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H.M. Bangur, President of  Cement Manufacturers' Association, on the objectives and economic impact of the proposed national policy on utilisation of fly ash that will enable cement manufacturers source fly ash at reasonable cost and produce more eco-friendly pozzolana cement.

 

Cement Manufacturers' Association and Shree Cement Ltd are seeking to formulate a comprehensive national policy on utilisation of fly ash which would enable the cement manufacturers source fly ash at reasonable cost and produce more eco-friendly pozzolana cement.

The national policy on fly ash utilisation, based on freight equalisation, would result in the production of more fly ash based cement and also result in lower energy consumption levels,  thereby lowering carbon footprint.


The objectives of the national policy on fly ash are as follows:

Fly ash utilisation
As per estimates, the annual fly ash generation in the country in 2007-08 (data of 2008-09 under compilation, expected to be 150 million tonnes) was about 125 million tonnes; fly ash recycled is about 30 per cent, i.e about 40 million tonnes. Out of this the cement industry consumes around 28-30 million tonnes which is above 70 per cent of the recycled ash. Hence, there is still a huge surplus of 85 million tonnes which is being disposed off as slurry in the ponds.

Another approximately 78,000 mw of new power generation capacity is expected to come up in the country within three-four years. Out of this major portion of around 60 per cent would come in form of thermal power. Estimated generation of fly ash till 2012 would be 175 million tonnes, which again would pose a serious problem of disposal. The major consumer of fly ash is the cement industry only, while some small quantities are used for making fly ash bricks, landfill etc.

As per the table, the utilisation of fly ash in the cement industry in manufacturing PPC cement is increasing on yearly basis. Further motivation and freight equalisation to cement industry can result into 100 per cent fly ash disposal in a most eco-friendly manner.

Thermal plant perspective
Huge surplus quantity of fly ash is being disposed as slurry in the ponds consuming enormous amount of power and water. This results in substantial financial cost to the thermal power plants. Utilisation of fly ash in dry form is the most ideal form of disposal through which huge savings can be made by TPPs.

Savings of large quantities of scarce water and power resources which can be used for other critical alternate purposes. Conservation of valuable land resources, which would otherwise be needed in huge areas for the ash ponds.

Cement industry perspective
Usage of fly ash means increased capacity/production resulting in saving of huge capital expenditure required for such capacity additions. Savings in utilisation of natural resources like limestone, ultimately increasing running life of mines. Availability of sustainable/ compatible product at a lower cost to the consumers. Optimal utilisation of clinker resulting in less carbon emissions, reduced pollution levels and CDM benefits.

Limestone policy
Optimum utilisation of natural resources, since limestone is the basic raw material required in cement industry which constitutes almost 70 per cent of total raw material. To create a task group for making a detailed programme regarding policy modifications/ relaxations for making forest and reserved reserves available for production. Single window facility for settlement of disputes/issues related to limestone bearing land. To ensure availability of limestone as per capacity additions and expansions.

 

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