High Volume Fly Ash Concrete

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

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

TABLE OF CONTENTS Objective…………………………………………………………………………………7 Background……………………………………………………………………………...7 Source Of Fly ash In India…………………………………..……………………...7  Present Scenario on Fly ash in India………………………………………………..11

Ash Collection………………………………………………………………..12

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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 India……………………………………………17 Current Ash Utilization…………………………………………………………….18  Present Scenario………………………………….……………………………………..19  Fly Ash Concrete Applications/ Projects………………………………………..19

 NTPC Dadri……………………………………………..………………….19  Road Construction and Paving……………………………………….20  HCC Project……………………………………………………………….20  ACC Road Project……………………………………………………….20  Other Projects……………………………………………………………20

Fact Sheets for States…………………………………………………………...21 Conclusion & Recommendation……………………………………………….21 Annexure……………………………………………………………………………23  Ministry of Environment & Forest………………………………………………23

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Notification of Fly Ash…………………………………….…………23

 Amendments…………………………..……………………………………………..23 List of Major Thermal Plants…………………………………………………28 Fly Ash Suppliers India……………………………………………………….32  Tanveer Enterprises………………………………………………………………33  Ash Tech……………………………………………………………………………..34 Fly Ash Fact Sheets……………………………………………………………35  Tamil Nadu……………………………………………..…………………………..35  Maharashtra…………………………………………………………………………38  Andhra Pradesh…………………………..………………………………………44  Uttar Pradesh……………………………………………………………………….49  Gujarat………………………………………………………………………………..55

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

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.

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

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.

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HIGH VOLUME FLY ASH CONCRETE TECHNOLOGY FLY ASH STATUS SUMMARY REPORT 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

1R 2R

Power Station

Installed Capacity (MW/day)

Generation (MW/day)

Badarpur I.P. Station

705 277.5

502 136

Coal per unit of electricity (kg/KWH) 0.81 0.86

Million KWH per day(MU)™ 14.87 2.96

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

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

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

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

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

PRESENT SCENARIO ON FLY ASH IN INDIA • • • • • • •

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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.

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%.

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

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.

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

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.%)

SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 LOI TiO2

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