High Volume Fly Ash Concrete

HIGH VOLUME FLY ASH CONCRETE TECHNOLOGY
FLY ASH STATUS SUMMARY REPORT In INDIA

FLY ASH STATUS SUMMARY REPORT IN INDIA
TABLE OF CONTENTS
Objective7 Background...7 Source Of Fly ash In India.....7 Present Scenario on Fly ash in India..11 Source of Fly Ash..13 Ash Content in Indian Control..13 Fly Ash..13 Fly Ash Transportation..15 Dry.16 Conditioned..16 Stockpiled..16 Lagoon... ..16 Current Fly Ash Generation In India17 Current Ash Utilization.18 Present Scenario...19 Fly Ash Concrete Applications/ Projects..19
Ash Collection..12
Fact Sheets for States...21 Conclusion & Recommendation.21 Annexure23 Ministry of Environment & Forest23 Amendments....23 List of Major Thermal Plants28 Fly Ash Suppliers India.32 Tanveer Enterprises33 Ash Tech..34 Fly Ash Fact Sheets35 Tamil Nadu....35 Maharashtra38 Andhra Pradesh..44 Uttar Pradesh.49 Gujarat..55
NTPC Dadri...19 Road Construction and Paving.20 HCC Project.20 ACC Road Project.20 Other Projects20
Notification of Fly Ash.23

DISCLAIMER
General Information: The Summary Report has been prepared with the intention of providing a centralized information on the Fly Ash Availability and Use in India under the "High-Volume Fly Ash Concrete Technology" project, supported by Canadian International Development Agency (CIDA). The lead partners are the International Centre for Sustainable Development of Cement and Concrete (ICON), CANMET, Natural Resources Canada, and the Confederation of Indian Industry (CII). All the contents of this report are only for general information or use. Copyrights: The report is for information and general use only. All copy rights for its production and distribution rests with CII and the HVFAC project. The report and its contents are not for commercial sale. Accuracy of Information: No representations, warranties or guarantees whatsoever are made as to the accuracy, adequacy, reliability, completeness, suitability or applicability of the information to a particular situation. The report has been compiled based on the information provided by different agencies and CII & HVFAC project does not guarantee completely on the authenticity of the information.

ACKNOWLEDGEMENT
CII and HVFAC Project Partners CANMET acknowledges the support provided by National Thermal Power Plants (NTPC), State Electricity Boards & Captive Thermal Power Plants of industry for providing valuable information and data for the purpose of this report. The project also acknowledges the contribution made by the industry partners, Hindustan Construction Company Ltd., The Associated Cement Companies Ltd., Grasim Industries Ltd. (Cement Business) Gujarat Ambuja Cements Ltd., for providing valuable information related to the Flay Ash Status and management in India.

SUMMARY REPORT ON INDIAN FLY ASH OBJECTIVE: The purpose of this report is to collate information regarding Fly Ash generation and use in India. The report is also intended to provide a ready reference for the users of Fly Ash in construction on the availability and use of Fly Ash, especially good quality Fly Ash in India. BACKGROUND: India at present produces around 120 Million Tonnes of Ash per annum. The power requirements of the country is rapidly increasing with increase in growth of the industrial sectors. India depends on Thermal power as its main source (around 80% of power produced is thermal power), as a result the quantity of Ash produced shall also increase. Indian coal on an average has 35 % Ash and this is one of the prime factors which shall lead to increased ash production and hence, Ash utilization problems for the country. Out of the total ash produced , Fly ash contributes to a small percentage, majority being Pond ash and bottom ash. This report provides a compilation of such fly ash along with its present areas of use potential areas of other uses. 1.0 Source of Fly Ash in India According to Central Electricity authority of India, there are around 83 major coal fired thermal power plants and 305 hydro plants existing in India. As per the ministry of power statistics, the total installed generating capacity (Thermal + wind) during 2003-2004 was about 79838 MW and hydropower generation was 29500 MW. In addition to this, there are more than 1800 selected industrial units which had captive thermal power plants of >1MW. Table 1 provides basic statistics for fuel and power generation at the coal fired power plants in India. Table 1: Power and coal usage statistics at the thermal power plants in India
Sr.No Power Station Installed Capacity (MW/day) 705 277.5 Generation (MW/day) 502 136 Coal per unit of electricity (kg/KWH) 0.81 0.86 Million KWH per day(MU) 14.87 2.96
1R 2R
Badarpur I.P. Station

3R 4R 5R 6R 7R 8R 9R 10R 11P 12R 13R 14R 15R 16R 17P 18P 19R 20R 21 22R 23 24R 25R 26R 27R 28R 29R 30R 31R 32R 33R 34R 35 36R 37P 38R 39P 40P 41P 42R 43P 44R 45R 46R 47R 48P 49R 50I 51I 52
Rajghat Faridabad Panipat Bhatinda Lehra Ropar Kota Suratgarh# Anpara Harduagang Dadri Obra Panki Paricha Rihand Singrauli Tanda Unchahar Kutch% Sabarmati# Dhurvaran Gandhi Nagar Sikka Ukai Wanakbori Bhusawal Chandrapur Dahanu Khaper Kheda Koradi Nasik Paras Trombay Parli Amarkantak Sanjay Gandhi Korba Ii&Iii Korba West Korba Stps Satpura Vindhyachal Kothagudem Rayalseema Nellore Ramagundam Rgundam(Stps) Vijayawada Ennore Mettur Neyvelli@
135 165 650 440 420 1260 850 500 1630 385 840 1442 274 220 1000 2000 330 840 215 330 534 870 240 850 1470 478 2340 500 840 1080 910 58 1150 690 290 840 400 840 2100 1143 2260 1170 420 30 63 2100 1260 450 840 600
62 131 362 300 425 840 856 516 1630 135 653 1014 165 80 960 1545 195 826 166 326 348 722 225 775 1048 445 1705 412 630 662 810 29 658 625 201 770 315 630 2153 845 2204 1004 432 23 58 2160 1281 157 860 550
0.83 0.97 0.82 0.73 0.73 0.70 0.75 0.73 0.70 1.02 0.65 0.88 0.9 0.88 0.66 0.61 0.96 0.74 0.73 0.73 0.73 0.60 0.67 0.72 0.67 0.79 0.79 0.62 0.76 0.84 0.74 0.82 0.73 0.80 0.72 0.72 0.97 0.68 0.68 0.88 0.65 1.08 0.78 1.21 0.73 0.63 0.73 0.94 0.75
1.93 2.96 9.74 6.83 9.96 22.67 20.40 11.85 37.71 3.07 18.9 21.30 3.56 1.75 24.09 44.06 4.9 19.66 3.65 6.6 8.23 17.09 4.99 16.74 25.14 10.80 44.39 10.77 14.84 17.03 17.6 0.96 15.61 14.73 4.7 17.19 7.29 14.48 50.14 19.22 51.13 22.39 10.08 0.45 1.45 50.65 30.41 3.75 20.33 12.77

53I 54I 55R 56R 57R 58R 59R 60P 61R 62R 63R 64R 65R 66R 67 68R 69R 70R 71 72R 73R 74R 75P 76P 77P 78 79R 80 81 TOT AL
North Madras Tuticorin Raichur Barauni Muzaffarpur Patratu Tenughat Kahalgaon Bokaro A&B Chandrapura Mejia Durgapur-Dvc Bandel Calcutta New Cossipore S.Gen Station Durgapur -Dpl Kolaghat Bakreshwar* Santaldih Titagarh Budgebudge* Farakka Talcher-Ntpc Talcher-Stps Ib Valley Tps Bongaigaon Chandrapur(Assam) Namrup All India
630 1050 1260 310 220 770 420 840 805 750 630 350 530 190 130 135 390 1260 630 480 240 500 1600 460 1000 420 240 60 30 53216
646 1070 850 40 65 274 200 745 260 100 475 300 150 141 50.6 136 93 1210 383 150 240 500 1470 390 490 406 0 7.82 5.13
0.76 0.74 0.76 1.06 1.09 0.96 0.87 0.84 0.80 0.79 0.70 0.62 0.59 0.89 0.62 0.74 0.73 0.77 0.60 0.64 0.77 0.83 1.01 0.75 0.91 0.66 0.66 0.66 0.73
15.2 25.13 21.2 1.25 1.5 5.23 4.8 17.7 5.70 3.39 9.9 7.2 4.87 3.07 2.11 3.26 4.39 29.0 9.2 3.6 5.76 12 34.95 9.4 11.60 9.70 0.8 0.33 0.21
* Kg/KWH are the average for the Eastern region # Kg/KWH are the average for the western region @ Lignite is used as the fuel Based on monthly average R Rail feed plant P Pit-head plant I Inter modal Note: Amarkantak and Amarkantak Extension are merged together. Similarly Korba II and III are merged together.
Some of the prominent Power Plants which are also producing and providing good quality Fly Ash includes the following: Ropar Kota Annapara Dadri Rihand Singrauli Unchahar Chandrapur Dahanu Trombay Vindyanchal Raichur Ramagundam Korba

PRESENT SCENARIO ON FLY ASH IN INDIA

Over 75% of the total installed power generation is coal-based 230 - 250 million MT coal is being used every year High ash contents varying from 30 to 50% More than 110 million MT of ash generated every year Ash generation likely to reach 170 million MT by 2010 Presently 65,000 acres of land occupied by ash ponds Presently as per the Ministry Of Environment & Forest Figures, 30% of Ash is being used in Fillings, embankments, construction, block & tiles, etc.
1.1
Ash Collection Ash can be collected in following categories Dry Fly Ash Dry ash is collected from different rows of electrostatic precipitators. It is available in two different grades of fineness in silos for use as resource material by different users. Bottom Ash Bottom ash is collected from the bottom of the boiler and transported to hydro bins and then ash mound for use in road embankment. Conditioned Fly Ash Conditioned fly ash is also available in ash mound for use in land fills and ash building products.
Source of Fly Ash: 2.0 Ash Content in Indian Coal The quality of coal depends upon its rank and grade. The coal rank arranged in an ascending order of carbon contents is: Lignite --> sub-bituminous coal --> bituminous coal --> anthracite Indian coal is of mostly sub-bituminous rank, followed by bituminous and lignite (brown coal). The ash content in Indian coal ranges from 35% to 50%.

The coal properties including calorific values differ depending upon the colliery. The calorific value of the Indian coal (~15 MJ/kg) is less than the normal range of 21 to 33 MJ/Kg (gross). According to National Thermal Power Corporation (NTPC), coal is used for approximately 62.3% of electric power generation in India, oil and gas accounts for 10.2%, hydro's share is 24.1%, nuclear, wind, and other contribute remaining 3.4%. Figure 1: Geographical location of major thermal power plants in India
3.0
Fly Ash Fly ash is a fine, glass powder recovered from the gases of burning coal during the production of electricity. These micron-sized earth elements consist primarily of silica, alumina and iron. When mixed with lime and water the fly ash forms a cementitious compound with properties very similar to that of Portland cement. Because of this similarity, fly ash can be used to replace a portion of cement in the concrete, providing some distinct quality advantages. The concrete is denser resulting in a tighter, smoother surface with less bleeding.

Fly ash concrete offers a distinct architectural benefit with improved textural consistency and sharper detail. Fly Ash is also known as Coal Ash, Pulverized Flue Ash, Pozzolona.
Typical Chemistry of Coal Fly Ash (in Wt.%) ClassF* low-Fe 46-57 18-29 6-16 1.8-5.5 0.7-2.1 1.9-2.8 0.2-1.1 0.4-2.9 0.6-4.8 1-2 ClassF* high-Fe 42-54 16.5-24 16-24 1.3-3.8 0.3-1.2 2.1-2.7 0.2-0.9 0.5-1.8 1.2-5.0 1-1.5 ClassC* high-Ca 25-42 15-21 5-10 17-32 4-12.5 0.3-1.6 0.8-6.0 0.4-5.0 0.1-1.0 <1 Class C* low-Ca 46-59 14-22 5-13 8-16 3.2-4.9 0.6-1.1 1.3-4.2 0.4-2.5 0.1-2.3 <1
SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 LOI TiO2
As per ASTM Standards Indian Standard (IS) On Fly Ash is as annexure 4.0 Fly Ash Transportation
Fly ash can be supplied in four forms: Dry: This is currently the most commonly used method of supplying fly ash. Dry fly ash is handled in a similar manner to Portland cement. Storage is in sealed silos with the associated filtration and desiccation equipment, or in bags.
Conditioned: In this method, water is added to the fly ash to facilitate compaction and handling. The amount of water added being determined by the end use of the
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fly ash. Conditioned fly ash is widely used in aerated concrete blocks, grout and specialist fill applications. Stockpiled: Conditioned fly ash not sold immediately is stockpiled and used at a later date. The moisture content of stockpiled ash is typically 10 to 15%. This is used mainly in large fill and bulk grouting applications. Lagoon: Some power stations pump fly ash as a slurry to large lagoons. These are drained and when the moisture content of deposited fly ash has reached a safe level may be recovered. Because of the nature of the disposal technique, the moisture content can vary from around 5% to over 30%. Lagoon fly ash can be used in similar applications to stockpiled conditioned fly ash. 5.0 Current Fly Ash Generation in India
The current electricity generation (as on March 31, 2004) in India is about 1,12,058 MW, 65-70% of which is thermal (mostly coal based). According to an estimate 100,000 MW capacity or more would be required in the next 10 years due to continually increasing demand for electricity. In India fly ash generation is around 110 million tonnes / year and is set to continue at a high rate into the foreseeable future. Presently majority of the coal ash generated is being handled in wet form and disposed off in ash ponds which is harmful for the environment and moreover ash remains unutilized for gainful applications. India has sufficient coal reserves. In India almost 65-70% of electricity production is dependent on coal which produces a huge quantity of Fly Ash as residue which is allegedly a waste product in Thermal Power Stations. Fly Ash has a vast potential for use in High Volume fly ash concrete especially due its physic-chemical properties. A good amount of research has already been done in India and abroad on its strength and other requisite parameters. Current fly ash generation and utilization in six major states; Gujarat, Maharashtra, Tamil Nadu, Rajasthan, Andhra Pradesh and Uttar Pradesh is presented in the present report 6.0 Current Ash Utilization
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According to the MOEF Gazette Notification dated Sept. 14, 1999, the existing power stations have to achieve 20% ash utilization within three years and 100% utilization in 15 years from the date of notification. New Stations have to achieve 30% ash utilization within 9 years and 10% ash utilization within 3 years and 100% utilization within 4 years and 100% annual increase. Presently, out of 110 million tonnes of Total ash generated, about (30%) is being utilized. Therefore thermal power stations are under great pressure to find useful applications of fly ash. The technology utilizing fly ash in high volume fly ash concrete can provide an avenue for utilization of fly ash on a bulk scale. PRESENT SCENARIO: Fly Ash Concrete Applications / Projects NTPC Dadri The NCPS Dadri project has the unique distinction of having Asia's first 100% dry ash extraction with transit ash storage silos and final storage place converted to a green ash mound.
Dadri ash has been used successfully in the following applications: Land fills Road embankments Road construction Portland Pozzolona cement Building products Concrete
Road Construction and Paving Ash has been used in concrete roads and roller compacted concrete roads which are not only durable,
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but have long service of 30-35 years without much maintenance in comparison to WBM and Bituminous Macadam roads.
HCC Projects Development of high strength and high performance triple blended concrete for the Bandra-Worli Sea Link project.* High performance concrete for RAPP (5&6) incorporating fly ash.& Development of high volume fly ash concrete mixes for pavement quality concrete for various road works ACC Road Project ACC has constructed demonstration roads using high volume fly ash concrete with upto 50 % replacement at its Greater Noida and Faridabad Ready Mix Plants. It has also constructed a small demonstration patch at Tikaria-Amethi, in its Cement Plant. Other Projects 1. Construction of road (experimental basis about 1.00 Km length) using fly ash, at Raichur,Karnataka.This Project was implemented by PWD(Public Works Department),Raichur and CRRI.(Central Road Research Institute) 2. Use of Roller Compacted concrete technology using high doses of fly ash for construction of Saddle Dam and upper Dam of Ghatghar pumped storage Scheme near Nashik, have been implemented in joint co operation of Maharashtra Irrigation Department,Central Soil and Mineral Research Station,University of Roorkee. FACT SHEET FOR STATES: India has a number of thermal power plants located all over the country. A state wise fact sheet for Fly Ash has been prepared. In the first step only six states have been selected. The selection of these states have been done keeping in view the amount of fly ash produced in these states and the amount of infrastructure development taking place in these states or planned for future. The states thus selected are Tamil Nadu, Karnataka, Uttar Pradesh, Maharashtra, Andhra Pradesh & Gujarat. CONCLUSION & RECOMMENDATIONS:
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The Fly Ash Summary Report provides a clear indication on a number of areas related to Fly Ash generation and use in the India. India produces a lot of Ash in its Thermal Power production process , but the quality of Ash produced is a major hindrance in its widespread utilization. The Fly Ash constitutes only a small fraction of the Total Ash produced, primarily because of the Technological Limitation of the Power Plants which are mostly old and still produce coarse and wet ash which is difficult to use for construction purposes. Also Wet Ash is difficult to handle ands transport, resulting in formation of huge Ash Ponds. Based on the information gathered, collated & analyzed, some of the Recommendations for enhancing use of Fly Ash in construction is as follows : Dry Collection Systems at thermal Power Plants needs to be enhanced. Facilities needs to be provided on-site at thermal power plants for conversion of coarser fly ash into finer one. Most of the finer fly ash is being sourced by cement plants for their PPC production, hence the Fly Ash available for construction is limited. The same may be better organized so as to enable the construction companies to access it more easily. Good transportation facilities need to be created and organized for enabling easy availability at point of use for the construction companies. Greater awareness to construction companies need to be provided for use of fly ash in construction.
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ANNEXURE
MINISTRY OF ENVIRONMENT AND FORESTS
Notification on Fly Ash

New Delhi, the 27th August 2003. S.O. 979 (E):- Whereas a draft of certain amendments to the Government of India in the Ministry of Environment and Forests notification number S.O.763 (E) dated 14th September, 1999 (hereinafter referred to as the said notification) which the Central Government proposes to make under sub-section (1) and clause (v) of subsection (2) of section 3 of the Environment (Protection) Act, 1986 (29 of 1986) read with clause (d) of sub-rule (3) of rule 5 of the Environment (Protection) Rules, 1986, were published in the Gazette of India, Extraordinary, Part II, Section 3, Sub-section (ii) dated the 6th November, 2002 vide S.O. 1164 (E), dated the 5th November, 2002 inviting objections and suggestions from all persons likely to be affected thereby before the expiry of sixty days from the date on which copies of the Gazette containing the said draft amendments were made available to the public. And, whereas copies of the said Gazette were made available to the public on 27 November 2002; And, whereas all the objections and suggestions received from all persons likely to be affected thereby in respect of the said draft notification have been duly considered by the Central Government;
th
Now, therefore, in exercise of the powers conferred by sub-section (1) and clause (v) of sub-section (2) of section 3 of the Environment (Protection) Act, 1986 (29 of 1986) read with clause (d) of sub-rule (3) of rule 5 of the Environment (Protection) Rules, 1986, the Central Government hereby makes the following amendments to the said notification, namely: AMENDMENTS 1. In the said notification, in the preamble, for the words "fifty kilometers, the words "one hundred kilometres shall be substituted. 2. In the said notification, in paragraph 1, (a) in sub-paragraph (1), for the words "fifty kilometers, the words "one hundred kilometres shall be substituted; (b) after sub-paragraph (1), the following sub- paragraphs shall be inserted, namely: -
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"(1A) Every construction agency engaged in the construction of buildings within a radius of fifty to one hundred kilometres from a coal or lignite based thermal power plant shall use fly ash bricks or blocks or tiles or clay fly ash bricks or cement fly ash bricks or blocks or similar products or a combination or aggregate of them in such construction as per the following minimum percentage (by volume) of the total bricks, blocks and tiles, as the case may be, used in each construction project, namely:(i) 25 per cent by 31st August 2004; (ii) 50 per cent by 31st August 2005; (iii) 75 per cent by 31st August, 2006; and (iv) 100 per cent by 31st August 2007. In respect of construction of buildings within a radius of 50 kilometres from a coal or lignite based thermal power plant the following minimum per centage (by volume) of use of bricks, blocks and tiles shall apply: (i) 50 per cent by 31st August 2004; (ii) 100 per cent by 31st August 2005. (1B) The provisions of sub-paragraph (1A) shall be applicable to all construction agencies such as Housing Boards and those in the private sector builders of apartments, hotels, resorts and cottages and the like. It shall be the responsibility of the construction agencies either undertaking the construction or approving the design or both to ensure compliance of the provisions of sub-paragraph (1A) and to submit such returns as may be called for and compliance reports to the State Government or Union territory Administration; (c) for sub-paragraph (2), the following sub-paragraphs shall be substituted, namely: (2) The authority for ensuring the use of specified quantity of ash as per subparagraph (1) shall be the concerned Regional Officer of the State Pollution Control Board or the Pollution Control Committee, as the case may be. (2A) The concerned State Government shall be the enforcing and monitoring authority for ensuring compliance of the provisions of sub- paragraph (lA).; (d) in sub-paragraph (3), for the words, brackets and figure under para (1) the words, brackets and figure under sub-paragraph (1) shall be substituted; (e) after sub-paragraph (3), the following sub-paragraphs shall be inserted, namely: (3A) A decision on the application for manufacture of fly ash bricks, block, and tiles and similar other fly ash based products shall be taken within thirty days from the
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date of receipt of the application by the competent authority. A decision on consent to establish the brick kiln shall be taken by the Pollution Control Board or the Pollution Control Committee, as the case may be, within a period of thirty days from the date of receipt of application by it. (3B) In case of non-compliance of the provisions of sub-paragraph (1) of paragraph 1, the competent authority, in addition to cancellation of consent order issued to establish the brick kiln, shall move the district administration for cancellation of the mining lease. (3C) All authorities sanctioning or renewing any land, soil or clay mining lease shall not grant such lease or extension of lease or renewal to clay brick, block or tile manufacturing unit within a radius of one hundred kilometres of the coal or lignite based thermal power plant in cases where the manufacturer does not mix a minimum of 25 per cent by weight of fly ash or pond ash in the manufacture of bricks or blocks or tiles. The cancellation of mining lease shall be decided by the district administration after giving the holder of such lease an opportunity of being heard. To enable the competent authority to verify the actual use of ash, the thermal power plant shall maintain month-wise records of ash made available to each brick kiln. (3 D) It shall be sufficient compliance of this notification if within twelve months from the date of issue of this notification, manufacturers of clay bricks, blocks and tiles located within a radius of 50 to 100 kilometres of a coal or lignite based thermal power plant comply with the provisions of sub-paragraphs (1) and (2).. (f) in sub-paragraph (4), after brackets and letters (AIBTMF), the words or a representative of local brick kiln owners association, federation, group. shall be inserted; (g) after sub-paragraph (4), the following sub-paragraphs shall be inserted, namely: -
"(5) No agency, person or organization shall, within a radius of 100 kilometres of a thermal power plant undertake construction or approve design for construction of roads or flyover embankments in contravention of the guidelines/ specifications issued by the Indian Road Congress (IRC) as contained in IRC specification No. SP: 58 of 2001. Any deviation from this direction can only be agreed to on technical reasons if the same is approved by Chief Engineer (Design) or Engineer-in-Chief of the concerned agency or organization or on production of a certificate of "Pond ash not available from the thermal power plant(s) (TPPs) located within 100 kilometres of the site of construction. This certificate shall be provided by the TPP within two working days from the date of making a request for ash.
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(6) Soil required for top or side covers of embankments of roads or flyovers shall be excavated from the embankment site and if it is not possible to do so, only the minimum quantity of soil required for the purpose shall be excavated from soil borrow area. In either case, the topsoil should be kept or stored separately. Voids created due to soil borrow area shall be filled up with ash with proper compaction and covered with topsoil kept separately as above. This would be done as an integral part of embankment project within the time schedule of the project. (7) No agency, person or organization shall within a radius of 100 kilometres of a coal or lignite based thermal power plant allow reclamation and compaction of lowlying areas with soil. Only pond ash shall be used for compaction. They shall also ensure that such reclamation and compaction is done in accordance with the byelaws, regulations and specifications laid down by the authorities mentioned in subparagraph (3) of paragraph 3.. 3. In the said notification, in paragraph 2, (a) for the marginal heading Utilisation of ash by Thermal Power Plants, the marginal heading Responsibilities of Thermal Power Plants shall be substituted; (b) for the opening words, All coal or lignite based thermal power plants shall utilise the ash generated in the power plants as follows: -, Every coal or lignite based thermal power plant shall take the following steps to ensure the utilisation of ash generated by it, namely: -; (c) in sub- paragraph (1), (i) after the words products such as cement, concrete blocks, bricks, panels, the words or a combination thereof shall be inserted; (ii) the following shall be added at the end, namely: The thermal power plants have to ensure availability of fair quantity of ash to each user including brick kilns.; 4. In the said notification, after paragraph 2, the following paragraph shall be inserted, namely: 2A. Utilization of fly ash for reclamation of sea. Subject to the rules made under the Environment (Protection) Act, 1986, (29 of 1986) reclamation of sea shall be a permissible method of utilization of fly ash.. 5. In the said notification, in paragraph 3, the following sub-paragraphs shall be inserted, namely: (2A) All agencies including the Central Public Works Department and State Government agencies concerned with utilization of fly ash for construction purposes shall, within three months from the 1st day of September, 2003 make provisions for
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the use of fly ash and fly ash based bricks, blocks or tiles or aggregates of them in the schedule of approved materials and rates. (2B) All agencies undertaking construction of roads or fly over bridges including Ministry of Road Transport and Highways (MORTH), National Highways Authority of India (NHAI), Central Public Works Department (CPWD), State Public Works Departments and other State Government Agencies, shall, within three months from the 1st day of September, 2003 a. make provisions in their tender documents, schedules of approved materials and rates as well as technical documents, including those relating to soil borrow area or pit as per sub-paragraph (7) of paragraph 1; and b. make necessary specifications/guidelines for road or fly over embankments that are not covered by the specifications laid down by the Indian Road Congress (IRC). . [F.No.16-2/95-HSMD] (Dr. V. Rajagopalan) Joint Secretary to the Govt. of India Footnote. - The principal notification was published in the Gazette of India, Part II, Section 3, sub-section (ii) vide S.O.763 (E) dated 14.9.1999.
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List of Major Thermal Power Plants Plant Owner City

Mettur North Chennai Ennore Neyveli Zero Chandrapur Trombay (coalfired section) Koradi Nasik Khaperkheda Parli Dahanu Bhusawal Ramagundam Vijayawada Tamil Nadu SEB Tamil Nadu SEB Tamil Nadu SEB CMS India Ltd. Maharashtra SEB Tata Power Co. Ltd. Maharashtra SEB Maharashtra SEB Maharashtra SEB Maharashtra SEB BSES Ltd. Maharashtra SEB NTPC Andhra Pradesh, Power Generation Corp. Andhra Pradesh, Power Generation Corp. NTPC Andhra Pradesh, Power Generation Corp. Rashtriya Ispat Nigam Ltd. Mettur Chennai Ennore Neyveli Durgapur Mumbai
Location State
Tamil Nadu Tamil Nadu Tamil Nadu Tamil Nadu
Fuel
Total Capacity (MW)

840 630 450 250 2,340 1150 1,100 840 690 500 483 2,100 1260
TAMIL NADU
Coal Coal Coal Coal
MAHARASHTRA
Maharashtra Coal Maharashtra Coal;Nat ural Gas, Koradi Maharashtra Coal Nasik Maharashtra Coal Khaperkheda Maharashtra Coal Parli Vaijnath Maharashtra Coal Thane Dist. Maharashtra Coal Jalgaon Maharashtra Coal Karimnagar Andhra Dist. Pradesh Krishna Andhra Pradesh Paloncha Andhra Pradesh Andhra Pradesh Andhra Pradesh Coal Coal
ANDHRA PRADESH
Kothagudem
Coal
1180
Simhadri Rayalaseema
Paravade Cuddapah Dist.
Coal Coal
1,000 420
Vizag Steel Works * Talcher Angul Smelter
Visakhapat Andhra nam Pradesh
Coal
236
ORISSA
NTPC National Aluminum Corp. Ltd. Ib Valley OPGC; AES Rourkela Works Steel Authority of * India Ltd. Choudwar Indian ChargeChrome Ltd. (ICCL) Angul Angul Orissa Orissa Coal Coal Coal Coal Coal 1,970 720 420 269 108
Barhanpalli Orissa Rourkela Orissa Choudwar Orissa
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KARNATAKA
Raichur Torangallu Works * KPCL Jindal Tractebel, Power Co. Ltd. Raichur Karnataka Dist. Torangallu Karnataka Coal 1,470 Blast 260 Furnace Gas;Coal Coal Coal Coal Coal Coal Coal Coal 2,260 1,143 840 300 270 112 106
MADHYA PRADESH
Vindhyachal Madhya Pradesh Satpura Madhya Pradesh SEB Betual Dist. Madhya Pradesh Sanjay Gandhi Madhya Pradesh SEB Umaria Madhya Dist. Pradesh Amarkantak Madhya Pradesh SEB Shahdal Madhya Pradesh NTPC BALCO NTPC Korba Madhya Pradesh Raigarh Works * Jindal Steel & Power Raigarh Madhya Ltd. Pradesh Nagda Works * Melodeon Exports Nagda Madhya Pradesh NTPC Sidhi
CHHATTISGARH
Korba STPS Korba West Korba East Farakka Kolaghat NTPC Chattisgarh SEB Chattisgarh SEB Bilaspur Bilaspur Bilaspur Chattisgarh Chattisgarh Chattisgarh Coal Coal Coal 2,100 840 400 1,630 1260 630 630 530 500 480 405 350 240 225 150 140 135 2,050
WEST BENGAL
NTPC West Bengal Power Development Corp. Bakreshwar West Bengal Power Development Corp. Mejia DVC Bandel West Bengal SEB Budge Budge CESC Ltd. Santaldih West Bengal SEB Durgapur West Bengal SEB Durgapur DVC DVC Titagarh CESC Ltd. Cossipore CESC Ltd. Mulajore CESC Ltd. Durgapur Works Steel Authority of * India Ltd. Southern CESC Ltd. Singrauli NTPC Murshidabad West Bengal Coal Medinipurt West Bengal Coal Dist. Birbhum Dist. West Bengal Coal Durlavpur Hooghly Calcutta Santaldih Burdwan Waria Titagarh Calcutta Shyamnagar Durgapur Calcutta West Bengal West Bengal West Bengal West Bengal West Bengal West Bengal West Bengal West Bengal West Bengal West Bengal Coal Coal Coal Coal Coal Coal Coal Coal Coal Coal
West Bengal Coal Coal
UTTAR PRADESH
Sonebhadra Uttar Pradesh
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Anpara Obra Rihand
UPRVUNL UPRVUNL NTPC
Dadri (coal-fired NTPC section) Unchahar NTPC Renusagar * Hindalco Industries Ltd. Harduaganj UPRVUNL Tanda NTPC Panki UPRVUNL Paricha UPRVUNL Wanakbori Gandhi Nagar Ukai Dhuvaran Sabarmati Surat Gujarat SEB Gujarat SEB Gujarat SEB Gujarat SEB Ahmedabad Electric Co. Ltd. Gujarat Industrial Power Corp. Ltd. (GIPCL) Gujarat SEB Gujarat SEB NTPC Bihar SEB
Dist. Mirzapur Dist. Obra Dist. Sonebhadra Dist. Dadri
Uttar Pradesh Uttar Pradesh Uttar Pradesh Uttar Pradesh
Coal Coal Coal Coal Coal Coal Coal Coal Coal Coal Coal Coal Coal Coal Coal Coal
1,630 1,550 1,000 840 840 619 440 440 279 220 1,470 870 850 534 450 250
Rai Bareilli Uttar Pradesh Renukoot Uttar Pradesh Harduaganj Faizabad Panki Jhansi Uttar Pradesh Uttar Pradesh Uttar Pradesh Uttar Pradesh Gujarat Gujarat Gujarat Gujarat Gujarat Gujarat
GUJARAT
Sevalia Gandhi Nagar Ukai Dam Anand Sabarmati Surat
Sikka Kutch Kahalgaon Barauni Jamshedpur Works * Muzaffarpur Bokaro Patratu Chandrapura Tenughat Bokaro Works *
Sikka Kutch
Gujarat Gujarat
Coal Coal Coal Coal Coal Coal Coal Coal Coal Coal Coal
240 210 840 310 238 220 805 770 750 420 287
BIHAR
Kahalgaon Bihar Hazaribagh Bihar Dist. Tata Iron & Steel Co. Jamshedpur Bihar Bihar SEB DVC Jharkhand SEB DVC Jharkhand SEB Steel Authority of India Ltd. Kanti Bihar Jharkhand Jharkhand Jharkhand Jharkhand Jharkhand
JHARKHAND
Bokaro Patratu Chandrapura Bokaro Dist. Bokaro
PUNJAB
Ropar Punjab SEB Guru Hargobind Punjab SEB Ropar Bhatinda Punjab Punjab Coal Coal 1,260 860
22

HARYANA
Tau Devi Lal Faridabad Haryana Power Panipat Generation Corp. Ltd. Faradibad Power Faridabad Systems Ltd. Rajasthan RV Utpadan Nigam Rajasthan RV Utpadan Nigam NTPC Indraprastha Power Generating Co. Ltd. Delhi Transco Ltd. Assam SEB Suratgarh Kota Haryana Haryana Coal Coal 860 165
RAJASTHAN
Suratgarh Kota Rajasthan Rajasthan Coal Coal 1,000 850
DELHI
Badarpur Indraprastha Rajghat Bongaigaon New Delhi Delhi Territory Coal New Delhi Delhi Territory Coal New Delhi Delhi Territory Coal 720 248 135 240
ASSAM
Salakati Dist. Assam Coal
Fly Ash Suppliers-India Tanveer Enterprises Tanveer Enterprises, with its corporate headquarters in Delhi, India, has recycled 12,50,000 tons approx. of fly ash in India during the last 10 years. With Four distribution terminals (NTPC- DADRI, NTPC-BARDARPUR, NTPC-RIHAND & PANIPAT THERMAL POWER STATION-HARYANA, MSEB Khaparkheda Maharashtra) Tanveer Enterprises (TE) is one of the major fly ash suppliers to Industries like Ready Mix Concrete, Cement Plants, Asbestos Sheet, Bricks, Blocks, Interlock Blocks & Pavers, and Building Contractors etc. Dry Graded Fly Ash from ESP, Silos can be supplied. TE has their own fleet of trucks, & highly trained staff for quality maintenance & round the clock operations. TE has installed its own state of art equipment for collection of Fly Ash from ESP's (Electro Static Precipitators) at the power plants.
Address
23

L-10,First Floor, Kailash Colony NEW DELHI 110048, India Tel. No.: 91-11- 55656805, 51622968 Tele. Fax: 91-11-51622968 E-mail: support@iflyash.com Web Site: www.iflyash.com AshTech AshTech, with its corporate headquarters in Delhi, India, has recycled 12,50,000 tons approx. of fly ash in India during the last 10 years. AshTech is one of the major fly ash suppliers to Industries like Ready Mix Concrete, Cement Plants, Larsen & Toubro / KSHI for Prestigious Delhi Metro Rail Corporation, Asbestos Sheet, Bricks, Blocks, Interlock Blocks & Pavers, and Building Contractors etc.
Fly ash from ESP, Silos, Ash Mounds, and Wet Ponds Ash can be supplied. AshTech has their own fleet
24

of trucks, & trained staff for quality maintenance & round the clock operations. AshTech has installed its own state of art equipment for collection of Fly ash from ESP's (Electro Static Precipitators) at the power plants. AshTech can supply fly ash of different quality and properties as per your specification at very competitive rates, in bulk carriers, or packed in HDPE bags (40 kgs). AshTech has its own fleet of pneumatic tank trailers for hauling bulk materials & trucks to deliver material to the Ready Mix Concrete, Construction, Asbestos, brick/block & paving industries. L-10, First Floor Kailash Colony New Delhi-110048, INDIA Tel No.: 91-11- 55656805, 51622968 TeleFax: 91-11-51622968 Web: http://www.ashtechindia.com E-mail : ashtech@touchtelindia.net
FLY ASH FACT SHEET State: Tamil Nadu

Tamil Nadu is the fourth largest State of the country. It has a population of 62.11 million, about 6.05 per cent of the total Indian population, and 30 administrative districts. Agriculture is the mainstay of the economy, with most of the population dependent upon it for their livelihood. Nevertheless, Tamil Nadu is among the most industrialised States and ranks next to Maharashtra in terms of the contribution made by the manufacturing sector to net state domestic product. Per capita income was below the national average during the 1980s but crossed the national average since the 1990s. There are four major coal based thermal power plants in the state with a capacity of around 2200 MW. 1.
State
Tamil Nadu
25

2. 3. I. II. III. IV.
Total number of thermal power plants Major thermal power plants Mettur Tamil Nadu SEB Mettur North Chennai Tamil Nadu SEB Chennai Ennore Tamil Nadu SEB Ennore Neyveli CMS India Ltd. Neyveli 840 MW 630 MW 450 MW 250 MW
26
Name of plant
Quantity of fly ash generation Total Dry Wet
Ash collection system
Current fly ash use Quantity Application used
Current user
Transportation data Mode of transport & distance km Trans portat ion cost
Other fly ash utilization activities Projects Cement producti on (PPC)
Neyveli Lignite Corporation Limited CMS india ltd.
1357298
1139975
217323
Silos are used.
1.2% of fly ash being used
0.2% of Fly Ash used in Bricks and blocks. 1.1% of Fly Ash used in Cement industries. 0.08% of Fly Ash used in Earth filling. 0.1% of Fly Ash used in NLC Precasting yard.
Madras Cement Ltd Dalmia cements Barath Limited Gracim Industries Limited The India Cements sankari works The indian cements Daiavoi Works Vijay Cements Pvt Ltd L &T Madras Cement Ltd Inbdia Cement Small Scale Industry
Chennai
Tamil Nadu State Electricity Board North Chennai
Pressurized dense Fly ash conveying system with PLC & silos.
26.58% of fly ash being used
2.42% of Fly Ash(Dry) used in Bricks and blocks. 22.48% of Fly Ash used in Cement industries. 1.68% of Fly Ash used in Concrete Mortar.
1319860
923902
395958
Ash dipper / bulker Ash dipper / bulker Ash dipper / bulker Ash dipper / bulker Ash dipper / bulker Ash dipper / bulker Tanker Tanker Tanker Tanker
45
125
95
200
48
90
125 275 275 25
FLY ASH FACT SHEET State: Maharashtra

Maharashtra is the second most populous State in the country, where per capita income is 40 per cent higher than the all India average. Maharashtra is located on the west coast along the Arabian Sea and is among the richer States of the country. It has an uneven natural resource endowment. Maharashtras 35 districts are divided into 6 revenue divisions. Being more urbanised than most States in the country, almost 43 per cent of its population, much of it migrant, lives in towns and cities. There are around eight major coal based thermal power plants in the state with a capacity of around 7500 MW. Most of these power plants are owned by the state government.
1. 2. 3. I. II. III. IV. V. VI. VII. VIII.
State
Total number of major thermal power plants Major thermal power plants Chandrapur Maharashtra SEB Durgapur Trombay (coal-fired section) Tata Power Co. Ltd. Mumbai Koradi Maharashtra SEB Koradi Nasik Maharashtra SEB Nasik Khaperkheda Maharashtra SEB Khaperkheda Parli Maharashtra SEB Parli Vaijnath Dahanu BSES Ltd. Thane Dist. Bhusawal Maharashtra SEB Jalgaon
Maharashtra
2,340 MW
1150 MW
1,100 MW
840 MW 690 MW 500 MW 483 MW
Name of plant
Quantity of fly ash generation Total Tons Dry Tons Wet Tons
Current fly ash use
Current user
Transportati on data
Mode of transport & distance (km) Transp ortatio n cost
Other fly ash utilization activities Projects Cemen t produc tion (PPC) Cement industry
Quantity used
Application
773371
618697
154674
Jalagaon Maharashtra SEB Bhusawal
Both wet and dry.

Ash is converted to slurry form by mixing water through hydroejector & then pumped to Ash bund from where ash is collected. Provision is made to the outlet of ESP hoppers to collect dry fly ash by user manually.
47 %of the fly ash used.
30 %of the fly ash used in FA bricks and blocks. 4%of the fly ash used in cement industry. 13 %of the fly ash used in agriculture.
Orient Cement Brick Manufacturing
Truck
25
Bircks, blocks
Truck and Tractor
100
Agriculture 50 Truck and Tractor
1146260
917000
233600
Parli Vaijnath
Maharashtra SEB Parli
Dry fly ash from all units is being collected in jumbo bags except first row.
1.9 %of both the fly ash used in FA bricks and blocks. 6.61%of both the fly ash used in cement industry. 0.50 %of the wet fly ash used in agriculture. 19.92 %of the wet fly ash used in land development.
565917
57350
108567
Thane District BSES Dahanu
Manually operated wet system
20% of the fly ash used
0.14% of the fly ash (dry) used in FA bricks and blocks. 0.58% of the fly ash (wet) used in Brick Kiln. 0.008% of the fly ash (dry) used in agriculture. 0.06% of the fly ash (dry) used in land development.
M/s Birla Super Cement Sholapur M/s Visaka Cement Ind. Ltd. Pune M/s New Sahyadri Ind. Ltd. Pune M/s Swastik Ind. Chinchwad Pune M/s Shakti Roofing Pvt Ltd. Pune M/s Everest Industries Ltd. Nashik M/s Jai Bilidicon Products Ltd. Pune M/s Proctor & Walker Pune M/s Ash Crete Pune M/s Ambica Bricks Parli -V Hemant Bafna Manchar Irani M/s Satish Carriers Plastichem Distributors Ashtech India Pvt. Ltd.
Truck
220
Truck
325
Truck
300
Truck
370
Truck
350
Truck
380
Truck
370
Truck Truck Truck
370 370 15 14 8
4990022
3742517
Durgapur Maharashtra SEB Chandrapur
1247505
Nil
0.79% of the fly ash (dry) used in FA bricks and blocks. 1.42% of the fly ash (dry) used in Cement Industry. 0.05% of the fly ash (wet) used in stowing in mines. 1.72% of the fly ash (wet) used in cement (pond ash). O.05% of fly ash (wet) used for other purposes.
Nil
FLY ASH FACT SHEET State: Andhra Pradesh

In the recent past, Andhra Pradesh has emerged on the forefront of economic development of the country. The state has taken rapid strides in industrialization and now enjoys leadership status in knowledge industry sectors like IT, Biotech, Drugs and Pharmaceuticals etc. The state forms an integral part of the growth powerhouse of the Southern Region. The average annual growth rate of Andhra Pradesh during the last three years was around 7 %. The State of Andhra Pradesh is ranked third in terms of investments received since liberalisation of Industrial Policy in 1991. According to official sources Andhra Pradesh is ranked fourth, with total industrial investment of 1,54,129 crores from 335 projects and is ranked first in terms of foreign industrial investment with 56,966 crores from 32 projects. Since liberalization in 1991, 3279 new proposals with investment worth Rs. 1, 10,109 crores were received in the state. Out of these, 1386 projects with an investment of Rs. 15,365 crores have gone into production. There are around six major coal based thermal power plants with a total capacity of around 6200 MW. Most of the major thermal power plants in the state are government owned and are efficient in operation. 1. Andhra State 2. 3. I. II. III. IV. V. Total number of major thermal power plants Major thermal power plants Ramagundam NTPC Karimnagar Dist. Vijayawada Andhra Pradesh, Power Generation Corp. Krishna Kothagudem Andhra Pradesh, Power Generation Corp. Paloncha Simhadri NTPC Paravade Rayalaseema Andhra Pradesh, Power Generation Corp. Cuddapah Dist. 2,100 MW 1260 MW 1180 MW 1,000 MW 420 MW Pradesh 06
VI.
Vizag Steel Works Rashtriya Ispat Nigam Ltd. Visakhapatnam
236 MW
Name of plant
Quantity of fly ash generation Total Dry Wet Tons Tons Tons
Current fly ash use Quantit Application y used
Current user
Transportation data Mode of transport and distance from plant Transp ortatio n cost
Other fly ash utilization activities Projects Cemen t produc tion (PPC)
893063
446400
Kadapa/ Cuddapah District Andhra Pradesh Power Generation Corp. Rayalseema
525308
Wet : ash is mixed with water and pumped to ash pond. Dry : ash is collected in two RCC silos of 360 MT capacity each and issued to cement factories and brick manufaturers.
20000
10000
10000
Paravade NTPC Simhadri
Three silos 150 T each.
22.45% of the fly ash (dry) used in FA bricks and blocks. 74.99 (2.11wet and 76.22 dry) % of the fly ash used in cement industry. 2.56% of the fly ash used in other purposes. Fly ash brick and blocks.
50 current users in Vishakha patnam. L&T using for RMC plant.
Bricks and Blocks.
Steel Plant Slag
FLY ASH FACT SHEET

Name of plant Quantity of fly ash generation Tot Dry Wet al Ton Ton Ton s s s Ash collection system Current fly ash use Quant Applicatio ity n used Current user Transportation data Mode of transpo rt and distanc e from plant Trans portat ion cost Other fly ash utilization activities Projec Ceme ts nt produ ction (PPC)
893063
446400
Kadapa/ Cuddapah District Andhra Pradesh Power Corp. Rayalseema Generation
525308
Wet : ash is mixed with water and pumped to ash pond. Dry : ash is collected in two RCC silos of 360 MT capacity each and issued to cement factories and brick manufaturers. Three silos 150 T each.
20000
10000
10000
Paravade NTPC Simhadri
22.45% of the fly ash (dry) used in FA bricks and blocks. 74.99 (2.11wet and 76.22 dry) % of the fly ash used in cement industry. 2.56% of the fly ash used in other purposes. Fly ash brick and blocks.
50 current users in Vishakha patnam. L&T using for RMC plant.
Bricks and Blocks.
Steel Plant Slag
State: Uttar Pradesh

Uttar Pradesh is the most populous state in the country accounting for 16.4 per cent of the countrys population. It is one of the largest state in geographical area covering 9.0 per cent of the countrys geographical area, encompassing 2,94,411 square kilometres and comprising of 83 districts The structure of state income shows that the contribution of primary sector has declined to 41 percent of the state income though the sector still sustain 73 percent of the total working force. The share of secondary sector, on the other hand, has gone up to 20 percent of the total state income, which now employ 9 percent of the total workers in the state. U.P.'s growth has been more capital intensive than labour intensive, more urban based than rural based and the shift income from primary to other sectors is not accompanied by corresponding change in employment pattern. Distinguishing feature of Uttar Pradesh's economy is its regional imbalances. In terms of economic indicators like agricultural productivity, infrastructural facilities, industrial
growth, the Uttar Pradesh's economy can be categorise into five regions; Western, Eastern, Central, Ruhelkhand and Hill. The Western Uttar Pradesh is agriculturally prosperous. It is relatively industrialized and has seen greater degree of urbanization. There are around 11 major thermal power plants in the state with a totatal capacity of around 10000 MW. Most of the larger thermal power plants in the state are either owned by NTPC or the state governments Rajya Vidyut Utpadan Nigam Limited. In general, the thermal power plants in the state are modernized and produce good quality of fly ash. 1. 2. 3. I. II. III. IV. V. VI. VII. VIII.
State
Total number of thermal power plants Major thermal power plants Singrauli NTPC Sonebhadra Dist. Anpara UPRVUNL Mirzapur Dist. Obra UPRVUNL Obra Dist. Rihand NTPC Sonebhadra Dist. Dadri NTPC Dadri Unchahar NTPC Rai Bareilli Renusagar Hindalco Industries Ltd. Renukoot Harduaganj UPRVUNL Harduaganj
Uttar Pradesh
2,050 MW 1,630 MW 1,550 MW 1,000 MW 840 MW 840 MW 619 MW 440 MW
IX. X. XI.
Tanda NTPC Faizabad Panki UPRVUNL Panki Paricha UPRVUNL Jhansi
440 MW 279 MW 220 MW
Name of plant
Quantity of fly ash generation
Total
Dry
Wet
Current fly ash use

Quantit y used
Current user
Transportation data Mode of transport & distance from plant Trans porta tion cost
Application
Other fly ash utilization activities Project Cement s product ion (PPC)
Bricks. raise of ash dyke cement industry
1689320
844660
844660
Renukoot Hindalco Industries Ltd. Renusagar
Both wet and dry.
48 %of fly ash used.
Sohnebhadra District
NTPC Rihand
Dry ash collection
35 %of fly ash used.
1050000
840000
210000
Faizabad NTPC Tanda
Have to install.
0.6 % dry FA used as FA bricks. 8.5 % dry FA used in cement industry. 13.90% dry FA used in land development. 25.0% dry FA used in raise of ash dyke 2.0% dry FA used as FA bricks. 1.3% dry FA used in cement industry. 96.13.90% dry FA used in land development. 25.0% dry FA used in raise of ash dyke Discharged in pond.
M/s Prism Cement Limited, Satna (M.P.)
Closed Bulkers 225 Km..
13.22
10.58
2.64
Nil
In process
25 trucks
Harduaganj UPRVUNL Harduaganj
Slurry collection system
Used in Ash pond.
Fly ash bricks.
2050000
Rai Barelli NTPC Unchahar
Dry ash collection Silo two in number 350 MT each.4
50 % of Fly Ash used inCement Industries. Fly ash bricks. Roads.
NHAI ACC Birla Corporate Prism cements Jai Prakash Nepal
FLY ASH FACT SHEET
State: Gujarat
Gujarat is situated in the west coast of India. The state is bounded by the Arabian sea on the west, Pakistan and Rajasthan in the north and north-east respectively, Madhya Pradesh in the south-east and Maharashtra in the south. The state covers an area of 196,024 sq km. One of India's most industrialized states, Gujarat maintains a variety of industries, the principal ones being general and electrical engineering and the manufacture of textiles, vegetable oils, chemicals, soda ash, and cement. New industries include the production of fertilizers and petrochemicals. Petroleum production began in 1960, and an oil refinery is located at Vadodara.
There are around eight major thermal power stations in Gujarat. Most of the thermal plants are quite old and are in the process of phase-wise up-gradation to increase their efficiency and ash collection system. At present, the major portion of usable fly ash is collected by the cement companies and only a small portion is available for other application like concrete and other real estate applications. The state has witnessed large infrastructure grown over the past few years. It has a total road length of 72950 km when survey last conducted for 31st march, 1999. Its National Highways constitute about 4.5 per cent of the total length of National Highways in India. The major ongoing infrastructure projects in the state include roads and other construction projects. However, there is very limited use of fly ash in high volume fly ash concrete technology in the state. A brief profile of the state is presented below:
4. 5. 6. V.
State
Total number of thermal power plants Major thermal power plants Sabarmati Thermal Power Plant Ahmedabad Electric Co. Ltd. Sabarmati Kutch Thermal Power Plant Gujarat SEB Kutch Ukai Thermal Power Plant Gujarat SEB Ukai Dam Wanakbori Thermal Power Plant Gujarat SEB Sevalia
Gujarat
450 MW
VI.
210 MW
VII.
850 MW
VIII.
1,470 MW
IX.
Gandhi Nagar Thermal Power Plant Gujarat SEB
870 MW
Gandhi Nagar
X. Dhuvaran Thermal Power Plant Gujarat SEB Anand Surat Thermal Power Plant Gujarat Industrial Power Corp. Ltd. (GIPCL) Surat Sikka Thermal Power Plant Gujarat SEB Sikka 534 MW
XI.
250 MW
XII.
240 MW
Fly ash details

Name of plant Quantity of fly ash generation Total Dry Wet Tons Tons Tons Ash collection system Current fly ash use Quantity Application used Current user Transportation data Mode of transport & distance (km) Transpo rtation cost Other fly ash utilization activities Projects Cement product ion (PPC)
262502
223127
39375
Sabarmati Thermal Power Plant Ahmedabad Electric Co. Ltd. Sabarmati
Major portions of ash is ollected in dry forms and bottom ash clinkers are deposited by wet system. In case of an outage in dry system, it is collected through wet system.
100% of the fly ash used
70% of the fly ash used for bricks/block s, cement and concrete. 30% used for other application
AEC Cement Gujarat Ambuja Cement Binani Cement JK Corporation Ultratech Cemco Gujarat Composite Tata Chemicals
Truck Truck
35 200
---
Tanker Tanker Truck Tanker Tanker
300 300 200 5 500
Housing projects, Construc tion of road dividers
PPC, Bricks and Cement sheets
Kutch Thermal Power Plant Gujarat SEB Kutch Ukai Thermal Power Plant Gujarat SEB Ukai Dam Wanakbori Thermal Power Plant Gujarat SEB Sevalia
Gandhi Nagar Thermal Power Plant Gujarat SEB
Gandhi Nagar
Dhuvaran Thermal Power Plant Gujarat SEB Anand Surat Thermal Power Plant Gujarat Industrial Power Corp. Ltd. (GIPCL) Surat Sikka Thermal Power Plant Gujarat SEB Sikka

High Volume Fly Ash Concrete

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HIGH VOLUME FLY ASH CONCRETE TECHNOLOGY

FLY ASH STATUS SUMMARY REPORT In INDIA