Fly Ash Utilisation in Odisha

Fly Ash Utilisation Conference, 2019, Goa27-28th, February, 2019

Dr. D.K. BeheraChief Env. ScientistState Pollution Control Board, OdishaBhubaneswar

Ministry of Environment , Forests &Climate Change, Govt. of India

Fly Ash Notification, 14th September, 1999

Amendments

i. S.O. 979 (E), dated 27th August, 2003

ii. S.O. 2804 (E), dated 3rd November,

2009

iii. S.O. 254 (E), dated 25th January, 2016

Under Env. Protection Act, 1986

To Promote utilisation of fly ash in building materials ,

construction activities, mine reclaimation and other

sectors etc.

To Protect the Environment, conserve top soil,

To Prevent the dumping and disposal of fly ashgenerated from Thermal Power Plants

Restrict excavation of top soil

Reduce land requirement for ash disposal

Objectives

Setting up of Fly Ash Resource Centre (FARC) in SPCB, Odisha

(Decision of High Power Committee Chaired by ChiefSecretary, 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

Another 2200 MW is likely to go

into operation in

2019.

Power plants are mostly

located near coal mines of Talcher and

Ib Valley

Total Thermal Power (Coal) to be in operation during 2019 is

18,095 MW

Thermal Power Plants in Odisha (2017-18)Capacity in

MWNo 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

Ash Generation from TPPsPower 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 31 MTPA(2017-18)

Ash generation likely to increase to about 38 MTPAduring 2019-20.

Land Requirement for Ash Disposal

Sl.Sl. Disposal method Area in Ac/ MW

1. Lean slurry disposal with complete recirculation ofwater 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 endof 9th year

0.5

4. High density disposal with 100% ash utilization by endof 9th year, using washed coal (34% ash)

0.3

5. High density disposal with 100% ash utilization by endof 5th year

0.25

6. High density disposal with 100% ash utilization by endof 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 28.22006-07 5655.9 12.16 3.38 27.82007-08 5784.2 13.62 3.34 24.52008-09 7073.5 15.44 5.41 35.02009-10 7742 19.23 8.45 43.932010-11 9685 21.18 10.68 50.422011-12 11400 23.57 12.77 54.192012-13 11980 24.67 14.62 59.292013-14 11969 24.44 15.17 622014-15 14512 24.69 12.99 52.612015-16 15742 27.90 16.39 58.732016-17 15832 30.69 20.66 67.322017-18 15895 30.92 24.96 80.74

Till December’ 18

(2018-19)15819 23.31 18.77 80.55

Year wise Thermal Power and Fly Ash Generation in Odisha

5415.9 5655.9 5784.2 7073.5 7742

9685 11400 11980 11969.33

14512 15742 15895 15895 15819

02000400060008000

1000012000140001600018000

2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19(Till

Dec'18)

POW

ER (

MW

)

YEAR

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 2017-18 2018-19(Till

Dec'18)

QU

QN

TITY

IN M

TPA

YEAR

Fly Ash Generation, Utilisation & Accumulation in Odisha

Fly ash Generated (Million TPA)Fly Ash Utilised In (Million TPA)Unutilized / Accumulation (Million TPA)

Fly Ash Generation & Utilisation, Odisha

2012-13Tons

2013-14Tons

2014-15Tons

2015-16Tons

2016-17Tons

2017-18,Tons

2018-19Till December’8

Fly Ash Generated 246,71158 244,42381 246,95551 279,09495 306,96663 309,22048 233,11404

Total Ash Utilisation 146,28506 151,69590 129,91470 163,90911 206,65987 249,65310 187,76728

% of Utilisation 59.29 % 62 % 52.61 % 58.73% 67.32 % 80.74 % 80.55 %

9,79,572 9,56,871 13,71,993 22,36,318

28,20,194 35,59,571

29,78,450

010,00,00020,00,00030,00,00040,00,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 (TillDec'18)

Fly

Ash

Util

isatio

n in

MT

Year

Brick Manufacturing

2012-13MT

2013-14MT

2014-15MT

2015-16MT

2016-17MT

2017-18MT

2018-19,Till December’18

MT

9,795723.97 %

9,568713.91 %

13,719935.56 %

22,363188.01 %

28,201949.20 %

35,5957111.51 %

29,7845012.78 %

Brick Manufacturing

8,81,449 9,16,555 7,97,996

11,59,555 12,76,208 13,41,285

12,51,592

0

2,00,000

4,00,000

6,00,000

8,00,000

10,00,000

12,00,000

14,00,000

16,00,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19(Till

Dec'18)

Fly

Ash

Utili

satio

n in

MT

Year

Cement

2012-13MT

2013-14MT

2014-15MT

2015-16MT

2016-17MT

2017-18MT

2018-19,Till December’18

MT

8,814493.57 %

9,165553.74 %

7,979963.23 %

11,595554.15 %

12,762084.18 %

13,412854.34 %

12,515925.37%

Cement Manufacturing

33,255

1,09,935 1,28,775

1,62,194

1,24,354

98,351

70,242

020,00040,00060,00080,000

1,00,0001,20,0001,40,0001,60,0001,80,000

Fly A

sh U

tilisa

tion

in M

T

Year

Asbestos

2012-13MT

2013-14MT

2014-15MT

2015-16MT

2016-17MT

2017-18MT

2018-19,Till December’18

MT

332550.13 %

1,099350.45 %

1,287750.52 %

1,621940.58 %

1,243540.41 %

983510.32%

702420.30 %

Asbestos Manufacturing

6,51,955 5,98,958

12,51,766 15,01,647

21,63,674

17,00,721 16,41,838

0

5,00,000

10,00,000

15,00,000

20,00,000

25,00,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 (TillDec'18)

Fly

Ash

Uti

lisat

ion

in

MT

Year

Quarry Filling

2012-13MT

2013-14MT

2014-15MT

2015-16MT

2016-17MT

2017-18MT

2018-19,Till December’18

MT

6,519552.64 %

5,989582.45 %

12,517665.07 %

15,016475.38 %

21,636747.08 %

17,007215.50%

16,418387.04%

Quarry Filling

12,75,814 12,45,704 13,64,292 14,26,133

11,56,006 12,11,542

8,45,809

02,00,0004,00,0006,00,0008,00,000

10,00,00012,00,00014,00,00016,00,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19(Till

Dec'18)

Fly

Ash

Uti

lisat

ion

in M

T

Year

Coal Mine Void Filling

2012-13MT

2013-14MT

2014-15MT

2015-16MT

2016-17MT

2017-18MT

2018-19,Till December’18

MT

12,758145.17 %

12,457045.096 %

13,642925.52 %

14,261335.11 %

11,560063.77 %

12,115423.92 %

84,58093.63 %

Coal Mine Void Filling

2012-13MT

2013-14MT

2014-15MT

2015-16MT

2016-17MT

2017-18MT

2018-19,Till December’18

MT

25,6530910.39 %

29,2175011.95 %

34,3517813.91 %

59,2519821.23 %

71,7508323.37%

82,5650326.70 %

50,9795921.87 %

25,65,309 29,21,750 34,35,178

59,25,198

71,75,083

82,56,503

50,97,959

010,00,000

20,00,00030,00,00040,00,00050,00,00060,00,000

70,00,00080,00,00090,00,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19(Till

Dec'18)

Fly

Ash

Uti

lisat

ion

in M

T

Year

Dyke Raising

Dyke Raising

2012-13MT

2013-14MT

2014-15MT

2015-16MT

2016-17MT

2017-18MT

2018-19,Till December’18

MT

76,5062631.01 %

80,1310332.78 %

44,3007517.94 %

31,5007019.22 %

44,7308314.58 %

67,2797821.76 %

58,1113424.93%

76,50,626 80,13,103

44,30,075

31,50,070

44,73,083

67,27,978 58,11,134

0

10,00,000

20,00,000

30,00,000

40,00,000

50,00,000

60,00,000

70,00,000

80,00,000

90,00,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19(Till

Dec'18)

Fly

Ash

Utili

satio

n in

MT

Year

Land Development

Land Development

2012-13MT

2013-14MT

2014-15MT

2015-16MT

2016-17MT

2017-18MT

2018-19,Till November’18

MT

5,891262.38 %

2,845651.16 %

1,964050.80 %

7,705692.76 %

14,523854.73 %

20,665856.69 %

10,721524.59 %

5,89,126 2,84,565 1,96,405

7,70,569

14,52,385

20,66,585

10,72,152

0

5,00,000

10,00,000

15,00,000

20,00,000

25,00,000

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 (TillDec'18)

Fly

Ash

Uti

lisa

tio

n

in M

T

Year

Road Making

Road Making

Locations of TPPs & Blocks within 100 Km

Nos. of Blocks in Odisha – 314Nos. of Blocks fully covered in 100 Km radius of TPPs – 262Nos. of Blocks Particially covered in 100 Km radius in TPPs – 27

Fly Ash Utilisation in Odisha by 38 Working Thermal Power Plants (>10MW) as on November, 2018

Sl. No.

Fly Ash utilisation in % Number of Thermal Power Plants

1 100 % or above 19

2 99 – 95 5

3 94 - 85 5

4 84 – 75 2

5 74 – 65 3

6 64 - 50 Nil

7 < 50 4

Initiatives byFly Ash Resource Centre (FARC) for utilization of

Fly Ash Development of Database on Fly Ash generation

and utilization from each TPPs. Composition of FAfrom individual TPP w.r.t. IRC GeotechnicalSpecifications (SP-58/2001).

Works Dept., Govt. of Odisha has included Fly Ash inthe schedule of rates and tender documents forroad construction.

Coordinate with NHAI, Works dept., CPWD and TPPsfor smooth availability of Fly Ash in road/buildingconstruction Projects.

Cement industries have been requested for enhancinguse of Fly Ash in cement making- more cementgrinding units coming up in Odisha

20 Sensitization workshops conducted at differentlocations in the State. ( Sector Specific)

TPPs were instructed to supply Fly Ash free of cost to flyash based construction material manufacturing unitsand for road construction. Further, all thermal powerplants above 100 MW capacity have been instructed tosupply fly ash at the user point of road making andmanufacturers of construction materials or provide asubsidy of Rs.150/- ton of fly ash.

Abandoned mine quarries, identified by the DistrictAdministrations and TPPs are linked for reclamation.

Third Party Audit of annual Fly Ash Generation andUtilization by TPP being conducted since 2012-13.

VSSUT, Burla was engaged to study on theEnvironment Impact of Fly Ash disposal sites inOdisha.

Coordination meetings with TPPs and Concessionerof NH/SH for smooth availability of fly ash

Simplification of procedure of CTE for landreclamation- Guideline available on website

Major Thermal Power Plants have been directed toconstruct village / panchayat Road of at least 1 kmusing fly ash under CSR activities.

Coordination with Research Institutes (IMMT, BBSR,OUAT, NIT, Rourkela, IIT , Bhubaneswar)

Availability of fly ash (free transportation upto 100 km or Rs.150/- per tonne) to develop a market. Included in Consent condition

Exemption of fly ash brick manufacturing units fromConsent 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 (LWA)

and Aerated Autoclave Blocks AAC) – Plants havecome up in Odisha

Notification (Works Dept.) for use of Fly ash bricks inall Govt. constructions

Complaint redressal mechanism in SPCB

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

Sl. No.

Name of the Project Length of the

Project

Required Quantity of Ash in

Tonne

Name of the Concession

er

Thermal Power Plants Allotted with

Quantity(Tonne)

1 NH-149Four Laning of Talcher to end of Kamakhyanagar

41.726 km 20,00,000 M/s Monte Carlo Ltd.

1. M/s GMR Dhenkanal2. M/s Bhushan Steel Ltd., (TATA), Dhenkanal

3.M/s NALCO, CPP, Angul4.M/s NTPC, Kaniha

5.M/s JSPL, Angul

6,00,000

6,00,000

1,00,000

6,00,000

1,00,000

2( i) NH-53KamakhyanagarBypass to Duburi335.946 km to 388.382 km

51.1 km 9,00,000 M/s G.R. InfraprojectsLtd.

1.M/s Talcher Super Thermal Power Station NTPC, Kaniha2. M/s GMR Energy Ltd., Dhenkanal3. M/s Bhushan Steel Ltd., (TATA), Dhenkanal

4,00,000

1,00,000

4,00,000

Sl. No.

Name of the Project

Length of the

Project

Required Quantity of

Ash in Tonne

Name of the Concessioner

Thermal Power Plants

Allotted with

Quantity(Tonne)

2(ii) Duburi-Chandikhole388.382 km to 428.074 km

39.4 km 16,00,000 M/s Gammon Engineers and Contractors Pvt.Ltd.

NTPC, Kaniha 16,00,000

3NH-520Rimuli-Koida

43 km 8,75,042 M/s MonteCarloLtd.

M/s TATA Sponge Iron Ltd., Keonjhar

4,00,000

4 (i) NH-149Biramitrapur-Brahmani Bridge

26 km 3,67,000 M/s GKC Projects Ltd.

M/s NSPCL-SAIL Rourkela

3,67,000

(ii) Brahmani Bridge-Rajamunda

43 km 11,00,000 M/s RKD Construction Pvt. Ltd.

M/s NSPCL-SAIL Rourkela

11,00,000

iii. Rajmunda-Barkote 50 km 1,00,000 M/s Gayatri Projects Ltd.

M/s NSPCL-SAIL Rourkela

1,00,000

iv. Koida-Rajmunda 53.6 km 4,05,000 M/s KMC-RKD M/s NSPCL-SAIL Rourkela

2,00,000

4 Laning of NH-55 (Sambalpur-Manguli-

Angul)

51 Lakh Tonne

NH-149,53 &520 75 Lakh Tonne

Total 126 Lakh Tonne

Proposed NH and Fly Ash Utilisation in Odisha

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 construction of rural roads

Promotion of utilization of fly ash in other

construction material such as Tile, pavement

blocks, door pannel etc.

Accountability of user agencies

Issues and Challenges

Promotion of quality fly ash based construction

material

Effective co-ordination between TPPs, DICs,

Entrepreneurs and user agencies (Role of SPCBs)

Development of market by creating awareness

Building approving authorities to promote use of fly

ash based materials

Action for availability of fly ash across

geographical locations

Review and monitoring

Way Forward

TPPS to link with the CEA's Mobile Phone App

Task Force, constituted in 2011 for fly ash use in

mines should be revitalized.

Ministry of Coal should identify list of abandoned

mines for utilisation of fly ash in mines backfilling

CPCB to come out with guidelines based on Odisha

SPCB experience for reclamation of low lying areas

and abandoned quarries with ash

NHAI should compulsorily use fly ash in their

projects’- with NTPC Guideline for payment of

transportation cost

Report to Niti Ayog by MOEF&CC

BIS should make standards for use of fly ash in

geo-polymer concrete and use of Bottom Ash as

replacement of Fine Aggregate (sand).

Alternate mode of transportation -BTAP (Bogie Tank

for Alumina Powder) wagons for bulk ash

transportation through rail and transportation

through Barge.

BIS should examine to increase fly ash use to 45 %

and take a suitable decision expeditiously.

to keep track of the movement of fly ash post-

generation- Rs1/ton- invoice can be generated.

Report to Niti Ayog by MOEF&CC

Notification 2016 for cities having population one

million or more –revisit by MOEF&CC

District Level Monitoring committee - Chairmanship

of DM for effective monitoring for implementation of

fly ash notification

TPPs should comply with the provision in the fly ash

notification of giving subsidies on the cost of

transportation to brick manufacturing units .

DM should use provision under Section 15 of EPAct,

86 against the violators of fly ash notification.

Report to Niti Ayog by MOEF&CC

Red clay brick kilns located within 300 km need to be

converted into fly ash based brick manufacturing unit. One-

year time frame should be given for conversion of such brick

units. To encourage the conversion, TPPs should provide fly

ash free of cost and bear the full transportation charges upto

300 km to such units. To encourage the conversion, capital

subsidy to the brick units for converting to fly ash may be

provided by the Ministry of Power / MSME or a long-term, low-

interest scheme may be provided by Banks/SIDBI. The money

available with TPPs from auctioning of fly ash should be used

to give transportation subsidy.

Report to Niti Ayog by MOEF&CC

Thank you