Ash Utilisation

A Grand Challenge for Ash Utilization Ideas is being conducted (from 1st to 24th December
2018) at PAN India level by NTPC to invite innovative ideas for achieving 100% ash
utilization on sustainable basis. Click here to Participate

Fly ash is a byproduct of power generation with coal. Sustainable ash utilisation is one of the
key concerns at NTPC. The Ash Utilisation Division (AUD), set up in 1991, strives to derive
maximum usage from the vast quantities of ash produced at its power stations. The ash is
now being looked at as a commodity that could generate wealth for the company in the long
run. The AUD proactively formulates policies, plans and programmes for ash utilisation. It
further monitors the progress in these activities and works for developing new segments of
ash usage. Ash Utilisation Cell at each station handles ash utilisation activities.
Research has shown that the quality of fly ash produced at NTPC’s power stations is
extremely good with respect to fineness, low unburnt carbon and has high pozzolanic activity
and conforms to the requirements of IS 3812 - 2003-Pulverized Fuel Ash for use as
Pozzolana in cement, cement mortar and concrete. The fly ash generated at NTPC stations
is ideal for use in the manufacture of cement, concrete, concrete products, cellular concrete
products, bricks/blocks/ tiles etc.

To facilitate easy availability of dry fly ash to end users, dry fly ash evacuation and safe
storage system have been set up at coal based stations. Further, at NTPC-Rihand facility for
loading fly ash into rail wagons has been provided so that fly ash can be transported in bulk
quantity through the railway network. Such facility is also being provided at all new upcoming
coal based power stations. NTPC also offers all types of ash along with infrastructure
facilities enabling evacuation of ash free of cost, wherever feasible.

Over the years, ash consumption level has reached from meagre 0.3 million ton in 1991 -
1992 to 30 million tons in 2012-13. The important areas for this utilisation are cement
industry, bricks industry, road embankment, mine filling, land development and ash dyke
raising. It is also a source of micro and macro-nutrients in agriculture.
Awareness/Training programme/Workshop organised by NTPC stations for spreading
awareness+Click for details
Awareness/Training programme/Workshop organised by NTPC stations for spreading
awareness in the adjoining area of 100 Kms distance of Power plants for promoting
Usage of Fly Ash Bricks in the Construction Sector
In compliance with NITI Aayog directive, workshop/training programmes were conducted in
the adjoining rural areas up to 100 Kms distance of the Power Plant, as per following details.

S.No. Name of NTPC station Workshop/Training Venue

1 NTPC Sipat RatanPur ,Dist Bilapur (C.G.)

Kawardha (CG)
 2 NTPC Tanda Dist. Head quarter ,Basti (U.P.)

3 NTPC Talcher-Kaniha Odash Stadium ,Khamar.Distt .Ang

4 NTPC Mouda At EDC NTPC Mouda

5 NTPC Rihand At Sirsoti Village

Distt : Sonebhadra (U.P.)
At Mayur Pur
Distt Sonebhadra(U.P.)

6 NTPC Korba Samudayik Bhawan, Dhanras villag

7 NTPC-Vindyachal At NTPC Vindyachal Training Cen

8 Ramagundam At Training Centre Ramagundam

9 NTPC Unchahar At Unchahar

10 NTPC Farakka

Awareness /Training Programme organized by NTPC Sipat on 28.03.2017 &

31.07.2017

In line with MoEF notification on fly ash utilization-2009 and as amended in 2016,with a view
to promote ash utilization in brick manufacturing in surrounding area, a workshop organised
by NTPC Sipat at Ratanpur,Distt Bilaspur on 28.03.2017 and at Kawarda (C.G) on
31.07.2017 and was attended 50 participants mainly brick manufactures and Pollution
control board authorities. Advantage of fly ash bricks over red bricks were explained in the
workshop and methodology of making fly ash bricks were explained. Literature containing
information on use of ash in fly ash bricks, high volume ash clay bricks, road embankments,
cement concrete and agriculture were distributed among the participants. Workshop was
attended by Brick manufacturers and local people along with Distt pollution Control Board
authorities.

Approx. 50 participants attended the Workshop at Kawardha from brick manufacturing Units
and Local entrepreneurs. In the Workshop, participants demanded compulsory use of fly ash
bricks in all Construction activities including Government Construction activities were
discussed. Workshop was chaired by Collector Kawardha(C.G.) and transportation of fly ash
at brick manufacturing site by Thermal Power stations. NTPC informed that such guidelines
for transportation of fly ash to brick units have been finalized by NTPC. NTPC informed that
fly ash is available “free of any Charge ” at NTPC stations.

Awareness/Training Workshop at Dist Head quarter Basti ( U.P.) –Organised by NTPC

Tanda

A one day workshop on “Ash Brick Manufacturing” was organized on 29th June 2017 by
NTPC, Tanda at District Headquarter Basti (U.P.) . The workshop aimed at creating
awareness among entrepreneurs/local villagers about various fly ash brick technologies and
motivating new entrepreneurs to set up ash brick plants. The workshop was also conducted
to bring together different manufacturers involved on a common platform to discuss
problems and their probable solutions .The workshop was attended by more than 50
participants including ash brick manufacturers, new entrepreneurs etc. In workshop brick
manufacturing methodology was explained and stressed over making quality bricks . NTPC
informed that fly ash is available “free of any Charge ” at NTPC stations.

Awareness /Training Workshop organised by NTPC Talcher –Kaniha on 17.07.2017

An awareness programme on Fly Ash Brick was organized by NTPC Talcher Kaniha at
Odash Stadium, Khamar on 17.07.2017.The programme was chaired by Suman Minz,
Addnl. Tahasildar Pallahara in presence of Smt. Rashmita Priyadarsini, SPCB Official, Angul
Regional Office and Shri A.K.Kamilla, AGM(EMG/AU),NTPC Kaniha.

The programme was attended by fly ash brick manufacturers, brick users as well as
masonry workers. About 120 persons participated in the programme.

Participants who have used fly ash bricks shared their views on their experience.
Participants queries were clarified by the guests regarding the longevity of the ash brick as
well as its strength. Addnl. Tahasildar, Pallahara Suman Minz, speaking on this occasion
shared the benefits of use of fly ash brick and impact of clay bricks on environment. In his
brief talk, he emphasized on the use of fly ash brick in construction activities.

Dy. Engr, Odisha State Pollution Control Board, Angul Regional Office, Smt. Rashmita
Priyadarsini, elaborated on the advantages of fly ash brick in respect of its cost effectiveness
and quality. She stressed on manufacturing bricks according to BIS in order to maintain
quality of the bricks and to gain confidence of the users to opt for ash bricks instead of clay
bricks. NTPC informed that fly ash is available “free of any Charge” at NTPC stations.

Awareness /training workshop at EDC Mouda –Organised by NTPC Mouda on

25.07.2017

A one day workshop on “Ash Brick Manufacturing” was organized on 25th July 2017 by
NTPC, Mouda, at Training Center. The workshop aimed at creating awareness among
entrepreneurs about various fly ash brick technologies and motivating new entrepreneurs to
set up ash brick plants . The workshop was also conducted to bring together different
manufacturers involved on a common platform to discuss problems and their probable
solutions .The workshop was attended by more than 40 participants including ash brick
manufacturers, new entrepreneurs etc.

The workshop was inaugurated by Mr. A.K.Nanda, GGM, NTPC -Mouda welcoming all the
participants and faculty members. AGM, Ash Utilization, delivering the welcome address,
highlighted on the various uses of fly ash thereby transforming a waste into a profitable
resource, if used judiciously. Workshop was also addressed by GM (O&M), NTPC MOUDA,
Mr K.S.RAO who emphasized for ash use in manufacture of cement, concrete, concrete
products, bricks/ tiles etc. as well as for construction of roads, embankments, dams, dykes
or for any other construction activity. GM(O), NTPC Mouda while addressing the participants
briefed about the advantages of joining this business and assured for all kind of support for
entrepreneurs interested to use fly ash for brick manufacturing purpose. NTPC informed that
fly ash is available “free of any Charge” at NTPC stations

Awareness /Training workshop organised by NTPC Rihand on 28.07.2017 & 09.08.2017

A one day workshop on “Ash Brick Manufacturing” was organized on 28th July 2017 by
NTPC, Rihand at Sirsoti, Distt Sonebhadra (U.P.) and on 09.08.2017 at Mayurpur Block of
Distt Sonebhadra(U.P.) The workshop aimed at creating awareness among entrepreneurs
about various fly ash brick technologies and motivating new entrepreneurs to set up ash
brick plants The workshop was also conducted to bring together different manufacturers
involved on a common platform to discuss problems and their probable solutions .The
workshop was attended by more than 50 participants including ash brick manufacturers, new
entrepreneurs ,local villagers etc.

Advantage of fly ash bricks over red bricks were explained in the workshop and methodology
of making fly ash bricks were explained. Literature containing information on use of ash in fly
ash bricks, high volume ash clay bricks, road embankments, cement concrete and
agriculture were distributed among the participants. Workshop was attended by Brick
manufacturers and local people along with Distt pollution Control Board authorities. NTPC
informed that fly ash is available “free of any Charge” at NTPC stations.

Awareness /TrainingWorkshop organized by NTPC Vindyachal on 31.07.2017

Awareness workshop on manufacturing and use of fly ash bricks has been organized at
NTPC Vindhyachal on 31.07.2017. Total 57 participants have participated in above
workshop on 31.07.2017.

In the open house, NTPC Vindhyachal has described in detail regarding best practices of fly
ash brick manufacturing, ideal raw mix design etc. for production of good quality bricks so
that it may be well accepted by the community at large. Additionally, case studies have been
discussed by various ash brick manufacturers on the following topics:

1. Problem faced by them during ash brick manufacturing process and modification
made by them in their raw mix design and manufacturing process.
2. Testing of their fly ash brick samples.
3. Method adopted by them regarding marketing of their ash bricks.
4. Cost of ash brick production.
5. Ideal practices to be followed while handling of ash bricks to avoid breakage.
6. Practices to be adopted while constructing a wall with ash bricks.
7. Photographs of the houses constructed with only fly ash bricks have also shown in
the workshop along with the screening of NTPC video of fly ash bricks. NTPC
informed that fly ash is available “free of any Charge” at NTPC stations.
Awareness/Training workshop organized by NTPC Korba on 29.07.2017

The awareness program of NTPC/Korba regarding ash brick was held on 29.07.2017 at
Samudayik Bhawan, Dhanras village, Korba(CG). In this program representative of CECB,
Korba Shri Manik Chandel and Ex. Sarpanch Shri Chhatrapal Singh Kanwar along with
around 50 villagers participated. Shri S.K. Sanbad, Shri Sudhir Kumar Agarwal and Shri V.R.
Thakur from NTPC side were present in this awareness program, where in the details of ash
brick manufacturing, its utility, better quality/strength over red brick and its price were
discussed. An effort was also made to motivate the people to manufacture ash brick & use
the same and make a source of earning. Shri Manik Chandel and Shri Chhatrapal Singh
Kanwar also expressed their view about quality ash brick being manufactured by
NTPC/Korba and to make extensive use of them. NTPC informed that fly ash is available
“free of any Charge” at NTPC stations.

AWARENESS /TRAINING WORKSHOP AT NTPC Ramagundam on 26.08.2017

Awareness programme organised by NTPC Ramagundam on 26.08.2017 at Training centre
at Ramagundam. Approx. 50 participants from clay brick manufacturers and fly ash brick
manufacturing units attended the programme. The methodology of making quality bricks was
explained in the workshop and participants were informed that fly ash is available “free of
any Charge ” at NTPC Ramagundam.

AWARENESS /TRAINING WORKSHOP AT NTPC UNCHAHAR on 29.08.2017

Awareness /Training workshop organised by NTPC Unchahar on 29.08.2017 at Unchahar/

Approx. 50 participants from clay brick manufacturers and fly ash brick manufacturing units
attended the programme. The methodology of making quality bricks was explained in the
workshop and participants were informed that fly ash is available “free of any Charge” at
NTPC Unchahar.

MoEF Notification on Fly Ash+Click for details

The Ministry of Environment & Forests (MoEF), Govt. of India vide its notification
(amendment) dated 3rd Nov 2009 has made it mandatory:

Major Projects where fly ash has been utilised

 Within 100 Km radius of a Thermal Power Plant

1. To use fly ash based building products such as cement or concrete, fly ash
bricks, blocks, tiles etc. in all construction projects
2. To use fly ash in road or flyover embankment construction
3. To use fly ash in reclamation of low lying areas
 Within 50 Km radius of a Thermal Power Plant (By Road)
1. To use fly ash in back filling of underground and open cast mines
 Financial institutions to include a clause in their loan documents for compliance of this
notification

 Road Embankment Construction & Filling Works:

1. 67 lakh Cubic Meters (Cu.M) of pond ash from NTPC Unchahar Station has
been utilised in Allahabad By-pass Road executed by NHAI.
2. 20 lakh Cu.M of pond ash from NTPC Badarpur Station has been used in
Noida - Greater Noida Expressway
3. About 1.5 lakh Cu.M of pond ash from Indraprastha thermal power station has
been utilised in 2nd Nizammudin approach road embankment
4. About 5.0 lakh Cu.M of pond ash from NTPC Badarpur Station has been
utilised in Yamuna Expressway & Badarpur Flyover
 5. More than 15 lakh Cu.M of pond ash has been used by Delhi Metro Rail
Corporation (DMRC) in their Shastri Park rail car depot from NTPC Badarpur
Station.
 Concrete Works:
1. Fly ash from NTPC Dadri Station is being utilised in all underground concrete
works by DMRC for its metro projects in Delhi.
2. Fly ash is being utilised by all Ready Mix Concrete (RMC) Plants
3. Fly ash used by ACC Ltd. in concrete road at its RMC Plant in Greater Noida
4. Fly ash used in concrete road construction from Dehra Jhal to NTPC Dadri
 Building Construction Works:
1. Administrative Building of Greater Noida Industrial Development Authority
(GNIDA) constructed with fly ash bricks.
2. NTPC’s own Buildings constructed with fly ash bricks
1. NETRA office at Greater Noida
2. 'D' Type residential quarters at Noida Township
3. Northern Region Headquarter building at Lucknow
4. All Projects and Township construction
3. Private real estate developers in various metro cities viz. Pune,
Visakhapatnam & NCR areas use fly ash bricks for construction of residential
complexes.
 Mine Filling:
1. South Balanda Mine being filled with ash from NTPC Talcher-Thermal
Station.
Developing New Segments of Ash Utilisation+Click for details
NTPC is constantly looking at innovative and new ways to utilise the ash generated.
Following research studies have been / are being conducted for development of new
segments having long term potential of ash utilisation:

 Railway Embankment:
To demonstrate use of ash in construction of railway embankment, research study
was carried out in association with the Central Road Research Institute (CRRI), New
Delhi. The design of railway embankment developed by CRRI was validated by
conducting Centrifuge Model Tests at IIT Bombay. Construction of railway
embankment for NTPC’s Merry Go-Round (MGR) rail track for coal transportation is
planned at NTPC Kahalgaon and NTPC Talcher-Kaniha.

 Mine Filling:
1. Feasibility study is being conducted at Talcher-Kaniha by M/s Desien for
finalising the techno economically optimum mode of transporting ash from
power plant to mines on long term basis. Infrastructure shall be created
accordingly for filling of mines with fly ash from NTPC Talcher- Kaniha.
2. Research study is being done by the Central Institute of Mining & Fuel
Research (CIMFR), Dhanbad for taking up technology demonstration project
for random filling of ash from NTPC Ramagundam with Mine over Burden
(MOB) at Medapalli Mines.
 Pre-stressed Railway Concrete Sleepers:
Use of fly ash in the manufacture of pre-stressed railway concrete sleepers
demonstrated in association with IIT Kanpur.
  Ash based Bituminous Road:
Demonstration project for construction of fly ash based bituminous roads have been
taken up in association with CRRI at NTPC Badarpur and Dadri.

 Flux bonded Bricks/Tiles:

Research study for use of fly ash in flux bonded bricks/tiles has been conducted at
NTPC Ramagundam, in association with NIIST Trivandrum.

 HDPE Products:
Use of fly ash in manufacturing of HDPE products taken up by Vindhyachal through
IIT Delhi.

 Showcase Projects on use of Ash in Agriculture:

Use of fly ash in agriculture, as a soil modifier and source of micro and macro
nutrients, has been successfully demonstrated through “Show case projects” in
collaboration with the local farmers under the direct guidance of reputed agriculture
institutions/universities.

1. At NTPC Simhadri in association with Annamalai University

2. At NTPC Unchahar in association with N.D University of Agriculture &
Technology, Faizabad (U.P)
3. At NTPC Talcher – Thermal in association with Annamalai University
4. At NTPC Vindhyachal in association with Annamalai University
5. At NTPC Dadri in association with Annamalai University
Various crops have been grown and harvested in varying agro-climatic conditions
and different soil-crop combinations and following increase in crops yield has been
successfully demonstrated:

S.No. Name of Crop

1 Wheat

2 Paddy

3 Sugarcane

4 Banana

5 Maize

6 Vegetables

Promotional Measures+Click for details

The AUD is constantly at work to promote and popularise multifaceted utilisation of fly ash as
a resource material in various segments and to create awareness among the prospective
users & entrepreneurs for the use of ash. It organises regular workshops and lecture series
for potential users.
Here are some of the campaigns undertaken by them in the recent past:

 Books
 Brochures
 Films
 Advertisements

 NTPC Guide for Users of Coal Ash

 Fly Ash Bricks – Modern Building Material; Towards Cleaner Environment
 Fly Ash for Cement Concrete – A Resource for High Strength and Durability of
Structure at Lower Cost