Ash utilization is one of the key concerns at NFL. NFL pro-actively formulates policy, plans and programme for ash utilization. It further monitors the progress in these areas and works at developing new fields of ash utilization. The quality of ash produced conforms to the requirement of IS 3812. The fly ash generated at NFL Steam Generation Plant Boilers is ideal for use in cement, concrete, concrete products, cellular concrete, lightweight aggregate, bricks/blocks/tiles etc. To facilitate availability of ash to end users, NFL’s Nangal Unit is working with one of cement industry for providing with the facility of dry ash collection system. As the emphasis on gainful utilization of ash grew, the usage over the years has increased.

1. Indian Road Congress (IRC) have issued guidelines (SP-58) for use of ash as fill material in Road Embankments (March 2001)
   
   

2. Indian Road Congress (IRC) has published “Rural Roads Manual” wherein various methods of utilization of ash in roads and embankment construction are covered. (Feb.2002)
   
   

3. As per Bureau of Indian Standards (BIS) fly ash up to 35% by weight can be used in manufacture of Portland Pozzolana Cement (PPC).
   
   

4. IS 456-2000: Code of practice for plain and reinforced concrete allows use of fly ash (up to 35%) as a cementitious content in concrete (where OPC is used).
   
   

5. IS 456-200: Code of practice for plain and reinforced concrete also allows use of fly ash based PPC in reinforced concrete works.
   
   

6. Items of Clay Ash Bricks and Fly Ash-Lime Bricks have been incorporated in CPWD’s Delhi Schedule of Rates (DSR-2002)
   

7. Ministry of Environment & Forests (GOI) has issued draft amendment (dt.6.11.2002) to Gazette Notification on ash utilization (dt.14.9.1999) which is under finalization and final notification is expected to be issued soon. It covers:
   

   1. Use of at least 25% ash in manufacture of clay bricks within 100 kms. Of coal based power stations.
      

   2. Mandatory use of ash based bricks/blocks/tiles etc. by construction agencies in phased manner within 100 kms of coal based power stations.
      

   3. Mandatory use of ash in low-lying landfill & construction of road embankments & flyovers within 100 kms of coal based power stations.

Fly ash can be used in various developmental and construction activities. Some of the prominent uses of fly ash are given as under:

1. For development of various value added products, viz. fly ash based bricks, blocks, mosaic tiles, glazed floor, wall tiles, partition boards, concrete products, cellular light weight concrete blocks, light weight aggregates etc.
   
   
2. For reclamation of waste land/filling of low lying areas
   
   
3. As mine fills in open cast mines and the underground mines can be stowed with ash
   
   
4. For use in concrete
   
   
5. In construction of embankments, dykes, road sub-base and base course.
   
   
6. In agriculture as a source of micronutrient for improvement of soil condition
   
   
7. Production of cement
   

AT NANGAL

National Fertilizers Limited at Nangal has three (3) no coal fired Boilers, each of 117 TPH (Gen. Steam) + 2 x 65 TPH Import Steam capacities. Each Boiler has two (2) sets of Electrostatic precipitators (ESP) called old ESP and new ESP. Old ESP has 6 Nos. of Hoppers with three (3) fields, each having two (2) hoppers. New ESP has 4 Nos. hoppers with two (2) fields each having two (2) hoppers.

Vacuum type Fly Ash Extraction System is installed in all the three (3) boilers. The fly ash is extracted from ESP hoppers of respective boiler through hydraulic exhausters by means of HP Water pumps up to a collector tank, where the fly ash is separated.

Fly ash is mixed with LP Water by wetting head provided before the collector tank and finally fly ash in slurry form is discharged into ash slurry sump common for all the three (3) boilers. Fly ash from slurry sump is pumped to disposal area called ash ponds by a set of slurry duty pumps.

The total volume of available wet ash in our ash ponds at present is about 3.5 Million M³.

Mecaber BK of Delhi has been entrusted detailed engineering for collection of dry fly ash. A cement plant is already lifting dry fly ash from the plant on small scale basis and shall lift the total generated quantity after installation of dry fly ash collection unit.

Contact Person:
Dy. General Manager (Technical Services),
NFL Nangal Unit
Naya Nangal-140126
01887-220533 (Office)

AT PANIPAT

At Panipat, Nitrogenous Urea Fertilizer is produced with a capacity of 1550 TPD. There are 4 nos. coal based boilers of which three are Steam Generation Plant Boilers supplied by M/s.BHEL. Each Steam Generation Plant Boiler is having a steam production capacity of 150 TPH. The fourth boiler is Captive Power Plant boiler supplied by M/s.MES with a steam production of 210 MTPH and is used for generating power of 26 MWH. The total coal requirement for operating the required boilers is about 1500 to 1600 TPD.

The ash content in the coal received is in the range of 40-45% and the ash generated is approx. 600 TPD or more. There are 38 nos. of ESPs (Electrostatic Precipitators) equipped in the boilers for collecting the ash which is then mixed with water and pumped in the form of ash water slurry up to ash ponds located at Dahar site about 8 kms away from the factory. This Dahar ash pond has a capacity of more than 32 lakhs m3 and the ash gets settled here.

0.3 Million M³ of total ash is generated every year, out of which fly ash is 0.2 Million M³.
Presently total 5.5 Million M³ of ash is available for disposal which can be used for :

Roads
Land filling
Bricks
House building plinths
Pavements

Panipat is offering this ash free of cost. Ash is a valuable material, which will help not only the user but also improve the environment. All manufacturers and consumers are encouraged to avail this opportunity. NFL Panipat may also make a facility for collecting Dry fly ash as and when required by a user.

CONTACT PERSON:
Chief Manager (Technical Services),
NFL Gohana Road,
Panipat.
0180-2681124 (Office)

This plant is having four coal fired boilers (Three in Steam Generation Plant (SGP) and One in Captive Power Plant (CPP). The total consumption of coal is about 1700 MT/day. The total generation of ash is about 700 MT/day. The average combustibles in the fly ash from SGP boilers is about 6-8%, whereas it is about 3-4% in the CPP boiler. The average combustibles in the bottom ash from SGP Boilers is about 13-15% and that in the CPP boiler is about 6-9%.

The ash generated in the plants is disposed off in the form of ash slurry into ash slurry ponds. Presently, the unit is having three ash ponds, designated as Ash Pond No.1, 3A & 3B. The details of these ponds are given as under:

The unit disposes off wet ash from their ash ponds for filling of nearby low-lying areas. The typical analysis of fly ash samples collected from the ash hoppers of CPP and SGP are given below:

We are looking for parties who may be interested in lifting dry/wet fly ash from our plant or ash slurry lagoons free of cost. We are interested to supply dry fly ash to parties as per their requirement up to maximum quantity of about 500 MT/day. We may install a dry fly ash handling cum storage facility, if the interested parties agree to lift dry fly ash from our plant on long- term basis. The detailed modalities for supply of dry fly ash from our plant to the party can be worked out mutually, if the parties agree to lift fly ash from our plant in principle on continuous basis for an appropriate period of time.

The total volume of available wet ash in our ash ponds at present is about 0.85 Million M³.

CONTACT PERSON:
Deputy General Manager (Technical Services),
NFL Bathinda unit,
Bathinda
0164-2271214 (Office)