Environment

Fly ash utilisation in Samruddhi Mahamarg

Published

6 years ago

January 10, 2019

admin

Maharashtra Government has undertaken an ambitious project, the first-of-its-kind (distance wise) in the country. The project has a big potential of using fly ash as a construction material. A glimpse of the project has been compiled by Sudhir Paliwal and Dr Ajitkumar Bhonsle.

Mumbai Nagpur Super Communication Expressway-also known as Maharashtra Samruddhi Mahamarg under construction-is a 701 km long, six-lane expressway, connecting the two capitals of Maharashtra – Nagpur and Mumbai. The expressway will run through 10 districts, 26 tehsils, and 390 villages in the State, and is expected to cut travel time between the two cities to eight hours. The project is expected to cost Rs 46,000 crore and requires the acquisition of 8,603 hectares of land.

The Maharashtra State Road Development Corporation is the nodal agency responsible for executing the project, which comprises building a completely greenfield expressway, designed for speeding up to 150 km/h on flat terrain and up to 100 km/h on the mountainous terrain of the Western Ghats section. The State Government also plans to build 24 townships along the route, which will include state-of-the-art healthcare facilities, skill management centres, IT parks and educational institutions. A total of 20,820 hectares of land is to be acquired for the project across 10 districts, out of which 8,520 hectares will be used for the highway, while 10,800 hectares would be for building townships.

The aim of the super communication expressway is to create connectivity to the last mile with best public transport facilities for quick and easy movement of people and goods. The expressway will enable a large population to have easy access to major centres in Maharashtra for a wide range of self-employment and wage employment opportunities, business, trade, education, health care and other necessary services.

Samruddhi Mahamarg Expressway
The expressway will pass through 10 districts, namely Nagpur, Wardha, Amravati, Washim, Buldhana, Aurangabad, Jalna, Ahmednagar, Nashik and Thane. It will connect Nagpur to Mumbai and have direct connectivity with the country’s largest container port – JNPT. This will enhance export-import trade of the State. Inter-connecting highways and feeder roads would be constructed to connect all important cities and tourist places along this route. This will connect another 14 districts, namely Chandrapur, Bhandara, Gondia, Gadchiroli, Yavatmal, Akola, Hingoli, Parbhani, Nanded, Beed, Dhule, Jalgaon, Palghar and Raigad. In this manner, a total of 24 districts in Maharashtra will be connected via this expressway.

Major tourist destinations in the State will also be connected to the expressway. The expressway, having a total width of 120 m with a central median of 22.5 m, will follow the international standards of design. There will be eight lanes, four on each side. In case there is a need to increase lanes on either side, a provision has been made in the centre of the expressway. Thus, no more land will be required for expansion in future. It will have service roads on both sides that will connect through underpasses.

The expressway will have around 50+ flyovers, 24+ interchanges, over five tunnels, 400+ vehicular and 300+ pedestrian underpasses provided at strategic locations. These underpasses and flyovers will be beneficial to those vehicles leaving or joining the expressway without disturbing the traffic flow. It will also benefit local citizens to go about their travel without any hindrance and also prevent accidents.

Extensive landscaping, tunnel lighting, bridge beautification, improved street lighting and digital signage will be used throughout the length of the expressway. Maximum locally available material, fly ash and plastic will be used to construct the expressway wherever possible. Rainwater will also be harvested from the expressway. The entry and exit at the expressway will be managed and toll will be charged based on the distance travelled. The toll collection is proposed to be automated. The expressway will be a Zero Fatality Mahamarg; it will have CCTV surveillance and free telephone booths at every 5 km to allow reporting in case of any accidents and emergencies. Utility Mahamarg along the expressway will be provided for OFC cables, gas pipelines, electricity lines, etc.

In case of any emergency, natural disaster or in a war-like situation, a facility to land an airplane on the expressway is proposed by temporarily converting the expressway to a runway. The Maharashtra Samruddhi Mahamarg will link the State of Maharashtra to the Delhi-Mumbai Industrial Mahamarg and the Western Dedicated Freight Mahamarg. Parts of Maharashtra will have direct connectivity to these Mahamarg and JNPT, the country’s largest container port. This, in turn, will enhance the EXIM trade of the State.

Advantages of using fly ash
The Indian Roads Congress (IRC) guidelines IRC:SP:58-2001 provide salient details regarding design and construction of road embankments using fly ash. Utilisation of fly ash will not only minimise the disposal problem but will also help in utilising precious land in a better way. Construction of road embankments using fly ash, involves encapsulation of fly ash in earthen core or with RCC facing panels. Since there is no seepage of rainwater into the fly ash core, leaching of heavy metals is also prevented. When fly ash is used in concrete, it chemically reacts with cement and reduces any leaching effect. Even when it is used in stabilisation work, a similar chemical reaction takes place, which binds fly ash particles. Hence chances of pollution due to use of fly ash in road works are negligible.

Fly ash is a lightweight material, as compared to commonly used fill material (local soils), therefore, causes lesser settlements. It is especially attractive for embankment construction over weak subgrade such as alluvial clay or silt where excessive weight could cause failure.

Fly ash embankments can be compacted over a wide range of moisture content, and therefore, results in less variation in density with changes in moisture content. Easy to handle and compact because the material is light and there are no large lumps to be broken down. Can be compacted using either vibratory or static rollers.

High permeability ensures free and efficient drainage. After rainfall, water gets drained out freely ensuring better workability than soil. Work on fly ash fills/ embankments can be restarted within a few hours after rainfall, while in case of soil it requires much longer period.

Considerable low compressibility results in negligible subsequent settlement within the fill.

Conserves good earth, which is precious topsoil, thereby protecting the environment.

Higher value of California Bearing Ratio as compared to soil provides for a more efficient design of road pavement.

Pozzolanic hardening property imparts additional strength to the road pavements / embankments and decreases the post construction horizontal pressure on retaining walls.

Amenable to stabilisation with lime and cement.

Can replace a part of cement and sand in concrete pavements thus making them more economical than roads constructed using conventional materials.

Fly ash admixed concrete can be prepared with zero slump making it amenable for use as roller compacted concrete.

Considering all these advantages, it is extremely essential to promote use of fly ash for construction of roads and embankments.

Use of fly ash in road works results in reduction in construction cost. If environmental degradation costs due to use of precious top soil and aggregates from borrow areas quarry sources and loss of fertile agricultural land due to ash deposition, etc. is considered the actual savings achieved are much higher.

Govt initiatives for fly ash utilisation in roads
Use of fly ash is mandatory in Road construction: As per para 5 of MoEF&CC notification dated November 3, 2009 – "No agency, person or organisation shall, within a radius of 100 km of thermal power plant undertake construction or approve design for construction of roads or fly-over embankment with TOP SOIL."

As per the para No.2 (14) of MOEF&CC notification dated January 25, 2016 – "The coal or lignite based thermal power plants shall within a radius of three hundred kilometres bear the entire cost of transportation of ash to the site of road construction projects under Pradhan Mantri Gramin Sadak Yojna and asset creation programmes of the Government involving construction of building, road, dams and embankments.

Maharashtra State has notified Ash Utilisation Policy – 2016 and constituted Maharashtra State Fly Ash Council under the Chairmanship of Chief Secretary, Maharashtra. As per the State ash policy, point No. 1, 2 & 3 under para "Government Decisions", – "fly ash to be transported free of cost for Government infrastructure projects, roads construction by the ash producers i.e. thermal power plants"

In compliance of MoEF&CC notifications NTPC has been issuing ash free of cost for road construction projects and also entering in to MoU with NHAI for bearing transportation cost of ash. More than 100 lakh tons of Fly Ash is utilised in NHAI projects in Maharashtra and other States where fly ash is generated.

Samruddhi Mahamarg between Nagpur and Mumbai is passing within 300 km radius of several power plants like Reliance Butibori, Ideal Energy, Mahagenco Khaprkheda/Koradi, NTPC Mouda, Ratan India Amraoti, Mahgenco Paras, Bhusawal, Parli & Nasik, Tata Power, Adani Power, etc.

The Ministry of Road Transport & Highways, Government of India also issued following directions wide letter dated August 27, 2018: The use of fly-ash in road construction is permitted as per the standards and specifications evolved by the Indian Road Congress. The physical and chemical properties of fly ash and the design methodology to be adopted for embankment construction has been specified in IRC:SP:58:2001: "Guidelines for use of fly-ash in road construction". Section 305 i.e. "Embankment Construction" of MoRT&H specifications for road and bridge works lays down the specifications for use of fly-ash in embankment construction.

Compliance to IRC specification No.SP:58 of 2001 related to use of fly ash has been made mandatory by the Ministry of Environment Forests & Climate Change by issuing an amendment to their fly ash notification while undertaking construction or approve design for construction of roads or flyover embankment.

The Ministry of Environment Forests and Climate Change (MoEF&CC) has issued various notifications for fly ash utilisation. The principal notification was issued on 14-9-1999, which was subsequently amended vide notifications dated 27-8-2003, 3-11-2009 and 25-1-2016. As per the notification of MoEF&CC, it is mandatory to use fly ash in the construction of road or flyover embankments within a radius of 300 km of a thermal power plant. Further, the relevant content of the notification dated 25-1-2016 of MoEF&CC regarding road/ flyover embankment construction are as under:

Para 14: The coal or lignite based thermal power plants shall within a radius of three hundred kilometers bear the entire cost of transportation of ash to the site of road construction projects under Pradhan Mantri Gramin Sadak Yojana and asset creation programmes of the Government involving construction of buildings, road, dams and embankments.

The issue of lesser off-take of fly-ash in road construction activities of the Ministry of Road Transport & Highways and its executing agencies (NHAI, State PWDs and NHIDCL) has been reviewed at the level of the Ministry. It was pointed out that the thermal power plants have been found to be reluctant to bear the transportation costs in accordance with the latest notification issued by the MoEF&CC on the subject. Accordingly Secretary, MoRTH took up the matter with the Secretary, Ministry of Power and the CMD of National Thermal Power Corporation (NTPC). The CMD of NTPC clarified that they had already issued instructions in this behalf to the officers-in- charge of all the NTPC plants. The availability of fly ash at various stations of NTPC is available at NTPC official web site www.ntpc.co.in under the tab "Ash Availability". The names of responsible persons along with telephone number/mobile number/e-mail address to communicate for issues of pond ash are mentioned. The same is also available in the app "ASHTRACK" launched by the Ministry of Power.

As per the Central Electricity Authority during 2017-18 about 196 million tonnes of fly ash was generated in India out of which only 131 million tonne could be utilised. However in roads and flyovers only 6.67 million tonne is utilised, which is just 3.4 per cent of total utilisation.

There is huge potential of utilisation of fly ash in roads like Samruddhi Mahamarg. Use of fly ash is mandatory in road construction: As per para 5 of MoEF&CC notification dated November 3, 2009 – "No agency, person or organisation shall, within a radius of 100 km of thermal power plant undertake construction or approve design for construction of roads or fly-over embankment with top soil."

As per the para No.2 (14) of MOEF&CC notification dated January 25, 2016 – ?The coal or lignite based thermal power plants shall within a radius of three hundred kilometres bear the entire cost of transportation of ash to the site of road construction projects under Pradhan Mantri Gramin Sadak Yojna and asset creation programmes of the Government involving construction of building, road, dams and embankments".

In compliance of MoEF&CC notifications NTPC has been issuing ash free of cost for road construction projects and also entering in to MoU with NHAI for bearing transportation cost of ash. More than 100 lakh tonne of fly ash is utilised in NHAI projects in Maharashtra and other States where fly ash is generated.

In the meeting of Maharashtra State Fly Ash Council held under Chairmanship of Chief Secretary in March 2018, MSPGCL and PWD were directed to sign MOU for fly ash utilisation for Samruddhi Mahamarg.

"In December 2018, an agreement was signed between Maharashtra State Power Generation Company and Nagpur Mumbai Super Communication Expressway to utilise about 300 lakh tonnes of pond ash and 15 lakh tonnes of dry fly ash for entire 700 km road.

ABOUT THE AUTHORs: Sudhir Paliwal is an Expert Member of the Maharashtra State Fly Ash Council Mumbai.

He can be contacted on: 8291089301. Dr Ajitkumar Bhonsle is an expert and advisor on use of fly ash. He can be contacted on: 9821127987

Concrete

India donates 225t of cement for Myanmar earthquake relief

Published

1 week ago

June 17, 2025

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On 23 May 2025, the Indian Navy ship UMS Myitkyina arrived at Thilawa (MITT) port carrying 225 tonnes of cement provided by the Indian government to aid post-earthquake rebuilding efforts in Myanmar. As reported by the Global Light of Myanmar, a formal handover of 4500 50kg cement bags took place that afternoon. The Yangon Region authorities managed the loading of the cement onto trucks for distribution to the earthquake-affected zones.

Concrete

Reclamation of Used Oil for a Greener Future

Published

1 week ago

June 16, 2025

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In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.

The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.

The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.

Circular economy in lubricants
In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt, and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.

Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.

Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)

The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.

On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:

Kinematic Viscosity
Flash Point
Total Acid Number
Moisture / Water Content
Oil Cleanliness
Elemental Analysis (Particulates, Additives and Contaminants)
Insoluble

The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.

Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.

About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

Concrete

Charting the Green Path

Published

1 month ago

May 13, 2025

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The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.