How is Patratu (Thermal) fly ash processed for cement production?

  

The fly ash, primarily dry fly ash (about 80%) collected from flue gases via electrostatic precipitators at Patratu Thermal Power Station (PVUNL), is stored in silos before pneumatic transport to UltraTech Cement's Patratu Works. It is pumped directly from closed bulkers into silos in a closed-loop system to prevent fugitive emissions, then integrated as a raw material substitute (up to 30% in PPC) alongside slag for blended cement production per Bureau of Indian Standards.



Fly ash is fed from silos into mills (e.g., ball mills or vertical roller mills) after metering, where coarse particles are pulverized to below 325 mesh, increasing surface area and breaking spherical microbeads for better cement integration. Open-circuit grinding directly produces fine Grade I/II ash without separation, while closed-circuit systems recirculate coarse material for regrinding until uniform fineness. Dust collectors capture fines during milling, minimizing emissions.


UltraTech incorporates the fly ash as a pozzolanic substitute in blended cements such as Portland Pozzolana Cement (PPC) and Portland Composite Cement (PCC), reducing clinker needs and carbon emissions. For instance, from December 2023 to June 2024, the plant used over 9,500 MT of fly ash for PPC and additional amounts for PCC production. This process leverages fly ash's properties to enhance concrete durability without extensive further processing beyond drying and transport.


๐Ÿง‘๐Ÿป‍๐Ÿซ Sudesh Kumar

๐Ÿ“ฌ help@patratu.com


instagram.com/patratu.in

Banhardih Coal Block

 

Banhardih Coal Block is a proposed opencast coal mine operated by Patratu Vidyut Utpadan Nigam Limited (PVUNL), located in Latehar. It is a joint venture between NTPC Ltd. (74%) and Jharkhand Bijli Vitran Nigam Limited (26%), with the coal produced mainly supporting the Patratu Thermal Power Station. The mine spans approximately 18 square kilometers, with total coal reserves around 1,372 million tonnes, including about 270 million tonnes of mineable reserves, primarily lignite for thermal use. Production capacity is planned at 12 million tonnes per annum, potentially peaking at 18 million tonnes.



The coal extracted from Banhardih Coal Block serves as a captive source of fuel for the Patratu Thermal Power Station, specifically supporting the larger 4,000 MW thermal power project for regional development and energy security. Environmental clearances have been obtained for this project, with water supply allocated from the nearby Patratu Dam (reservoir) to support operations.


Financial backing for the Banhardih Coal Block includes long-term funding from the Indian Railway Finance Corporation (IRFC), which sanctioned a loan of ₹3,388.51 crore in September 2025 to support development and operational activities at the coal block.


๐Ÿง‘๐Ÿป‍๐Ÿซ Sudesh Kumar

๐Ÿ“ฌ help@patratu.com


instagram.com/patratu.in

Patratu Thermal and UltraTech Cement

    

A model of industrial synergy emerges between Patratu Thermal Power Station (PTPS) renamed as Patratu Vidhyut Utpadan Nigam Limited (PVUNL) and UltraTech Cement’s Patratu unit known as the Patratu Cement Works. This partnership showcases how sustainable collaboration can transform waste into value while reducing environmental burden.  



Patratu Thermal Power Station generates large volumes of coal ash as a by-product of electricity production. About 80 percent of this ash is fine fly ash collected in dry form from flue gases using electrostatic precipitators, while the remaining 20 percent is bottom ash handled through wet disposal systems. The collected dry fly ash is stored in silos and made available to industries under regulated supply programs.  


UltraTech Cement (Patratu Cement Works) stands as a major beneficiary and partner in this cycle. The plant utilizes the fly ash as a key substitute material in manufacturing blended cements like Portland Pozzolana Cement (PPC) and Portland Composite Cement (PCC). By sourcing fly ash locally from PVUNL, the UltraTech reduces its dependence on virgin raw materials and minimizes carbon emissions associated with clinker production.  


This relationship not only optimizes resource use but also mitigates the environmental challenges of ash disposal. Fly ash is transported in closed tankers to maintain air quality and comply with regulatory norms. Together, PVUNL and UltraTech Cement demonstrate how industrial collaboration can foster cleaner production, and a shared path toward sustainability.


๐Ÿง‘๐Ÿป‍๐Ÿซ Sudesh Kumar

๐Ÿ“ฌ help@patratu.com


instagram.com/patratu.in

Jindal Steel and Power Limited

  

Jindal Steel & Power Limited (JSPL) has a manufacturing facility in Patratu, Jharkhand, which is a significant steel production unit with a total finished steel capacity of 1.60 million tonnes per annum (MTPA). The facility includes a Bar Rod Mill with 1 MTPA capacity and a Wire Rod Mill (WRM) of 0.6 MTPA capacity, along with a rebar service center. JSPL's presence in Patratu began when it took over the defunct Bihar Alloys and Steel Limited (BASL) assets in the area around 2007.



The Wire Rod Mill was commissioned in 2010, followed by the Bar Mill in 2011, and the rebar service center was established in 2012. This manufacturing plant uses state-of-the-art technology and produces superior quality products such as Wire Rods, TMT Rebars, Rounds, Angles, and ready-to-use products like Weld Mesh and Cut & Bend rebars. The company launched its retail brand of TMT Rebars under the name Jindal Panther, which are produced here using High Yield Quenching and Self-Tempering (HYQST) technology, certified under the Fe500S grade of BIS 1786, making them particularly strong and suitable for high seismic zones.


JSPL Patratu is also notable for having commissioned India’s largest Producer Gas Plant to fuel its furnaces. The plant has received international safety awards, reflecting its commitment to operational excellence and safety standards. The steel plant at Patratu initially aimed for a capacity expansion to 6 MTPA and continues to be an important part of JSPL's steel production and expansion plans in Jharkhand.

เคชเคคเคฐाเคคु เคตिเคฆ्เคฏुเคค เค‰เคค्เคชाเคฆเคจ เคจिเค—เคฎ เคฒिเคฎिเคŸेเคก


11 เคฎाเคฐ्เคš (2025) เค•ी เคธुเคฌเคน เคชเคคเคฐाเคคु เคฎें เคธूเคฐเคœ เค•ी เคชเคนเคฒी เค•िเคฐเคฃ เคœैเคธे เคนी เคซैเคฒी, เค‰เคธी เคตเค•्เคค เคเค• เค”เคฐ “เคŠเคฐ्เคœा เค•ी เค•िเคฐเคฃ” เคœเคจ्เคฎ เคฒे เคšुเค•ी เคฅी। เคชเคคเคฐाเคคु เคตिเคฆ्เคฏुเคค เค‰เคค्เคชाเคฆเคจ เคจिเค—เคฎ เคฒिเคฎिเคŸेเคก (PVUNL) เคจे เค…เคชเคจे เคธ्เคตเคช्เคจ เค•ो เคนเค•ीเค•เคค เคฎें เคฌเคฆเคฒเคคे เคนुเค 3x800 เคฎेเค—ाเคตॉเคŸ เคธुเคชเคฐ เคฅเคฐ्เคฎเคฒ เคชाเคตเคฐ เคช्เคฐोเคœेเค•्เคŸ เค•े เคชเคนเคฒे 800 เคฎेเค—ाเคตॉเคŸ เคฏूเคจिเคŸ เค•ो เคธเคซเคฒเคคाเคชूเคฐ्เคตเค• เคธिंเค•्เคฐोเคจाเค‡เคœ़ เค•เคฐ เคฆिเคฏा। 


เค‡เคธ เคช्เคฐเค•ाเคฐ PVUNL เคจे เค˜ोเคทเคฃा เค•ी เคนै เค•ि เคซेเคœ-1 เค•े 3x800 เคฎेเค—ाเคตॉเคŸ เคฏूเคจिเคŸ्เคธ เค•ो เคฆिเคธंเคฌเคฐ 2025 เคคเค• เคชूเคฐी เคคเคฐเคน เคธे เค•เคฎिเคถเคจ เค•เคฐ เคฆिเคฏा เคœाเคเค—ा, เคœिเคธเคธे เคฒเค—เคญเค— 2400 เคฎेเค—ाเคตॉเคŸ เคฌिเคœเคฒी เค‰เคค्เคชाเคฆเคจ เคถुเคฐू เคนो เคœाเคเค—ा। เค‡เคธเค•े เคฌाเคฆ เคซेเคœ-2 (2x800 เคฎेเค—ाเคตॉเคŸ) เค•ी เคฏोเคœเคจा เคนै เคœो เคซिเคฒเคนाเคฒ เคฏोเคœเคจा เคšเคฐเคฃ เคฎें เคนै เค”เคฐ เค‰เคธเค•े เคฒिเค เคธ्เคคเคฐ เคชเคฐ เค…เคจुเคฎเคคि เค”เคฐ เคช्เคฐเค—เคคि เค…เคญी เคฌाเค•ी เคนै।




On the morning of March 11, 2025, as the first rays of the sun spread over Patratu, another “ray of energy” was born. Patratu Vidyut Utpadan Nigam Limited (PVUNL) turned its dream into reality by successfully synchronizing the first 800 MW unit of its 3x800 MW Super Thermal Power Project.


With this achievement, PVUNL announced that all three units under Phase-1 (3x800 MW) will be fully commissioned by December 2025, enabling power generation of about 2400 MW. Following this, Phase-2 (2x800 MW) is planned, which is currently at the proposal stage, awaiting necessary approvals and progress.


๐Ÿ‘จ‍๐Ÿซ Sudesh Kumar

✉️ help@patratu.com