash Utilisation

To avoid adverse impact on public health and to give effect to the “ Precautionary Principle “ & the “ Polluter Pays “ principle applied under Section -20 of NGT act -2010

Amount to be deposited with CPCB , 12% interest will be charged for delayed payment

Any false claim attracts 5 times penalty

Require an Innovative Approach in Ash Management

An ISO 9001 : 2015 Certified Company

Vision Statement

Ashtech India ( Pvt) Ltd, shall be professionally Managed companycommitted to total customer satisfaction and enhancing stakeholdervalue

Ashtech India ( Pvt) Ltd, shall be innovative, entrepreneurial andempowered team constantly creating value and attain globalbenchmarks.

Ashtech India ( Pvt) Ltd, shall foster a culture of caring, trust andcontinuous learning while meeting the expectations of employees,stakeholders and society.

Company Profile

• With vast and rich experience of above two decades inthe field of Fly Ash utilization , Ashtech has achievedmany laurels.

• An ISO 9001: 2015 certified company.• We have a dedicated team of professionals and

experts to maximise gainful utilisation of Fly Ash

-- Contd.

Key Personnel• Sri. U.P. Pani - Ex. Director (H.R) N T P C • Dr. Vimal Kumar - Ex. Director Fly Ash Mission ( GOI)• Sri. Prasad Rao - Ex. Sr. V P Reliance • Sri. Anil Pillai - Ex. CEO , JSW Cement• Sri. Subhas Bidwai - Ex. G.M ( Demech)• Sri. Vipin Dave - Ex. G.M Reliance• Sri. Sudhir Jetti - Expert AAC Units• Sri. Rakesh Kaul - Expert Cement Plants• Sri. Bankat Mandhania - Director Ashtech• Sri. Sanjay Mandhania - Director Ashtech• Sri. Satish Mandhania - Director Ashtech

Infrastructure

• Handling about 7.0 Million tons per annum of Fly ash fromvarious power stations across the country.

• With more than 1700 employees and 550 + heavy vehicleslike dumpers , trucks, bulkers , transit mixtures cater tothe requirement of customers across the country.

Company Owned FleetType Vehicles

Trucks

560

Bulkers DumpersTransit Mixers Trailer

Packaging

Jumbo BagsSmall Bags Bulk Carrier Sea Vessel

Railways Tipper Trucks

Manufacturing Facilities

Manufacturing Unit

Production of Ultra Fine Fly Ash @ Adani, Tirora

Manufacturing Unit

Cement blending & packing plant 1500 TPD @ Adani, Mangalore. Ash transportation through Pneumatic Conveying

Manufacturing Unit

Cement blending & packing plant 1500 TPD @ Raichur

TesTingLABS..

Our Principles

USA

Our Exports & Presence

● ●

● ● Europe ●

●

Saudi Arabia

Bahrain

●

●●

●

● UAE

Oman QatarIran● ● ● GCC● ●

● MENA

• Hiranandani Gardens, Mumbai

• L&T Mono Rail Project, Mumbai

• Nirmal Lifestyle, Mumbai

• SD Corporation – Twin Towers, Mumbai

• Bandra-Worli Sea Link Project, Mumbai

• Tata Atomic Power Station Project, Boisar

• SCLR Project, Vidyavihar

• Magarpatta City, Pune

• Reliance Metro Project, Mumbai

• Nanded City, Pune

• Pipavav Shipyard Limited, Gujarat

• Bangalore International Airport, Bangalore

Important Projects in India

Twin Towers, Mumbai

Mumbai Metro Project – Phase 1, Andheri

Pipavav Port, Gujarat

Important Projects in India

• The Burj Khalifa (Tallest Building in the World), Dubai

• Palm Islands, Dubai

• Dubai Marina, Dubai

• Etisalat Head Office, Dubai

• Abu Dhabi Cricket Stadium, Abu Dhabi

• Hidd Port Project, Kingdom of Bahrain

• Financial Harbor Project, Kingdom of Bahrain

• Shaikh Khalifa Causeway Bridge, Kingdom of Bahrain

• Alba Extension Silos, Kingdom of Bahrain

• Hidd Pump Station, Kingdom of Bahrain

• Khalifa Sports City, Qatar

• Ras Lafan Project, Qatar

• Shahid Rajaee Port Project, Iran

• Naga Hamadi Barrage Project, Egypt

• Salalah Port, Oman

• Baka Power & Desalination Plants, Oman

Palm Islands, Dubai

The Burj Khalifa, DubaiEtisalat Head Office, UAE.

Important Projects outside India

Use of Information Technology

• GPS based System to track transportation on real time • E- Fleet System ( Logistic Support Services )• Implementation of ERM• Video Conference facility with customers & project

sites

Above Systems improved Service delivery , Customer satisfaction , Efficiency of operations

• Ashtech transports 7.0 Million Tons ( per annum) of Fly Ash from various Power Plants to end users.

• Out of which about 6.0 Million Tons of Fly Ash is used in Cement Plants, RMC & Value added products.

Contribution to Environment

Contributing to reduction of 5.6 Million Tons of Greenhouse gas per annum.

Define

Measure

AnalyzeImplement

Control

Business Improvement - System Approach

• Pneumatic conveying system• Air Classification system• Cement manufacturing• AAC ( Light Weight Block) manufacturing• Cenosphere processing• Pond Ash Management• Embankment / Low Lying area Filling.

Complete Ash Management Solution Provider

We have a successful track record of converting waste into a resourcefulraw material.

Achieved 100% Ash Utilisation at :• Dahanu T P S• Rosa• Butibori• GMR , Kamalanga• NTPC, Badarpur• TNEB Ennore TPS , etc.

Ashtech - A business partner in Power Generation Management

- Contd ……

From a negative cost , created value from Fly Ash for above Power Plants. We are confident of replicating the same at other locations.

Gainful Utilization of Fly Ash

CementRMC Blocks / Pavers Asbestos

Back Fill Road Embankment

Ashtech - A business partner in Power Generation Management

• Installing AAC Block Manufacturing Unit and Cementgrinding unit inside power plant locations - to Utilize FlyAsh Sustainably and generate revenue for the powerplants

• We are in the process of installing India’s Firstmechanised Cenosphere Collection & Processing Unit.

Awards and Accolades

Awards and Accolades

Tree Plantation

Proactive Approach to take care of Environment -

Plantation outside factory Premises.

Care for Environment

Tree Plantation

Involvement of Employees in Green Belt Development

Thank You