Team_Alchemy_Korba_PC_2022.pptx

1. Team Alchemy Welcomes Respected Dignitaries Korba STPS

4. Context 4 • Focus of NGT on Ash Utilization in Distt Korba. • Exploring Un-utilized Avenues. • Prospects for Team Alchemy. • Idea Generation. • Existing Methods of Ash Utilization at NTPC Korba. • Utilization of Idea. • Ash Dyke Issues.

5. GoI’s Ash Notification-2015/16 Clause-2.11/ 2.12 & 5.0 2.11 – The Coal based TPP shall promote, adopt & setup Ash based manufacturing facilities within their premises or vicinity. 2.12 – The coal based TPP in the vicinity of the cities shall promote, support and assist in setting up of ash based product manufacturing units so as to meet the requirements of bricks and other building construction materials and also to reduce the transportation. 5.0 – 100% utilization of Fly Ash generated by 31.12.2017.

6. NTPC’s Ash Policy-2015 Clause-11.0 “Efforts for New Area of Ash Utilization - Geopolymers” 11.1 Fly Ash based light weight sand. 11.2 Fly Ash based Geo-Polymer Concrete. *These activities shall be financed from Ash Fund. Material Requirement 1) Sodium Silicate – Na2SiO3 2) Sodium Hydroxide – NaOH 3) Fly Ash Activator

7. Concept of Geopolymers Geo-polymerisation involves alkaline activation of materials rich in silica and alumina. Reaction conditions Temp/ Time Solid aluminosilicate raw material Alkali activator Geopolymer paste It give a three- dimensional silico-aluminate structure by polycondensation.

8. Potential at NTPC Korba • Sodium Hydroxide – Pellets used in DM Plant for Resin Regeneration. Required only for preparation of alkali activator. • Sodium Silicate – Required as Binder in alkali activator solution. It is an inorganic sodium salt which has silicate as the counterion. To be arranged/ sourced. 2x NaOH + SiO2 → (Na2O)x·SiO2 + x H2O • Aggregate material – Sand/ Gravel or any other coarse material to be iterated as per availability. Raw Material Availability • Solid Aluminosilicate Raw Material – Available as Fly Ash in plenty. Iterations

9. Iteration I – Silica Gel 9 NTPC’s Zero Deviation Document – • Disposal of Silica Waste - P.No. 36 of 55. • Material Type – Hazardous as per HWM Rules- 2016. • Authorization from PCB – Required for Disposal. • Disposal – Sale to Recycler or disposal at TSDF facility. • Documentation – Annual Return/ Storage permission from PCB. Present stock at NTPC Korba: • At Stores – 5 MT • At site – 1 MT • Validity of Authorization for NTPC Korba: Qty – 10 MT/ annum. Period – 21.11.2024. Silica Gel stored at NTPC Korba

10. Preparation of Sodium Silicate solution 1. Removing water and impurities from Silica gel and Sodium Hydroxide. 2. Weighment as per stoichiometric requirement. 3. Addition and Preparation of Reactants. 4. Maintaining reaction conditions (100-120 deg C with stirring). 5. Filtration of reaction product. 6. Stocking of sodium silicate solution. 1 5 4 3 2 6

11. Iteration II – Mill Reject as aggregate 11 • Available quantity – 75, 000 MT (approx). • Material Type – Waste with minimal resale value. • Authorization – Not required. • Disposal – Sale on online platform MSTC. • Utilization proposed – As aggregate for GP concrete mix after crushing. • Potential – 1, 35, 000 sqm area.

12. Design Parameters 12 Mix Design parameters selected for Fly Ash Geopolymer Mortar Ratio of alkaline liquid to fly ash by mass 0.35 Concentration of NaOH solution (in molar) 8 Ratio of Na2SiO3 to NaOH (by mass) 2.5 Initial Curing Method Oven Initial Curing Temp (deg C) 60 Curing Time (in hrs) 24 Rest Period (in hrs) 168 Preparation of Fly Ash Geopolymer concrete Mortar blocks 9X9X9 cm. Preparation of blocks using Sand-Fly Ash Geopolymer concrete 15X15 X15 cm. Preparation of blocks using Mill Reject-Fly Ash Geopolymer concrete 15X15X15 cm. 9X9X9 cm Mould 15X15X15 cm Mould

13. Detailed Mix Proportions 13 Details of mix proportions for Fly ash geopolymer concrete Mix-type proportion GP-Mortar Block Sand-Fly Ash GP Mill Reject-Fly Ash GP Fly Ash Only (kg/ m3) 1201 721 960 Sand (kg/ m3) - 480 - Mill Reject (kg/ m3) - - 241 Extra Water (kg/ m3) 10 10 10 NaOH (kg/ m3) 41 43 45 Na2SiO3 (kg/ m3) 103 108 113 Na2O/SiO2 0.1 0.12 0.15 SiO2/Al2O3 4.68 4.8 4.95 H2O/SiO2 14.70 14.40 14.10 Water to Solids by weight 0.2 0.2 0.2

14. Preparation Process Raw Material - Fly Ash GP Mortar Raw Material – Sand Fly Ash GP Concrete Raw Material – Mill Reject Fly Ash GP Concrete Step-1 – Preparation of Precursors & Raw aggregates

15. Preparation Process Raw Material – Sand Fly Ash GP Concrete Raw Material – Mill Reject Fly Ash GP Concrete Step-2 – Mixing of Raw aggregates

16. Preparation Process Addition of Alkali Activator Making Dough Mix Step-3 – Preparation of Dough Mix Sand-Fly Ash Mill Reject-Fly Ash

17. Preparation Process Mould Sand-Fly Ash Mould Mill Reject-Fly Ash Step-4 – Filing of Mould Mould Filing

18. Preparation Process Blocks after temperature curing Step-5 – Temperature Curing and Resting Temperature Curing @ 24 Hrs at 60 deg C Mould after Temperature Curing

19. Preparation Process Sand-Fly Ash Geopolymer Concrete Step-6 – Final Fly Ash Geopolymer Concrete Block after 4 days Fly Ash Mortar Geopolymers Mill Reject - Fly Ash Geopolymer Concrete

20. Testing planned of GP Fly Ash Concrete Blocks 20 Tests Planned • Dimensions & Tolerances • Compressive Strength at 7, 21 & 28 days. • Abrasion Resistance. • Water Absorption Tests after 28 days. • X-ray Diffraction test for crystallinity. • SEM analysis to study morphology and distribution of particles. Other Iterations proposed – • Use of Bottom Ash as aggregate material for construction of test blocks.

21. Advantages & Disadvantages 21 Advantages • Reduces Carbon footprint. • Utilize Fly Ash. • High Compressive & Tensile Strength. • Very low Creep and Shrinkage. • Resistant to Heat & Cold. • Chemical Resistant. Disadvantages • Slight Difficult to create. • Require handling of chemicals. • Field is Nascent and still under study.

22. 22 Areas available for Testing Geopolymer Concrete DM Plant CW P/p House CT Area Construction Stores ZLD Area

23. Cost savings/100 sqm concreting of 0.15m thickness 23  Cement required 28 bags @ Rs 300/ bag (1:2:4) (tentative) = Rs 8, 400/-  Sand & Aggregates Cost @ Rs 3/ kg (1:2:4) (tentative) = Rs 5, 120/-  Total material savings for 100 sqm fly ash geopolymer concreting with mill reject = Rs 13, 520/-  Cost to be incurred for alkali activator per 15 m3 of fly ash GP concrete = Rs 42/-  Nominal cost of Mill reject @ Rs 650/ m3 = Rs 4, 062/-  Gross material savings/ 100 sqm fly ash GP concreting = Rs 9, 416/- • NaOH required for alkali activator can be further reduced by using effluent of regeneration (2M) in DM plant.

24. NTPC Green Initiatives 24  Our company has planned to replace 11000 MW Thermal Power Plants older than 25 years with Energy Efficient Super Critical Plants.  Our company is running more than a dozen initiatives to get rid of fly ash.  Our company has planted 20 million trees till date in and around its projects.  Our company have committed to use treated sewage water at its Dadri Power Station.  Our Company has set ambitious targets for promotion of Green Hydrogen as alternate fuel for Transport and Gas turbines.

25. Conclusion 25  Our company has been at the forefront of Agro Residue and Municipal Solid Waste Management, to give the capital and NCR cleaner air.  Our company has invited developers to set up 100 waste-to- energy plants.  Our company has gone for Paperless Office through “PRADIP” Project.  Going Green begins at home’ is the company’s mantra in all aspects of its operations.

26. 26 • The savings on account of use of Fly Ash GP may not be huge. • As a responsible corporate entity, NTPC can spread environment protection message among its industry peers. • Inhouse utilization of fly ash will help NTPC to achieve the GoI set target of 100% ash utilization from TPP’s • Moreover, this initiative will add one more feather in already bright cap of NTPC towards environment protection. Conclusion

27. 27 /ntpc1 /ntpclt d1 /ntpclimite d /Company/nt pc /ntpclimited Follow us Thank You Website: www.ntpc.co.in | Email: chandansharma@ntpc.co.in, vikeshkumar@ntpc.co.in, shreyaroy@ntpc.co.in, dcsnaidu@ntpc.co.in Migratory Birds at NTPC Dadri NTPC Ramagundam

30. Laboratory Testing of GP Fly Ash Concrete Blocks 30 Sample Block Compressive Strength at 25 oC in N/mm2 (IS 15658: 2006) *Cement Mortar Blocks 7.5 *Concrete Blocks (M25) 18.3 **Fly Ash GP Mortar Blocks **Fly Ash - Sand GP Blocks **Mill Reject - Sand GP Blocks *Source – IS 2185: 2005 “Concrete Masonry Units”.

31. Laboratory Testing of GP Fly Ash Concrete Blocks 31 Sample Block (after 28 days curing) Water Absorption at room temp % (IS 15658: 2006) *Cement Mortar Blocks 1.5 *Concrete Blocks 2.4 Fly Ash GP Mortar Blocks Sand – Fly Ash GP Blocks Mill Reject – Fly Ash GP Blocks *Source – IS 2185: 2005 “Concrete Masonry Units”.

Team_Alchemy_Korba_PC_2022.pptx

Team_Alchemy_Korba_PC_2022.pptx

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