Market Study on Ash Utilization in the surroundings of Dr. Narla Tata Rao Thermal Power Station (Dr....

Market Study on Ash Utilization in the surroundings of Dr. Narla Tata Rao Thermal Power Station (Dr. NTTPS)

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Market Study on Ash Utilization in the surroundings of Dr. Narla Tata Rao Thermal Power Station (Dr. NTTPS) Ibrahimpatnam,

Krishna District, AP

of

Andhra Pradesh Power Generation Corporation Ltd.

for

Assessment of demand for Ash of different types for various purposes by Industry and for validation of potential for

100% (Full) Utilization of Ash generated from APGENCO’s Dr. NTTPS

Conducted by

Environment Protection Training & Research Institute

Hyderabad

April 2015


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Preface

The Andhra Pradesh Power Generation Corporation Ltd (APGENCO) vide their work order PO.No.490000968 CE/CHY/SE/CHY/EE5/C63/2014-15 dated 27-03-2015 assigned the Environment Protection Training & Research Institute (EPTRI) to conduct a Market Study on Ash Utilization in the surroundings of Dr. Narla Tata Rao Thermal Power Station (Dr. NTTPS) Ibrahimpatnam, Krishna District, AP. The purpose of this report is to provide a clear understanding of the state of the art that has evolved since the realization that Ash from Thermal Power Stations can find full utilization as a green material and substitute for materials mined from nature such as sand, clay, gravel and limestone for making concrete, cement, bricks, roads etc. in the context of Dr. NTTPS of APGENCO and the sustainable benefits that can result to the local industry and economy from use of coal ash. A team from EPTRI visited Dr. NTTPS and conducted field visits from 5th to 11th April 2015 as part of study:

1. to collect historical data concerning ash generation, storage and sale/disposal for utilization by different industries and inspect facilities at Dr. NTTPS for ash handling and management.

2. to collect information on industries that use ash as raw material for manufacture of products such as cement, roofing sheets, Ready Mix Concrete (RMC), AAC blocks, and fly ash bricks, offices of Andhra Pradesh Pollution Control Board (APPCB) and District Industries Centre (DIC) of Krishna, Guntur and West Godavari Districts at Vijayawada, Guntur and Eluru were visited.

3. to understand development plans for the region in terms of creation of new Capital Amaravati for the State of Andhra Pradesh by visits to Capital Region Development Authority (CRDA) at Vijayawada and areas in Guntur District that are planned for inclusion in new capital region of Andhra Pradesh such as Tullur, Amaravati and Mangalagiri

4. visit of manufacturing units that use fly ash as raw material such as units making cement, roofing sheets, AAC blocks and fly ash bricks within 150 Kms radius from Dr. NTTPS for first hand appraisal of their activity.

Findings from this market study reveal that there is growth in industry using ash as raw material and with it an increase in demand for ash. The current generation is about 10000 MT per Day, of which 6500 MT is lifted by various industries and full utilization of the ash generated at Dr. NTTPS is expected to be realized in 2 years. The infrastructure requirements for new Capital and potential for use of ash in making of roads, highways, embankments, filling low lying areas etc., are likely to escalate demand for ash from Dr. NTTPS in the near future that would deplete reserves of ash in ponds as well as reduce ash that has to be sent to the pond. This market study affirms that the growth in demand for ash that is envisaged in the near future will ensure full utilization of additional ash of about 1300 MT a day that is expected to be generated on commissioning of STAGE V 1 x 800 MW at Dr NTTPS of APGENCO. Officers from APGENCO coordinated and accompanied the EPTRI team during the field visits. I hope, this report, an outcome of the market study conducted by EPTRI for APGENCO, fulfils and meets the expectations of the client. Director General EPTRI


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Table of Contents

Preface 1

Table of Contents 2

Introduction 4

Background Information 5

Purpose & Scope of the Study 7

100% Utilization of Ash 7

Potential Areas for Ash Utilization 8

Measures taken by Dr. NTTPS to increase Ash Utilization 8

Ash Utilization Potential for the Station 10

Details of Generation and Utilization of Ash at Dr. NTTPS from 2004-05 to 2014-15 in MT 10

Month wise Details of Generation and Utilization of Ash at Dr. NTTPS in 2012-13 in MT 11



Month wise Details of Ash Generated and Utilized in 2014-15 and Inventorization of excess Generated over Utilized in Ash Pond 14

Details of Number of Trucks and Quantity Lifted by MOU and Non MOU Companies using Fly Ash from Dr.NTTPS for 2012 -13 15



Fly Ash Lifting Details of Companies with MOU Agreements during 2014-15 and Estimation of Total Capacity (Present + Expansion) 19

Yearly Details from 2011-12 to 2014-15 of Total Fly Ash Lifted by Companies with MOU Agreements 20

Potential for Dry Fly Ash Utilization by Cement Industries 20

Details of Cement Plant contacted during field visit of EPTRI Team 21


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Potential for Dry Fly Ash Utilization by Autoclaved Aerated Concrete (AAC) Bricks/Blocks /Tiles Industry 22

List of AAC Block Plants in the vicinity of Dr. NTTPS 22

Details of AAC Block Plant contacted during field visit of EPTRI Team 22

List of New Companies that have sent request letters for Fly Ash for manufacture of Autoclaved Aerated Concrete (AAC) Blocks and Fly Ash Bricks to NTTPS in last six months (as on April 2015) 24

Potential for Dry Fly Ash Utilization by Roofing Sheets Manufacturers 25

Details of Roofing Sheet Unit contacted during field visit of EPTRI Team 26

Potential for Ash Utilization by Brick Units, RMC and other Industries 26

Brick/Block Products 26

Details of Brick Plants contacted during field visit of EPTRI Team 27

Potential for Utilization of Pond Ash/Bottom Ash in

Construction of Roads including Flyovers 28

Potential for Utilization of Pond Ash / Bottom Ash in Development of Roads in New Capital City under Capital Region Development Authority (CRDA) 29

Revised Action Plan for next 3 Years to achieve 100 % Ash Utilization at Dr. NTTPS 31

Balance Capacity Assessment of Ash Pond as on March 2015 31

Advise & Suggestion to APGENCO for 100% Ash Utilization 33

Executive Summary & Conclusions 33

Findings of the Study 34

Appendix 37

Letters from Companies Seeking Allotment of Ash from Dr. NTTPS 37


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Introduction

One of the most common sources for energy generation is from coal-fired power

plants. According to the World Coal Association, coal-fired power plants currently

fuel more than 40% of global electricity, and this percentage is much higher in

certain countries.

Coal-fired power plants use millions of tons of coal each year. During the coal

burning process, by-products are produced which are known as Coal

Combustion Products (CCPs) or Coal Combustion Residuals (CCR). CCPs include

fly ash, bottom ash, synthetic gypsum, and other power plant by-products.

Fly ash is a fine grained siliceous or alumino-siliceous material ideal for use in

cement/concrete, road base material, and in asphalt paving. One of the primary

uses for coal fly ash is in the cement industry because fly ash can easily combine

with calcium hydroxide to form needed compounds in the cement process,

providing a lower-cost substitute for clay, sand, limestone and gravel. Fly ash

produces a strong, durable concrete that is resistant to harsh chemicals.

Fly ash doesn’t just have economical benefits over conventional cement

ingredients, it also has environmental ones. The American Coal Ash Association

web site states that for every ton of fly ash used to replace traditional cement,

one less ton of carbon dioxide enters the Earth's atmosphere; over the past

decade fly ash recycling eliminated nearly a billion tons of greenhouse gas. Other

environmental advantages include reduced mining and conservation of the

traditional raw materials used to make cement, reduced landfill disposal,

conservation of water, and reduced kilning, which protects the atmosphere from

carbon dioxide release.

The Andhra Pradesh State Electricity Board (APSEB) was incorporated during

1959 with the intention to establish and maintain the power sector efficiently.

The High Level Committee formulated during 1995 was further recommended to

unbundle the organisation, APSEB to function efficiently, into APGENCO,

APTRANSCO and four distribution companies (AP DISCOMS). As per the Andhra


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Pradesh Electricity Reforms Act 1998, the APGENCO commenced its business

operations from 1999 and has to acquire, establish, construct and operate the

power generating stations.

After reorganisation of State of Andhra Pradesh during 2014, the following power

projects have come under the control of the APGENCO:

1. Dr.Narla Tata Rao Power Station (Dr. NTTPS) STAGE I, II, III AND STAGE IV with an installed capacity of 1760 MW

2. Rayalaseema TPP STAGE I, II, III of 1050 MW and

3. Rayalaseema TPP Stage IV of 600 MW (under construction).

The Hydel Power Stations at Machkund, Tunga Bhadra Dam, Hampi, Bellary

District, Upper Sileru, Donkarayi Canal, Lower Sileru, Srisailam Right Bank,

Nagarjuna Sagar Right Canal, Penna Ahobilam and Chettipeta Mini Hydel with a

total installed capacity of 1747.6 MW that includes the APGENCO share from

neighbouring States.

In addition to the above 2.0 MW of Non-Conventional Power through Wind Mills

is being generated by APGENCO. The Total Generation is 4559.6 MW.

The Rayalaseema Thermal Power Project STAGE –IV with a capacity of 600 MW

and 50 MW Hydel Project at Nagarjuna Sagar Tail Pond Dam are under

construction.

Background Information In 2014, the State of Andhra Pradesh was reconstituted as the States of

Telangana and Andhra Pradesh. This has resulted in the need of creating new

infrastructure facilities, industries, highways; construction of new capital city

etc., accordingly the demand for power has increased.

In pace with the requirement of other activities, the APGENCO is heading for a

new power plant with a capacity of 800MW at Dr. NTTPS by utilising the existing

infrastructure having water, coal transport facilities etc.


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However keeping in view the overall environmental management, APGENCO is

committed to operate and maintain power plants, efficiently and in an

environmental friendly manner, conduct all operations complying with statutory

(State and Central) Notifications, Rules, Regulations and also ensuring the

environmental requirements are complied with by all stake holders.

In view of the Environmental Policy, Environmental Impact Assessment is being

regularly carried out at all Power Stations and appropriate environmental

management plan is prepared well in advance and implemented during

construction and operation of the power plants. High efficiency Electro static

precipitators are installed to control the suspended particle matter below 100

mg/Nm3. Continuous online stack monitoring systems are also installed at Dr.

NTTPS and at RTTP.

As regards to management of Fly ash, the annual generation of ash from all

thermal Power Plants of APGENCO is about 6.8 million tonnes. APGENCO has

been implementing the following measures:

Dry fly ash is being issued free of cost to manufacturers of fly ash

bricks/blocks/tiles including AAC bricks/blocks/tiles.

Pond ash is being issued free of cost to all consumers like cement plants,

manufacturers of roofing sheets, National Highways, bricks/blocks/tiles

manufacturers etc

Dry fly ash is being issued at nominal price to manufacturers of

cement/roofing sheets/ RMC

Own, in house Brick plants were set up at Dr. NTTPS and RTPP and 100% fly ash bricks are being utilised in APGENCO’s constructions.

Free loading facilities are provided at the ash pond of Dr. NTTPS to attract

pond ash users and improve ash utilisation.

Advertisements are being issued in news papers and in APGENCO website stating the availability of ash and terms and conditions for issue to different

users.


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Purpose & Scope of the Study Andhra Pradesh Power Generation Corporation Limited (APGENCO) has proposed

to establish an expansion unit of 800 MW supercritical Thermal Power Plant at

Dr. NTTPS, in addition to the existing 1760 MW (6x210 MW + 1x500 MW) at

Ibrahimpatnam, Krishna District, Andhra Pradesh to meet the growing demand

for power.

As per the directives of Terms of Reference (ToR) issued by MoEF vide Lr.No J-

13012/26/2012-IA.II(T) dated 26th September 2012, one of the conditions is to

ensure the proper disposal and utilisation of the ash generated from the ensuing

power plant.

Hence, for obtaining the environmental clearance from MoEF & CC, APGENCO

has approached EPTRI to conduct a necessary market survey in the 150 km

radius of Dr. NTTPS spread over four districts, i.e. Krishna, Guntur, West

Godavari and Nalgonda Districts where many industries are located in the

vicinity using Fly Ash and Bottom Ash for various purposes.

The Market Study around 150 Km radius from Dr. NTTPS was to assess existing

and future demand for fly ash, pond ash and bottom ash from Dr. NTTPS from

existing and upcoming industries like cement, brick/ block/ tile, roofing sheet,

Ready Mix Concrete etc and for road formation, river embankment protection,

filling of low lying areas etc., by Govt. Departments like Municipal Administration

& Urban Development, Irrigation, Housing, Panchayat Raj etc., duly considering

the requirements of New Capital of AP coming up in Guntur District. The report

includes specific recommendations regarding the steps to be taken by APGENCO

to achieve 100% ash Utilization at Dr. NTTPS including the proposed 800 MW

unit under Stage V.

100% Utilization of Ash Dr. NTTPS is presently operating coal based Thermal Power Units of total

installed capacity 1760 MW (6 x 210 MW and 1x 500 MW). The coal


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consumption during the year 2014-15 of the existing Units was 9.58 Million

Tons. The ash generation was 4.07 Million Tons in 2014-15 with average ash

content of coal being 42.50%.

Potential Areas for Ash Utilization

As pozzolanic material for manufacturing of Portland Pozzolano Cement

For manufacturing of fly ash based bricks/blocks/tiles

As part replacement of cement in concrete

In manufacture of roofing sheets

For manufacturing of Cellular concrete building blocks and tiles

For preparation of base and sub-base course for roads

For embankments of Roads, Ash dykes and filling low lying areas

As soil improvement/ conditioning for agricultural purposes

Measures taken by Dr. NTTPS to increase Ash Utilization

1) Dry fly ash collection systems provided for Stage-I & II units (lower

capacity at the time of commissioning of units) upgraded to 100% extraction

capacity. The Stage III & Stage IV units were commissioned with 100%

extraction capacity.

2) Agreements were concluded with 18 Nos. Cement/Roofing Sheet/RMC

Industries for supply of 4609 MT/ day of fly ash from Dr. NTTPS regularly.

About 4750 tonnes/day of dry fly ash is issued to several cement Companies

(18 Nos.), Roofing Sheets Companies (4 Nos.), RMC (14 Nos.) and brick units

(590 Nos.) from the silo systems. The fly ash is issued to fly ash brick

manufacturing units free of cost, thus encouraging ash based industries for

ash utilization. Bottom ash and pond ash is also made available free of cost

to all industries and other users to increase ash utilization. M/s. National

Highways Authority of India is permitted to lift pond ash for widening of NH-5

road embankments.

3) Poclains are engaged by APGENCO at Ash Pond for free loading of pond ash

to users as a promotional measure.

4) 3 Nos. fly ash brick plants (30,000-bricks/day of total installed capacity)

setup at Dr. NTTPS produced 11.42 lakh bricks from 04/2013 to 03/2014.

The bricks are used to meet the in house requirement. The bricks are made


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with very high ash content of 65% to demonstrate optimum utilization of fly

ash.

5) High volume fly ash concrete roads of about 3 KM stretch containing 50% of

fly ash in binder content is laid in plant and colony area.

6) Interaction is being made continuously with private builders and with A.P.

State Govt. departments, other private and public works departments on

utilization of fly ash.


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Ash Utilization Potential for the Station

Details of Generation and Utilization of Ash at Dr. NTTPS from 2004-05 to 2014-15 in MT

Year Dry Fly Ash

Cement Roofing Sheet Bricks RMC Filling Total

2004-05 743922 78666 202439 13465 0 1038492

2005-06 854537 86819 159966 11122 0 1112444

2006-07 944381 64793 128999 12003 0 1150176

2007-08 1512230 89269 221849 8976 0 1832324

2008-09 1616738 117585 269861 12756 0 2016940

2009-10 1432925 142295 391097 8123 0 1974439

2010-11 1318362 126741 496610 26466 0 1968179

2011-12 1247441 156257 611854 39953 0 2055505

2012-13 1271500 141922 644106 58732 0 2116260

2013-14 1120760 95965 700593 54687 6495 1978502

2014-15 1004902 138520 751035 27806 8860 1931123

Year Pond Ash

Agriculture Cement Bricks National Highways Filling Total

2004-05 811 62123 17429 0 76894 157257

2005-06 36 233123 12619 0 132605 378383

2006-07 0 211718 0 0 352091 563809

2007-08 0 0 0 0 177590 177590

2008-09 0 0 0 0 160716 160716

2009-10 0 0 0 0 89630 89630

2010-11 0 0 0 0 151819 151819

2011-12 0 1395 30525 162586 147957 342463

2012-13 1034 0 53389 507657 181183 743263

2013-14 0 38535 48546 520330 247195 854606

2014-15 0 80967 79330 16660 357115 534072

Year Bottom Ash

Bricks Filling Total

2004-05 9530 2535 12065

2005-06 9720 0 9720

2006-07 12550 0 12550

2007-08 0 9060 9060

2008-09 0 9000 9000

2009-10 0 35903 35903

2010-11 0 45622 45622

2011-12 0 22095 22095

2012-13 32834 24626 57460

2013-14 52810 23819 76629

2014-15 122200 23712 145912

Year

TOTAL

Ash Utilized Ash Generated % of Ash

Utilization

2004-05 1207814 2619461 46.11

2005-06 1500547 2645673 56.72

2006-07 1726535 2770590 62.32

2007-08 2018974 2989293 67.54

2008-09 2186656 3030357 72.16

2009-10 2099972 3211156 65.40

2010-11 2165621 3586773 60.38

2011-12 2420063 4037190 59.94

2012-13 2916984 4100653 71.13

2013-14 2909737 4050705 71.83

2014-15 2611106 4068505 64.18

The supply of dry fly ash to the cement, roofing sheets, bricks and RMC has increased from 10.38 lakh MT to 19.31 lakh

MT from 2004 to 2015. There is an increase in consumption by nearly 100%. Similarly, the consumption of pond ash has increased from 1.57 lakh MT to 5.34 lakh MT during the same period. The consumption of bottom ash by bricks/blocks/tiles manufacturers and for filling of low lying areas has increased from 0.12 lakh MT to 1.45 lakh MT from 2004 to 2015. The total ash utilization has increased from 46.11% during 2004 to 64.18% by 2015. The growth rate in utilization clearly shows the importance of ash utilization in the above sectors replacing the conventional raw materials.


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Month wise Details of Generation and Utilization of Ash at Dr. NTTPS in 2012-13 in MT

Month

Dry Fly Ash Pond Ash Bottom Ash

Cement Asbestos Bricks RMC Filling Total Agriculture Cement Bricks National

High ways

Filling Total Bricks Filling Total

April 110243 14121 56963 3925 185252 33 7249 25621 6116 39019 0 1500 1500

May 112327 13709 67178 4297 197511 263 3123 24117 11264 38767 0 1800 1800

June 105745 13163 47756 4923 171587 684 1170 14746 16248 32848 0 2164 2164

July 101848 13981 46042 6003 167874 42 1052 37102 13683 51879 0 3150 3150

August 83098 13728 46120 4641 147587 0 423 31110 14255 45788 0 1630 1630

September 101587 9967 44194 4515 160263 12 3015 48688 26284 77999 0 3130 3130

October 107062 8217 44907 3281 163466 0 2961 32130 13037 48128 0 2500 2500

November 79324 9260 50240 3251 142075 0 4882 81719 16512 103113 0 2040 2040

December 106099 12839 59201 4434 182572 0 5126 80636 16013 101775 6370 1693 8063

January 110469 10012 53033 5612 179126 0 9866 35840 11203 56909 7960 1536 9496

February 118965 11538 57484 5857 193843 0 7687 51884 15136 74707 7796 1710 9506

March 134734 11388 70988 7993 225103 0 6835 44064 21432 72331 10709 1773 12482

TOTAL 1271500 141922 644106 58732 0 2116260 1034 0 53389 507657 181183 743263 32834 24626 57460

Month

TOTAL in 2012-13


Utilization

April 225771 357583 63.14

May 238078 389679 61.10

June 206599 379874 54.39

July 222903 351498 63.42

August 195005 307740 63.37

September 241392 349645 69.04

October 214094 317484 67.43

November 247228 285605 86.56

December 292410 308821 94.69

January 245531 332341 73.88

February 278056 334009 83.25

March 309916 386374 80.21

TOTAL 2916984 4100653 71.13


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Month



Highways Filling Total Bricks Filling Total

April 111301 10485 61519 6152 0 189457 0 1241 8525 35598 22287 67651 13428 1812 15240

May 113610 9680 61272 5021 0 189583 0 5831 1581 18717 12489 38618 5230 2277 7507

June 102273 12479 55894 4701 953 176300 0 3519 220 0 19862 23601 2783 1824 4607

July 110760 10125 58378 3746 2342 185351 0 5083 712 11033 26231 43059 2899 2837 5736

August 108542 4673 51639 4730 0 169584 0 4267 2533 77180 16629 100609 1063 1686 2749

September 88334 6204 57403 2951 0 154892 0 2752 3197 63903 23736 93588 1416 1692 3108

October 54804 4791 40911 1576 3200 105282 0 2550 851 98294 19248 120943 2155 2621 4776

November 75848 2249 56680 7671 0 142448 0 2805 6685 132957 24308 166755 3401 1686 5087

December 76389 3032 63977 8672 0 152070 0 2497 5116 78024 18637 104274 3887 2094 5981

January 86012 11452 57900 2824 0 158188 0 2958 6682 4624 16660 30924 1648 1801 3449

February 90690 10402 60774 3044 0 164911 0 1870 5880 0 16293 24043 5926 1839 7765

March 102197 10393 74247 3599 0 190436 0 3162 6564 0 30815 40541 8973 1650 10623

TOTAL 1120760 95965 700593 54687 6495 1978502 0 38535 48546 520330 247195 854606 52810 23819 76629

Month

TOTAL in 2013-14

Ash Utilized Ash

Generated % of Ash

Utilization

April 272348 341406 79.77

May 235708 407609 57.83

June 204508 402920 50.76

July 234146 378687 61.83

August 272942 293078 93.13

September 251588 319243 78.81

October 231001 265772 86.92

November 314290 282523 111.24

December 262325 307157 85.40

January 192561 374692 51.39

February 196719 321160 61.25

March 241600 356458 67.78

TOTAL 2909737 4050705 71.83


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Month



High ways

Filling Total Bricks Filling Total

April 92375 12343 56529 2860 1561 165668 0 3689 7142 0 39342 50173 8661 3510 12171

May 85180 14761 49544 2299 820 152604 0 2043 2343 0 28437 32823 2700 2340 5040

June 94266 13001 58425 3523 198 169413 0 425 818 0 21605 22848 6415 45 6460

July 95903 13086 65747 2600 0 177336 0 0 2103 0 19998 22101 8641 1172 9813

August 86088 9818 59356 2111 0 157373 0 0 4452 0 23005 27457 9570 1770 11340

September 75271 8673 60516 1878 91 146429 0 4338 6523 6069 15618 32548 11632 2397 14029

October 67688 12236 63273 2469 933 146599 0 8453 6402 8585 24163 47603 12980 1987 14967

November 71278 11323 65194 2015 1040 150850 0 13694 7103 2006 29879 52682 12810 2512 15322

December 76961 10019 65864 2155 3292 158291 0 17227 12580 0 34575 64382 5835 2747 8582

January 85484 8928 59805 1835 0 156052 0 12138 11492 0 41897 65527 10334 1914 12248

February 81318 11226 64389 2078 0 159011 0 7090 7611 0 39325 54026 15449 1668 17117

March 93090 13106 82393 1983 925 191497 0 11870 10761 0 39271 61902 17173 1650 18823

TOTAL 1004902 138520 751035 27806 8860 1931123 0 80967 79330 16660 357115 534072 122200 23712 145912

Month

TOTAL in 2014-15


Utilization

April 228012 370527 61.54

May 190467 364514 52.25

June 198721 331394 59.97

July 209250 333957 62.66

August 196170 298589 65.70

September 193006 289581 66.65

October 209169 337995 61.89

November 218854 359172 60.93

December 231255 309483 74.72

January 233827 342316 68.31

February 230154 340820 67.53

March 272222 390157 69.77

TOTAL 2611107 4068505 64.18

From the above tables from 2012-13 to 2014-15, the trend in percentage of utilization has been reduced from 71.83% to 64.18%. It is because of the agitations for / against bifurcation of the State into Andhra Pradesh and Telangana by which the development of infrastructure has been stalled temporarily. M/s. National Highways Authority of India lifted less quantity from ash pond.


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Month wise Details of Ash Generated and Utilized in 2014-15 and Inventorization of excess Generated over Utilized in Ash Pond

Month

Dry Fly Ash Bottom Ash Total

Cement Roofing Sheet

Bricks RMC Filling Total Filling Bricks Total Ash Utilized Ash Generated Ash conveyed to Ash Pond

April 92375 12343 56529 2860 1561 165668 8661 3510 12171 177839 370527 192688

May 85180 14761 49544 2299 820 152604 2700 2340 5040 157644 364514 206870

June 94266 13001 58425 3523 198 169413 6415 45 6460 175873 331394 155521

July 95903 13086 65747 2600 0 177336 8641 1172 9813 187149 333957 146808

August 86088 9818 59356 2111 0 157373 9570 1770 11340 168713 298589 129876

September 75271 8673 60516 1878 91 146429 11632 2397 14029 160458 289581 129123

October 67688 12236 63273 2469 933 146599 12980 1987 14967 161566 337995 176429

November 71278 11323 65194 2015 1040 150850 12810 2512 15322 166172 359172 193000

December 76961 10019 65864 2155 3292 158291 5835 2747 8582 166873 309483 142611

January 85484 8928 59805 1835 0 156052 10334 1914 12248 168300 342316 174016

February 81318 11226 64389 2078 0 159011 15449 1668 17117 176128 340820 164692

March 93090 13106 82393 1983 925 191497 17173 1650 18823 272222 390157 117935

Total 1004902 138520 751035 27806 8860 1931123 122200 23712 145912 2138936 4068505 1929569


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Details of Number of Trucks and Quantity Lifted by MOU and Non MOU Companies using Fly Ash from Dr.NTTPS for 2012 -13

S.No Name of the Company No. of Trucks Quantity in M.Ts

(i) MOU Companies

1 DECCAN CEMENTS LTD. 2636 57242.770

2 HYDERABAD INDUSTRIES LTD 4839 84911.130

3 INDIA CEMENTS LIMITED 14866 335003.580

4 MY HOME INDUSTRIES LTD 4255 86111.590

5 NAGARJUNA CEMENTS LTD 3814 71088.600

6 PENNA CEMENTS LIMITED 924 19909.370

7 RAIN CEMENTS LIMITED 3686 106173.110

8 SAGAR CEMENTS LTD 2523 56647.910

9 ULTRATECH CEMENT LTD 446 8265.060

10 VISAKA INDUSTRIES 1319 23761.570

11 ZUARI CEMENT LTD 6022 123358.160

12 PARASHAKTHI CEMENTS LTD 2516 52893.090

13 SRI CHAKRA CEMENTS LIMITED 968 22442.650

14 BHAVYA CEMENTS LIMITED 19 396.710

Total 48833 1048205.30

(ii)Non-MOU Companies

1 ARIES GRANITES 1 16.600

2 APPOLO CONCRETE 178 4265.180

3 BHAGYALAKSHMI IND & CEMENTS 23 673.640

4 BHEEMA CEMENTS LTD . 199 3830.980

5 GAMMON INDIA LIMITED 1 34.280

6 GLOBAL READYMIX 51 1590.300

7 GOWTHAM CEMENTS PVT(LTD) 40 853.300

8 GRAY GOLD CEMENTS, 92 1409.780

9 GURU RAGAVENDRA INFRASTUCTURES 268 5472.270

10 HEMADRI CEMENTS LTD. 523 10563.960

11 HYDERABAD INDUSTRIES KERALA 78 1410.600

12 INTRA INDUSTRIAL TECHNOLOGIES 19 369.800

13 KANAKA DURGA INDUSTRIES. 1 18.030

14 KAVERI CEMENTS 4 128.630

15 KBC INFRASTRUCTURES PVT LTD 84 1655.360

16 KCP CEMENTS LTD. 2572 58199.780

17 KEERTHI IND 281 5661.420

18 LAFARGE AGGREGATES & CONCRETE 127 2568.140

19 LAKSHMI SRINIVASA INDUSTRIES, 1 17.170

20 NAVAYUGA INFRATECH(I) PVT LTD 62 986.740

21 NAVAYUGA ENGG COMPANY LTD 11 229.850

22 NEW TECH MINERALS&CHEMICALS 34 544.280

23 MR INDUSTRIES 11 180.720

24 PM FLYASH BRICK & CO 7 148.830

25 PRAGATHI INFRATECH PVT LTD 9 144.08

26 PREMIER BUILDING MATERIALS PVT LTD 314 6965.93

27 R M C READY MIX. 162 3280.29

28 RMC READYMIX (INDIA) C 261 5452.44

29 RAMCO INDUSTRIES LIMITED (TN) 410 8664.32


16

30 RAMCO INDUSTRIES, 1165 18147.95

31 ROCKY INFRACON IND PVT LTD 6 107.47

32 RAMKY INFRASTRUCTURE LTD 24 497.37

33 SKR PACK TECH PVT LTD 63 1339.04

34 SRINIVASA READYMIX 181 3527.52

35 SRI NAGA READYMIX CONCRETE 23 462.18

36 SAIVENKATAKRISHNA READYMIX IND 190 3777.30

37 SUDHARSHANA BIO FUELS 4 72.32

38 SURYA CEMENT INDUSTRIES, 22 360.78

39 V N S READY MIX 240 4709.92

40 VEERAVALI CONCRETE PVT. LTD. 114 2228.89

41 VIPASSANA READYMIX CONCRETE 28 595.62

42 ZUARI CEMENT LTD © 1256 28107.36

Total 9140 189270.42

(iii)Bricks

1 BRICK 35814 637254.795

2 APGENCO 364 6701.48

Total 36178 643956.275

ABSTRACT

MOU 48833 1048205.3

Non-MOU 9140 189270.42

Bricks 36178 643956.275

GRAND TOTAL 94151 1881432


S.No Name of the Company No. of Trucks Quantity in MTs

(i) MOU Companies




4 THE RAMCO CEMENTS LTD 2454 47220.090












16 THE KCP LIMITED, 179 4911.68

Total 44402 993721.525


1 APPOLO CONCRETE 33 698.550

2 BHAGYALAKSHMI IND & CEMENTS 6 183.880


17

3 BHEEMA CEMENTS LTD . 62 1260.700

4 ESSAR WATER PROOFING CHEMICALS 2 32.090


6 GOWTHAM CEMENTS PVT(LTD) 13 306.850





11 KCP CEMENTS LTD. 2086 53175.260

12 KEERTHI IND 54 1067.040



15 PM FLYASH BRICK & CO 14 296.420

16 PRAGATHI INFRATECH PVT LTD 3 61.580

17 PREMIER BUILING MATERIALS PVT LTD 122 2621.860

18 R M C READY MIX. 31 623.260

19 RMC READYMIX (INDIA) C 376 7909.850

20 RAMCO INDUSTRIES LIMITED (TN) 154 3279.580


22 ROCKY INFRACON IND PVT LTD 34 705.720

23 RAMKY INFRASTRUCTURE LTD 148 3103.75

24 SARVANI READY MIX CONCRETE IND 2 36.78

25 SKR PACK TECH PVT LTD 21 446.95




29 V N S READY MIX 214 4232.88

30 ZUARI CEMENT LTD © 1140 24923.00

Total 7083 154604.43

(iii)Bricks

1 BRICK 38364 696069.38

2 APGENCO 223 4227.16

Total 38587 700296.54

ABSTRACT

MOU 44402 993721.525

Non-MOU 7083 154604.43

Bricks 38587 700296.54

GRAND TOTAL 1848623


S.No Name of the Company No.Of Trucks Quantity in MTs

(i) MOU Companies

1 ANJANI PORTLAND CEMENTS LIMITED 601 13322.330




5 THE RAMCO CEMENTS LTD 5249 105000.760




18










17 THE KCP LIMITED, 1962 48856.600

18 VISAKA INDUSTRIES(TELENGANA) 572 12251.980

19 SAHYADRI INDUSTRIES LIMITED, 121 2417.750

20 HYDERABAD INDUSTRIES LTD(TEL) 459 9638.820

Total 46114 1040403.800







6 KEERTHI IND 32 685.730

7 LAFARGE AGGREGATES & CONCRETE 55 1504.940




11 SARVANI READYMIX CONCRETE INDU 251 4504.430




15 V N S READY MIX 219 4447.620

16 SAI SNIGDHA CONSTRUCTIONS PVT 3 61.010

Total 3187 64213.740

(iii)Bricks

1 BRICK 36072 706173.875

2 APGENCO 155 2792.28

Total 36227 708966.155

ABSTRACT

MOU 46114 1040403.8

Non-MOU 3187 64213.74

Bricks 36227 708966.16

GRAND TOTAL 85528 1813584


19

Fly Ash Lifting Details of Companies with MOU Agreements during 2014-15 and Estimation of Total Capacity (Present + Expansion)

Sl.No

Name of the Company Date of MOU Agreement for 5 Years

Quantity Allotted per Day in MT

Quantity Allotted per Year in MT

Quantity Lifted during the Year in MT

%age of Fly Ash Lifted to Quantity Allotted

Present Capacity in Million MTPA

Expansion Capacity in Million MTPA

Total Capacity in Million MTPA

1 Anjani Portland Cements Ltd 13.08.2011

45 13725 13322 97 1.92 1.92

2 Deccan Cements Ltd. 05.09.2011

135 41175 42122 102 1.30 1.30

3 Hyderabad Industries Ltd (Roofing Sheets) 27.05.2011

180 54900 72980 133

4 India Cements Ltd 12.05.2011

1,143 348615 135281 39 2.5 2.5

5 The Ramco Cements Ltd 01.08.2011

500 152500 105001 69 3.4 1 4.4

6 NCL Industries Ltd 26.03.2012

248 75640 73371 97 0.891 0.891

7 My Home Cements Ltd 28.03.2012

400 122000 3547 3 2.674 2.674

8 Rain Cements Ltd 13.09&26.07.20

11

387 118035 128635 109 2.77 2.77

9 Sagar Cements Ltd 05.07.2011

180 54900 98070 179 2.35 2.35

10 Visakha Industries Ltd (Roofing Sheets) 01.07.2011

120 36600 42760 117

11 Zuari Cement Ltd 25.05.2011 432 131760 111888 85 1.20 1.20

12 Parasakti Cements Ltd 26.02.2012 200 61000 48012 79 1.557 1.557

13 Penna Cement Industries Ltd 12.09.2012 150 45750 60709 133 1.24 1.24

14 Sri Chakra Cements Ltd 27.12.2011 60 18300 15399 84 0.660 0.660

15 Ultratech Cements Ltd (Ready Mix Concrete) 05.06.2013 50 15250 6356 42

16 Bhavya Cements Ltd 01.10.2013 100 30500 31674 104 1.40 1.40

17 The KCP Cements Ltd (Krishna & Guntur) 01.10.2013 200 61000 48857 80

2.35 2.35

18 Sahyadri Industries Ltd (Roofing Sheets) 05.06.2013

99 30195 2418 8

19 Andhra Cements Ltd (Guntur)

1 1.31 2.31

20 Ckoromaandel Cements Ltd

21 Jaypee Balaji Cement Plant

5.0 5.0

22 Chettinad Cement Corporation Ltd

3.5 3.5

23 Ambuja Cements

5.75 5.75

24

Saraswathi Power & Industries Pvt. Ltd.

3.5 3.5

25 Vertex Cements P Ltd

2.64 2.64

1411845 1040402 74 32.21 17.70 49.91


20

Yearly Details from 2011-12 to 2014-15 of Total Fly Ash Lifted by Companies with MOU Agreements

Year Total Quantity Allotted per Year in MT

Total Quantity Lifted during the Year in MT

%age of Fly Ash Lifted to Quantity Allotted

2011-12 1527525 1247720 97.67

2012-13 1600525 1119331 90.33

2013-14 1618775 1085936 73.88

2014-15 1411845 1040402 74

Potential for Dry Fly Ash Utilization by Cement Industries There are 16 major cement companies with installed capacity of 32.21 Million

MTPA within 150 Kms from Dr. NTTPS. Another 4 cement companies are under

construction. Total capacity of all the 20 companies including expansion

capacities is about 49.91 Million MTPA.

The total dry fly ash lifted by cement companies during 2014-15 is 10.05 lakh

tonnes. The reason for less consumption of dry fly ash is due to sluggish

economy and State bifurcation resulted in retarded developmental activities.

Now that the AP State bifurcation has been completed and New Capital Area

Development Plan is almost finalized, the infrastructure developmental works like

roads, bridges, buildings etc., for the New Capital are likely to be commenced

from January 2016. Therefore the demand for PPC is likely to be increased

significantly from April 2016 onwards.

Considering the existing cement production capacity of 32.21 Million MTPA,

cement companies will achieve increase in production to 75% of capacities from

the present 40-50 % operation comprising 50% PPC (with 25% Fly Ash) and 50%

OPC and PSC, the fly ash demand from cement companies is projected as

32.21x0.75x0.5x0.25 = 3.02 Million MTPA.


21

Taking into consideration the expansion and new projects, the total capacity will

be 49.91 Million MTPA and the projected fly ash requirement of cement

companies will be 49.91x0.75x0.5x0.25 = 4.67 Million MTPA.

Details of Cement Plant contacted during field visit of EPTRI Team

The Unit of The Ramco Cements Limited (formerly Madras Cements Limited) at

Jayanthipuram that procures Fly Ash from Dr. NTTPS was visited by EPTRI

Team.

The Fly Ash consumed per day is about 1300/MT and they have two silos of

2800 MT capacity each and can store material for about 4 days of production.

Their production of types of cement is usually in the ratio 40% OPC (Ordinary

Portland), 50% PPC (Pozzolana Portland) with 29% Fly Ash and 10%

PSC(Pozzolana Slag).

They are currently producing about 120000 MT/Month of Cement utilizing 40 to

50% of their capacity and expect demand to pick up again soon. They intend to

expand their capacity from 3200 TPD to 4400 TPD.


22

Potential for Dry Fly Ash Utilization by Autoclaved Aerated Concrete (AAC) Bricks/Blocks /Tiles Industry There are eight AAC Block Units that are either under operation or expected to

start production soon in the vicinity of Dr. NTTPS. As can be seen from the list

below there has been a growth in this segment. The Ash percentage usually used

for making of AAC Blocks is around 65% and a Unit producing 500 M3 of AAC

Blocks/Day would consume about 200 MT of Ash/Day. This segment of Industry

using Ash as a key ingredient in the manufacture of its products is currently the

second largest consumer of Ash from Dr. NTTPS after Cement. There has been a

growth in number of Units manufacturing AAC Blocks using mostly equipment

imported from China and involving an investment of about Rs. 15 Crores to set

up a Unit with production capacity of about 500 M3.

List of AAC Block Plants in the vicinity of Dr. NTTPS

Details of AAC Block Plant contacted during field visit of EPTRI Team Greenway Building Products Production Capacity: 150,000 m3 / Annum that is about 75,000,000

Blocks/Bricks

500 m3 / Day i.e. about 182 MT/ Day or about 5000 MT/ Month is expected to be doubled by January 2016 to 400 MT/Day

Land Area: 6 Acres

Employees: 120 persons Capital Investment: Rs. 23 Crores

Project Cost: Rs. 14.31 Crores

AAC Block Size (length x height x width in mm):

600 x 200 x 230, 600 x 200 x 200, 600 x 200 x 150, 600 x 200 x 100 and 600 x 200 x 75

S. No.

Name of Unit Location Production Capacity in

M3 / Day

Fly Ash Requirement

in TPD

Age of Unit as on April 2015

1 Bhagwati Jaggaiahpet 500 180 1 Month (new)

2 NCL Alltek G Kondur 800 300 To start in 4 Months

3 VS Eco Blocks Nawabpeta 300 167 6 Months

4 Greenway Building Products Paritala 500 180 2 Years

5 Aarush Building Materials Jaggaiahpet 500 180 8 Years

6 Ecocare Building Products Jaggaiahpet 300 160 3 Years

7 Sri Veeranjaneya Eco Bricks Khammam 500 180 1 Year

8 GSR Eco Bricks Private Limited Prakasam 750 600 To start in 3 Months


23

Price of AAC Blocks: Good Blocks Rs. 40 for 4” width (100 mm) Rs. 60 for 6” width (150 mm), Rs. 80 for 8” width (200 mm) and Rs. 90 for 9” width (230 mm),

second grade blocks with corner breakings and third grade damaged/scrap are

sold as lower prices like for purposes such as for toilet construction under Swach Bharat.

Raw Materials for making of AAC Blocks:

Lime, Cement, Aluminium Powder (for rise), Soluble Oil and Fly Ash (65 to 70%)

1 Cake = 3.456 m3 1 m3 = 364 Kgs.

3.456 m3 = 1260 Kgs.

1 Cake = 288 Blocks of 4” width Manufacturing produces third grade usable scrap of about 11%, 2% green waste

that is recycled and 4% filling scrap.

The Unit gets no exemption from Excise Duty @12.5%, VAT @5% and CST @2%. The Unit would have option of buying things from elsewhere rather than local

materials from Jaggaiahpet if it were exempted from VAT.


24

Sri Veeranjaneya Eco Bricks

Project Cost: Rs. 11.53 Crores

Capacity: 50,000 m3 / Annum

1 m3 = 36 to 39 Bricks of size 600 x 300 x 300 mm, 600 x 250 x 250 mm and 600 x 200 x 200 mm

List of New Companies that have sent request letters for Fly Ash for manufacture of Autoclaved Aerated Concrete (AAC) Blocks and Fly Ash Bricks to NTTPS in last six months (as on April 2015) NCL Alltek & Seccolor Ltd. AAC Blocks Unit

Sy. No. 300, Kavuluru Village,

G. Konduru Mandal, Krishna District, A.P. – 521228 Tel: 0866-2872070

E-Mail: [email protected]

Contact: P.S. Chandra Sekhara Varma, Vice President Mobile: 9676933533 9573633566


25

Autoclaved Aerated Concrete Bricks Production Unit. Capacity: 800 M3 per day of AAC Blocks using 65% Fly Ash. Daily Requirement of Fly Ash 300 MT

(9000 MT per Month).

GSR Eco Bricks Private Limited

Uppumaguluru Village, Ballikurava Mandal,

Prakasam District, AP 523301

AAC Blocks Manufacturing Unit. Capacity: 750 M3 per day of AAC Blocks. Daily Requirement of Fly Ash 350 MT to 600 MT (10500 MT to 18000 MT

per Month).

V.S. Ecoblocks Private Limited

Survey No.134/2A & 134/2C, NH-65 to Mullapadu Donka Road,

Opposite to SPDCL Sub-station, Nawabpeta – 521190 Penuganchiprolu Mandal, Krishna District. AP.

AAC Blocks Manufacturing Unit. Capacity: 10000 M3 per month of AAC

Blocks. Monthly Requirement of Fly Ash 5000 MT.

Potential for Dry Fly Ash Utilization by Roofing Sheets Manufacturers

The following is a list of Roofing Sheet producing units that have entered into an

agreement with Dr. NTTPS to regularly lift fly ash from the Station.

The potential for fly ash demand by above Industries is arrived based on their

expansion plans in near future. The leading Roofing Sheet brands are

Charminar, Visakha, Swastik and Ramco.

Sl. No

Name Present fly ash usage (Average) MT/day

Potential for fly ash use MT/day

1 Hyderabad Industries, Hyderabad 66 100

2 Hyderabad Industries, Kondapalli 127 384

3 Visakha Industries, Patancheruvu 190 475

4 Ramco Industries Limited, Ibrahimpatnam 70 100

Total 383 959


26

Details of Roofing Sheet Unit contacted during field visit of EPTRI Team Ramco Industries Ltd

Land Area on lease from Dr. NTTPS: 20 Acres

Lease 33 Yrs, Year of establishment: 2005 Fly Ash requirement: 70 MTPD

Silo Capacity: 120 TPD.

Curing: 15 days in open Production Capacity: 108000 MTPA

Weight of Roofing Sheet: 12.4 Kg/m of standard width 1.05 m

Capacity Utilization: 40%

Materials used for production of Roofing Sheets:

1) White Crystal Asbestos Fibre (Imported) 2) Cement

3) Fly Ash – 30%

4) Cotton Rag Pulp

Potential for Ash Utilization by Brick Units, RMC and other Industries

Brick/Block Products

A number of fly ash brick/block manufacturing plants were established in the

vicinity of the station. At present there are about 590 such plants which are

lifting fly ash from the station. The quantity of ash lifted by these companies from

Dr. NTTPS during 2014-15 was about 7 Lakh MT. Due to announcement of AP

Capital in Guntur District near Dr. NTTPS, the land rates within 100 Kms of Dr.

NTTPS have gone up abnormally high. Therefore procurement of clay for

manufacturing clay bricks has become unviable. As the enforcement authorities

are insisting that brick manufacturers must utilize at least 25% fly ash for

manufacture of bricks as per MoEF notifications and new capital works are likely

to be taken up from January 2016, the demand for fly ash based

bricks/blocks/tiles is going to increase multifold.

Once the state level monitoring committee becomes operational, it will monitor all

construction agencies of Central/State/Local Govt. and Private or Public Sector

engaged in the construction of the buildings within a radius of 100 km from a

coal or lignite based thermal power plants for utilization of only fly ash based

products such as PPC, fly ash bricks / blocks/tiles/clay fly ash bricks etc. This


27

will result in increase of ash utilization for brick, RMC and other industries.

During field visits, it was observed that although bricks made using Fly Ash had

better durability and were available at a price similar or lower than clay bricks,

clay bricks were still being widely made, procured and used for building

construction work going on within 100 Km radius of Dr. NTTPS. Certain people

were reported to hold a negative sentiment of using building material using ash

as an ingredient and this was mentioned as among the causes for continued use

of clay bricks. In spite of this, the choice and growth in use of products made

from fly ash is on the upward trend and can be enhanced with promotion

campaigns for sensitization and awareness creation about the benefits to brick

manufacturers, traders, builders and house owners.

Details of Brick Plants contacted during field visit of EPTRI Team Three Brick Plants were established at Dr. NTTPS of Capacity 10000

Nos/Day/Plant

The composition of the bricks is: Fly Ash: 56%

Crusher Dust: 37.3%

and Cement: 6.7% Brick Weight: 3 Kgs

Size: 230 x 110 x 70 mm

Rate for customers: Rs. 2.75/Brick In house Rate for Dr. NTTPS: Rs. 2.25/Brick

Total Labour per Plant: 16 Persons

Curing: 21 Days

Daily Production: 7500 to 8000 Bricks per Day 25 Kgs of Cement and 20 Ltrs of water are required for manufacture of 120

Bricks.

Venu Build Products Adjacent to Dr. NTTPS Brick Plant on land leased by Dr. NTTPS using Lime and

Gypsum instead of Cement as in the Dr. NTTPS Brick Plant along with Crusher

Dust and lesser %age (45% of Fly Ash) Prices of raw materials other than Fly Ash used in making of Bricks:

Gypsum: Rs. 2.25/Kg

LimeRs. 3.00/Kg

Crusher Dust: Rs. 3.00/Kg Brick Size: 9” x 4” x 3”

Brick Weight: 2.7 Kgs

Rate: Rs. 3/Brick


28

The composition of the bricks is: Fly Ash: 45%

Gypsum: 3 to 5%

Lime: 10 to 11% Crusher Dust: 40%

Daily Production: 3000 Bricks

Compressive Strength: 50 Kgs/cm2

Labour Charges: Rs. 600 per 1000 Bricks

Potential for Utilization of Pond Ash/Bottom Ash in Construction of Roads including Flyovers

One more potential area for increased utilization of ash is in formation of roads

and construction of flyovers by National Highways Authority of India Ltd and

Urban Development Authorities / R&B Department of GoAP.

The National Highways Authority of India is utilizing pond ash for filling during

the construction of Highways and Flyovers. AMR Construction Pvt. Limited, sub-

contractors of M/s. Gammon Infrastructure Projects Ltd, Mumbai, have


29

requested to issue permission to lift Pond ash to an extent of 15 lakh tonnes for

the work of 6-Laning of Vijayawada Gundugolanu Section of NH- 5 for a length of

54 Kms including 6-lane Hanuman Junction Bypass (length 6.70 Kms) and 4-

lane Vijayawada Bypass (length 47.88 Kms), that is proposed to be constructed

with Ash from Dr. NTTPS. The total length is 103.59 Kms. The work which may

commence during the year 2014-15 is expected to be completed in 3 years

Potential for Utilization of Pond Ash / Bottom Ash in Development of Roads in New Capital City under Capital Region Development Authority (CRDA) The development of the Capital City with all the infrastructure facilities is

envisaged with the formation of new Andhra Pradesh State after bifurcation.

The CRDA is formulated to look into all requirements of the capital starting from

land acquisition and coordinating with all the departments of the state and

business organizations for the speedy implementation of all requirements for the

full fledged capital development.


30

The CRDA has prepared a zonal plan with an area of 6856 Sq. Kms of which 212

Sq. Kms is identified for the buffer zone of capital city in which again 8 Sq. Km is

separately identified for the construction of Assembly, Raj Bhavan, Secretariat,

Commissionerates and Directorates along with internal roads etc. It is also

proposed to construct four connecting bridges over River Krishna, three bridges

on the side of the back waters and one bridge is proposed on the downstream

side. There are seven industrial zones that have been identified near and around

the capital city and one Inner Regional Expressway and one Outer Regional

Expressway connecting the national highways, ports, cities. The Government of

India has already released Rs. 500 Crores for the core capital city development

and Rs. 147.37 Crores released for the development of Vijayawada city for

constructing 4096 houses. Rs. 1364 Crores was released for the infrastructure

development of Vijayawada and Guntur and for the development of drainage

facilities and roads.

The proposed Inner Regional Expressway is having a length of 188.57 Km. The

Inner Regional Expressway is designed as eight lane expressway for which the

construction is to start immediately. The length of proposed Outer Regional

Expressway is estimated at 364.57 Kms which is likely to be commenced after

five years as eight lane expressway. The requirement of pond ash/bottom ash for

formation of roads in and around the proposed capital city is assessed as follows:

The pond ash / bottom ash required to be supplied assuming minimum

thickness of 1 M utilization as sub surface area for the construction of the

inner and outer expressways is estimated as 18.806 Million Cubic Meters.

The ash required for the proposed 10 Nos of radial roads with a length of

50 Kms each is estimated as 13.50 Million Cubic Meters.

The proposed core capital zone having 800 Hectares (8Sq.Kms) with an

assumed area of 20% for roads is required to rise with 1 M thickness of

ash. The total requirement is estimated as 1.6 Million Cubic Meters.

The total requirement of ash for CRDA region proposed for the Inner

Expressway, radial roads, internal roads and Outer Expressway is

estimated as 33.906 Million Cubic Meters (40.69 Million Metric Tonnes)


31

Revised Action Plan for next 3 Years to achieve 100 % Ash Utilization at Dr. NTTPS All figures are in million tons / annum

Year Ash Generation

Ash utilization

% Utilization

Cement

Brick / RMC & Roofing Sheets

For Road formation and Filling

Total

2015-16 4.05 1.60 1.0 0.64 3.24 80

2016-17 4.05 1.80 1.10 1.15 3.645 100

2017-18 4.05 2.05 1.20 1.50 4.05 180

The ash utilization strategy for 3 years time frame for the station is prepared, by

considering the potential for Fly ash demand by user Industries.

Balance Capacity Assessment of Ash Pond as on March 2015


32

Ash Pond at Dr. NTTPS


33

Advise & Suggestion to APGENCO for 100% Ash Utilization 1) A senior officer from APGENCO shall be identified to co-ordinate with the town planning,

municipal administration and other urban & rural regulating authorities to ensure the implementation of the directives of the principal secretary to Govt. vide memo no. /10235/M1/2014 dtd 27th Jan 2015 or this job may also be entrusted to a govt. environmental agency for monitoring and implementation.

2) Conduct seminars in neighbouring district head quarters disseminating the knowledge of

use of Fly Ash in all the said activities, twice in a year. 3) The engineers interested in environmental promotion and ash management activities shall

be identified & posted permanently, ensuring promotions on par with other departmental heads, which will sustain and help in for implementation/addressing the fly issues in a constructive manner for achieving long run objectives.

Executive Summary & Conclusions

Andhra Pradesh Power Generation Corporation Limited (APGENCO) has proposed

to establish an expansion unit of 800 MW supercritical Thermal Power Plant at

Dr. NTTPS , in addition to the existing 1760 MW (6x210 MW + 1x500 MW) at

Ibrahimpatnam, Krishna District, Andhra Pradesh to meet the growing demand

of power after formation of the New State of Andhra Pradesh. As per the

directives of Terms of Reference (ToR) issued by MoEF vide Lr.No J-

13012/26/2012-IA.II(T) dated 26th September 2012, one of the conditions is to

ensure the proper disposal and utilisation of the ash generated from the ensuing

power plant. Hence for obtaining the environmental clearance from MoEF & CC,

APGENCO has approached EPTRI to conduct a necessary market survey in the

150 km radius of Dr. NTTPS spread over in four districts where many industries

are located in the vicinity using Fly Ash and Bottom Ash for various purposes.

The EPTRI team conducted the following activities to fulfil the work assigned by

APGENCO.

Collection of historical data concerning ash generation, storage and

sale/disposal for utilization by different industries and study of facilities available at Dr. NTTPS for ash handling and management.


34

Collection of information on industries that use ash as raw material for manufacture of products such as cement, roofing sheets, Ready Mix

Concrete (RMC), AAC blocks, fly ash and clay bricks from offices of Andhra

Pradesh Pollution Control Board (APPCB) and District Industries Centre (DIC) of Krishna, Guntur and West Godavari Districts.

Study of development plans for the region in terms of creation of new

Capital Amaravati for the State of Andhra Pradesh by visits to Capital Region Development Authority (CRDA) at Vijayawada and areas in Guntur

District that are planned for inclusion in new capital region of Andhra

Pradesh such as Tullur, Mangalagiri and Rural areas of Guntur.

Field study through visits to manufacturing units that use fly ash as raw

material such as units making cement, roofing sheets, AAC blocks and fly ash bricks within 150 Kms radius from Dr. NTTPS for a first hand

appraisal of their activity.

Expert analysis of data and information collected for the study.

Findings of the Study

1.0 The ash generation at Dr. NTTPS has increased from 2.62 Million

Tonnes during 2004-05 to 4.07 Million Tonnes during 2014-15 due to

increase in capacity of the plant from 1260 MW to 1760. The utilization

of ash has increased from 1.2 Million Tonnes during 2004-05 to 2.9

Million Tonnes in 2014-15. The percentage of ash utilization during

2014-15 is 64.18 percent.

2.0 Agreements were concluded with 18 Nos. Cement / Roofing Sheet /

RMC Industries for supply of 4609 MT/ day of fly ash from Dr. NTTPS

regularly. About 4750 tonnes/day of dry fly ash is issued to several

cement Companies (18 Nos.), Roofing Sheets Companies (4 Nos.), RMC

(14 Nos.) and brick units (590 Nos.) from the silo systems. The fly ash is

issued to fly ash brick manufacturing units free of cost, thus

encouraging ash based industries for ash utilization. Bottom ash

and pond ash is also made available free of cost to all industries and

other users to increase ash utilization. M/s. National Highways

Authority of India is permitted to utilize pond ash for widening of NH-5

road embankments. Poclains were engaged by APGENCO at Ash Pond

for free loading of pond ash to users as a promotional measure.


35

2.1 The existing cement production capacity in the vicinity of Dr. NTTPS is

50.86 Million MTPA. However due to sluggish economic conditions and

State bifurcation process, no major construction activities are going on

in AP and hence most of the cement companies are operating at 40-50%

of their capacity. Due to less activities in Government Sector, the

demand for PPC got reduced drastically. In the circumstances, the dry

fly ash lifted by cement companies from Dr. NTTPS during 2014-15 was

only 1004902 MT.

2.2 Now that the AP State bifurcation has been completed and New Capital

Area Development Plan is almost finalized, the infrastructure

developmental works like roads, bridges, buildings etc., for the New

Capital are likely to commence from January 2016. Therefore the

demand for PPC is likely to be increased significantly from April 2016

onwards. The annual cement production capacity of plants in the

vicinity of Dr. NTTPS is likely to be increased from 32.21 to 49.91

million MT.

Assuming that the cement companies will achieve increase in

production to 75% of capacities from the present 40-50 % operation

comprising 50% PPC (with 25% Fly Ash) and 50% OPC and PSC, the fly

ash demand from cement companies would be 32.21x0.75x0.5x0.25 =

3.02 Million MTPA.

2.3 The present ash utilization by AAC bricks and conventional fly ash

bricks is 9.52 lakhs tonnes which would increase to 13.42 lakh tonnes

from 2015-16 onwards. The demand for fly ash for bricks/blocks/tiles

will increase multifold as construction activity of the new capital city of

AP gains pace.


36

2.4 The present utilization of fly ash in roofing sheets and ready mix

concrete (RMC) is about 1.66 lakh tonnes which will increase multifold

as construction activity of the new capital city of AP gains pace.

2.5 The present utilization of ash in filling low lying areas and road

formation is 4.06 lakh tonnes and this is expected to increase multifold

as construction activity of the new capital city of AP gains pace. In fact,

the ash requirement for the proposed inner and outer express ways,

radial roads and other internal roads is estimated as 33.906 million

cubic meters (40.69 million tonnes), which will be sourced from existing

Ash Pond of Dr. NTTPS.

2.6 The proposed addition of 1x800 MW power plant at Dr.NTTPS will

generate 1294 TPD of ash(1035 TPD of dry fly ash + 259 TPD bottom

ash) for which M/s. Vertex Cements (P) Ltd has MoU for lifting of 1035

TPD of dry fly ash from the day of commissioning of the plant in 2018-

19. The bottom ash will be collected in hydrobins and issued to user

agencies like brick manufacturers and construction companies for

filling.

2.7 Considering the details enumerated at para nos. 2.1-2.6, 100 %

utilization of ash from the existing units (6x210 MW + 1x500 MW)

would be achieved by 2016-17 well before the commissioning of 1x800

MW power station at Dr. NTTPS in 2018-19.


37

Appendix

Letters from Companies Seeking Allotment of Ash from Dr. NTTPS


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Market Study on Ash Utilization in the surroundings of Dr. Narla Tata Rao Thermal Power Station (Dr....

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Transcript of Market Study on Ash Utilization in the surroundings of Dr. Narla Tata Rao Thermal Power Station (Dr....