Fly Ash Utilisation in Odisha

Fly Ash Utilisation in Odisha Fly Ash Utilisation Conference, Delhi 15 th, March, 2018 Dr. D.K. Behera Sr. Env. Scientist State Pollution Control Board, Odisha Bhubaneswar

Setting up of Fly Ash Resource Centre (FARC) in SPCB, Odisha (Decision of High Power Committee Chaired by Chief Secretary, Odisha, July, 2013) Objectives 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

Growth of Thermal Power in Odisha Present generation of thermal power (Coal) 15, 895MW Power plants are mostly located near coal mines of Talcher and Ib Valley About 33237 MW different stages of clearance/ construction. Total capacity including pipeline projected: 49,132MW

Ash Generation from TPPs Power grade coal in Odisha contains about 35 48% of ash. Specific ash generation is 7-9 /day/mw. Annual ash generation in Odisha is about 32 PA Ash generation likely to increase to about 100 PA after commissioning of proposed power plants.

Land Requirement for Ash Disposal Sl. Disposal method Area in Ac/ MW 1. Lean slurry disposal with complete recirculation of water 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 end of 9 th year 4. High density disposal with 100% ash utilization by end of 9 th year, using washed coal (34% ash) 5. High density disposal with 100% ash utilization by end of 5 th year 6. High density disposal with 100% ash utilization by end of 5 th year, using washed coal (34% ash) 0.5 0.3 0.25 0.15

Year wise Thermal Power and Fly Ash Generation in Odisha 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 28.2 2006-07 5655.9 12.16 3.38 27.8 2007-08 5784.2 13.62 3.34 24.5 2008-09 7073.5 15.44 5.41 35.0 2009-10 7742 19.23 8.45 43.93 2010-11 9685 21.18 10.68 50.42 2011-12 11400 23.57 12.77 54.19 2012-13 11980 24.67 14.62 59.29 2013-14 11969 24.44 15.17 62 2014-15 14512 24.69 12.99 52.57 2015-16 15742 27.90 16.39 58.51 2016-17 15895 32.56 22.08 67.66 Till Jan 18 15895 25.51 18.67 73.18 Installed Capacity (MW) of Thermal Power in Odisha

QUQNTITY IN PA 35 Fly Ash Generation, Utilisation & Accumulation in Odisha 30 25 20 15 10 5 0 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 YEAR Fly ash Generated (Million TPA) Fly Ash Utilised In (Million TPA) Unutilized / Accumulation (Million TPA)

Thermal Power Plants in Odisha (2016-17) Capacity in MW No 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

Fly Ash Generation & Utilisation, Odisha 2012-13 Tons 2013-14 Tons 2014-15 Tons 2015-16 Tons 2016-17 2017-18, TillJanuary 18 Fly Ash Generated 246,71158 244,42381 246,95551 279,09495 325,60377 255,19888 Total Ash Utilisation 146,28506 151,69590 129,91470 163,90911 220,83824 186,76501 % of Utilisation 59.29 % 62 % 52.61 % 58.73% 67.82 % 73.18 %

Fly Ash Utilisation in Brick Manufacturing 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18, Till January 18 9,79572 3.97 % 9,56871 3.91 % 13,71993 5.56 % 22,36318 8.01 % 32,67858 10.04 % 28,27006 11.08 % 3,500,000 3,000,000 2,500,000 2,000,000 1,500,000 1,000,000 500,000 0 Brick Manufacturing 1,371,993 979,572 956,871 2,236,318 3,267,858 2,827,006 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 (Till Jan'18) Year

Fly Ash Utilisation in Cement Manufacturing 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18, Till January 18 8,81449 3.57 % 9,16555 3.74 % 7,97996 3.23 % 11,59555 4.15 % 14,96944 4.60 % 10,16654 3.98 % 1,600,000 1,400,000 1,200,000 1,000,000 800,000 600,000 400,000 200,000 0 Cement 881,449 916,555 797,996 1,159,555 1,496,944 1,016,654 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 (Till Jan,18) Year

Fly Ash Utilisation in Asbestos Manufacturing 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18, Till January 18 33255 0.13 % 1,09935 0.45 % 1,28775 0.52 % 1,62194 0.58 % 1,24354 0.38 % 78487 0.31 % 180,000 160,000 140,000 120,000 100,000 80,000 60,000 40,000 20,000 0 33,255 Asbestos 128,775 109,935 162,194 124,354 78,487 Year

Fly Ash Utilisation in Quarry Filling 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18, Till January 18 6,51955 2.64 % 5,98958 2.45 % 12,51766 5.07 % 15,01647 5.38 % 20,48282 6.29 % 14,36504 5.63 % Quarry Filling 2,500,000 2,000,000 2,048,282 1,500,000 1,251,766 1,501,647 1,436,504 1,000,000 651,955 598,958 500,000 0 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 (Till Jan'18) Year

Fly Ash Utilisation in Coal Mine Void Filling 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18, Till January 18 12,75814 5.17 % 12,45704 5.096 % 13,64292 5.52 % 14,26133 5.11 % 11,56006 3.55 % 10,05915 3.94 % Coal Mine Void Filling 1,600,000 1,400,000 1,200,000 1,000,000 800,000 600,000 400,000 200,000 0 1,275,814 1,245,704 1,364,292 1,426,133 1,156,006 1,005,915 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 (Till Jan'18) Year

Fly Ash Utilisation in Dyke Raising 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18, Till January 18 25,65309 10.39 % 29,21750 11.95 % 34,35178 13.91 % 59,25198 21.23 % 64,31344 19.75% 56,90853 22.30 % Dyke Raising 7,000,000 6,000,000 5,925,198 6,431,344 5,690,853 5,000,000 4,000,000 3,000,000 2,565,309 2,921,750 3,435,178 2,000,000 1,000,000 0 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 (Till Jan'18) Year

Fly Ash Utilisation in Land Development 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18, Till January 18 76,50626 31.01 % 80,13103 32.78 % 44,30075 17.94 % 31,50070 11.29 % 56,58451 17.38 % 48,41305 18.97 % Land Development 9,000,000 8,000,000 7,000,000 6,000,000 5,000,000 4,000,000 3,000,000 2,000,000 1,000,000 0 7,650,626 8,013,103 4,430,075 3,150,070 5,658,451 4,841,305 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 (Till Jan'18) Year

Fly Ash Utilisation in Road Making 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18, Till January 18 5,89126 2.38 % 2,84565 1.16 % 1,96405 0.80 % 7,70569 2.76 % 18,43916 5.67 % 17,77805 6.96 % Road Making 2,000,000 1,800,000 1,600,000 1,400,000 1,200,000 1,000,000 800,000 600,000 400,000 200,000 0 589,126 284,565 196,405 770,569 1,843,916 1,777,805 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 (Till Jan'18) Year

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

Initiatives by Fly Ash Resource Centre (FARC) for utilization of Fly Ash Development of Database on Fly Ash generation and utilization from each TPPs. Composition of FA from individual TPP w.r.t. IRC Geotechnical Specifications (SP-58/2001). Works Dept., Govt. of Odisha has included Fly Ash in the schedule of rates and tender documents for road construction. Coordinate with NHAI, Works dept., CPWD with TPPs for smooth availability of Fly Ash in road/building construction Projects.

Cement industries have been requested for enhancing use of Fly Ash in cement making. 20 Sensitization workshops conducted at different locations in the State. ( Sector Specific) TPPs were instructed to supply Fly Ash free of cost to fly ash based construction material manufacturing units and for road construction. Further, all thermal power plants above 100 MW capacity have been instructed to supply fly ash at the user point of road making and manufacturers of construction materials or provide a subsidy of Rs.150/- ton of fly ash.

Abandoned mine quarries,identified by the District Administrations and TPPs are linked for reclamation. Third Party Audit of annual Fly Ash Generation and Utilization by TPP being conducted since 2012-13. VSSUT, Burla has been engaged to study on the Environment Impact of Fly Ash disposal sites in Odisha. Coordination meetings with TPPs and Concessioner of NH/SH for smooth availability of fly ash Simplification of procedure of CTE for land reclamation Major Thermal Power Plants have been directed to construct village / panchayat Road of at least 1 km using fly ash under CSR activities.

Other Promotional Activities Availability of fly ash (free transportation upto 100 km or Rs.150/- per tonne) to develop a market. Included in Consent condition Proposal for banning clay bricks within 100 km radius in phased manner. Exemption of fly ash brick manufacturing units from Consent 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 and aerated autoclave blocks.. Notification (Works Dept.) for use of Fly ash bricks in in all Govt. construction

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

Ash Dumping Ash Leveling Ash Compacting Water Sprinkling Top Soil Covering Plantation Management of Mine Void / Stone Quarry NAVA BHARAT

NAVA BHARAT Green Belt at Balanda Mine Void

Lawn Children's Playing Equipment Lawn Benches Plantation Green Lawn NAVA BHARAT Park developed at Balanda Mine Void

Demonstration Rural Road Project using Fly Ash-Vedanta Limited, Jharsuguda, IIT, Bhubaneswar 1.0 m 3.75 m 1.0 m Shoulder 200 mm thick PCC M-30 100 mm thick PCC M-15 2H:1V RR Masonry or stone pitching 75 mm thick WBM Gr-II + 75 mm thick WBM Gr-III 15 cm Side drain 2.0 m 100 mm thick Granular sub-base Fly ash or pond ash Thickness: 1.5/2.0 m 0.5 m 1.0 m 0.6 m Natural ground level 0.6 m 1.0 m Earth cover MDD=1.94 g/cc Subgrade 9.95 m

Demonstration Rural Road Project using Fly Ash-Vedanta Limited, Jharsuguda =19,875 tonnes =231.75 tonnes 20,106.75 tonnes

Geopolymer Concrete ( II, Bhubaneswar) Source materia l Alkalin e solution AGGREGATES GPC Fly Ash NaOH and Na 2 SiO 3 Fine aggregate Coarse aggregate Final hardened product

40 m Geopolymer Concrete Road, Vedant Lanjigargh

Light weight aggregates (LWA) made out of fly ash is now a replacement for stone chips. LWA uses around 90 % of Fly Ash Light weight concrete blocks and slabs Structural light weight concrete Floor and roof slabs Highway construction Sound proof requirement Why use Light Weight Aggregate (LWA) Reduction in weight - reducing loading Improve thermal properties Improve fire resistance Improve Acoustic Properties Improve durability Indian Standard (IS: 9142 1979) Specifies for use of Artificial Light weight Aggregates for Concrete Masonry Units.

Aerated Autoclaved Fly Ash Blocks (AAC) AAC is a steam cured manufactured from pulverised fly ash, Cement, Lime and an Aeration Agent. High pressure steam curing in Autoclaves helps achieving the desired physical strength in the Blocks. These are Light weight Blocks having density of 600kg/M 3

RAW MATERIAL % BY WEIGHT 15 9 1 75 FLY ASH OPC CEMENT LIME OTHERS

High usage of Fly Ash

Issues and Challenges 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 road construction (SH, NH and rural roads). Promotion of utilization of fly ash in other construction material such as Tile, Concrete mortar etc.

Way Forward Promotion of fly ash based construction material Availability of Fly Ash in scarce area Availability of quality fly ash- business model Availability of Technology for manufacturing of Fly ash based construction materials Development of market by creating awareness Project approving authorities to promote use of fly ash based materials Manufacturing of quality products Exploring export potential Review and monitoring

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