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2
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
3
INSTALLED CAPACITY AT Dr.NTTPS
4
AWARDS WON BY Dr.NTTPS
Productivity Economic
Year Award Operation Award Award Received Medal Received
( Rs lakhs ) ( Rs Lakhs)
Contd.. 8
MAIN FACTORS FOR SUCCESS
Contd.. 9
MAIN FACTORS FOR SUCCESS
10
ORIGINAL DRY FLY ASH SYSTEMS INSTALLED
ALONG WITH MAIN EQUIPMENT
Unit No. Method of Collection Efficiency of the
System
1 Vacuum - Hydrovector 30%
2 Vacuum - Hydrovector 30%
3 Vacuum - Hydrovector 30%
4 Vacuum - Hydrovector 30%
5 Vacuum + Pressure 100%
6 Vacuum + Pressure 100%
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.
12
Cenospheres are also issued from the ash ponds of other stations
USE OF FLY ASH FOR PPC
COMPLIANCE OF IS-SPECIFICATIONS
CHEMICAL PARAMETERS OF FLY ASH
Constituent Test results IS 3812
Dr. NTTPS requirement
SiO2 72.3 35.0 min
SiO2 + Al2O3 + Fe2O3 90.1 70.0 min
MgO 1.65 5.0 max
Total sulphur as SO3 1.24 2.75 max
Alkalies as Na2O - 1.5 max
Loss on Ignition (LOI) 0.29 12.0 max
14
CEMENT PLANTS NEARER TO Dr.NTTPS
Name of the Cement Plant Installed
Capacity
(MTPA)
M/s The India Cements Ltd 4.80
M/s My Home Industries Ltd 2.76
M/s Sri Vishnu Cements Ltd 2.16
M/s Madras Cements Ltd 2.00
M/s Rain Commodities Ltd 1.10
M/s Andhra Cements Ltd 1.02
M/s Penna Cement Industries Ltd 1.00
M/s NCL Industries Ltd 0.85
15
Contd..
CEMENT PLANTS NEARER TO Dr.NTTPS
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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 incorporate
fly 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.
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IS CODES ON FLYASH
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PRACTICAL DEMONSTRATION OF FLYASH
BASED PRODUCTS
• Guidelines to all stations under APGENCO to use fly ash for in-house
consumption.
• 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.
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USE OF ASH FOR AGRICULTURE
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.
The field studies indicate increase of yield but final results are yet
to be received.
20
RESEARCH STUDIES THROUGH ANGRAU
Research studies through 4 research stations of Acharya N.G. Ranga
Agricultural University, Hyderabad are taken up for different crops.
21
RESEARCH STUDIES THROUGH ANGRAU
Contd..
Increase of yield in tons/Ha is reported as follows.
Treatments Maize at Rice at Rice at
Utukur Jagtial Vuyyuru
1) Farmers practice (FP) 2.73 6.46 7.3
2) FP + Fly ash at RD 3.65 8.11 7.35
22
RESEARCH STUDIES THROUGH ANGRAU
Contd..
Results
23
YEAR 2002 – A TURNING POINT
25
EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-1,3&4
Following equipment installed for each unit
Contd.. 26
EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-1,3&4
27
EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-2
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
Contd.. 28
EQUIPMENT INSTALLED FOR
UPGRADATION OF UNIT-2
29
PERFORMANCE AFTER UPGRADATION
Unit No. Up-gradation completed by Fly ash extraction
31
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Fly Ash Utilization at other stations of
APGENCO
Year RTPP KTPS V RTS ‘B’
Installed capacity 420 MW 500 MW 62.5 MW
1997-1998 1006040 1043409 107253
Ash Produced
Ash Utilised 4952 - -
% Utilised 0.5% - -
1998-1999 1162744 1159713 108165
Ash Produced
Ash Utilised 12385 - -
% Utilised 1.07% - -
1999-2000 1241078 993495 132401
Ash Produced
Ash Utilised 162044 - -
% Utilised 13.05% - - 33
Year RTPP KTPS V RTS ‘B’
2000-2001
Ash Produced 1176004 796940 139605
Ash Utilised 126193 - 2400
% Utilised 10.73% - 1.50%
2001-2002
Ash Produced 1005552 1085236 127524
Ash Utilised 188896 17023 2525
% Utilised 18.8% 1.6% 2%
2002-2003
Ash Produced 976302 1220469 112237
Ash Utilised 315310 44721 23495
% Utilised 32.3% 3.7% 20.9%
34
Year RTPP KTPS V RTS ‘B’
2003-2004
Ash Produced 892345 1087354 129180
Ash Utilised 369355 296164 23249
% Utilised 41.4% 27.2% 18.0%
2004-2005
Ash Produced 821224 1064937 109400
Ash Utilised 445131 238483 52400
% Utilised 54.2% 22.4%% 47.9%
2005-2006
Ash Produced 603205 895778 106770
Ash Utilised 385588 169207 71943
% Utilised 63.9% 18.9% 67.4%
35
Year RTPP KTPS V RTS ‘B’
2006-2007
Ash Produced 900307 1199861 93000
Ash Utilised 521459 356154 62391
% Utilised 57.92% 29.68% 67.09%
2007-2008
Ash Produced 1469548 1077312 129317
Ash Utilised 845354 451142 102234
% Utilised 57.52% 41.87% 79.05%
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Status of fly ash utilization at NTPC Limited
Name of Installed Coal Ash Fly ash Fly Ash %
TPS Capacity in Consumption Content in Generation utilization Utilization
MW In mtpa % In mtpa In mtpa
Ramagunda 2400 13.05 38.76 4.67 2.88 61.64
m
Simhadri 1000 5.84 38.94 2.27 1.83 71.47
Kahalgoan 1340 5.43 33.98 1.88 0.63 37.09
Korba 2100 12.47 39.57 4.94 3.03 61.44
Badarpur 705 4.09 32.58 1.33 1.08 81.10
Vindhyacha 3260 16.60 30.23 6.02 1.90 37.83
l
Talchar(KA 3000 16.38 37.11 6.82 1.20 17.62
N)
Talchar 460 2.79 38.00 1.06 1.04 98.40
(TPS)
Rihand 2000 10.51 28.90 3.04 1.86 61.10
Singrauli 2000 11.05 32.00 3.61 1.18 32.71
Unchar 1050 5.95 40.13 2.39 2.39 100.00
Tanda 440 2.70 39.07 1.06 0.64 60.87
Dadri 840 4.54 35.73 1.62 1.47 90.72
Farakka 1600 9.47 35.26 3.34 2.71 81.06 37