India’s fly ash utilisation reaches 96.34% in 2024-25

India’s coal-fired power stations utilised 307 million tonnes of fly ash in 2024-25, taking the national utilisation rate to 96.34%, up from under 10% in 1996-97. The data comes from the Central Electricity Authority (CEA) report covering 189 grid-connected thermal power plants with a combined capacity of 214 GW.

The aggregate figure indicates near-full utilisation. However, performance varies sharply across ownership segments and plant types.

Sector-wise gaps and state-level underperformance

Central sector plants recorded an average utilisation of 99.26%. Private sector plants exceeded 100%, reflecting the use of legacy ash alongside current-year generation. State sector plants achieved 88.3%.

Within the state segment, pit-head plants reported the lowest utilisation at 30%. Uttar Pradesh, with 21 plants generating around 37 million tonnes of ash annually, recorded 32.8% utilisation in its state sector. This is a key factor behind the gap between the national average and full utilisation.

Utilisation patterns also differ by plant location. Pit-head plants, located near coal mines, direct roughly two-thirds of their ash towards road construction and depend on bulk disposal in nearby areas. Non-pit-head plants rely more on cement manufacturers and brick producers, where transport costs are typically borne by end users, supporting more stable and higher-value utilisation.

Demand trends and regulatory context

Road and highway construction was the largest utilisation segment, accounting for 34% of total volumes, followed by cement at 28%. Mine void filling and reclamation of low-lying areas together accounted for 21%.

Brick and block manufacturing declined, from 490 lakh metric tonnes in 2023-24 to 405 lakh metric tonnes in 2024-25, indicating a slowdown in that segment.

Utilisation rates above 100% reflect the use of legacy ash in addition to current-year generation. Under the Ministry of Environment, Forest and Climate Change framework, thermal power plants are required to clear legacy ash by 2032, with annual targets starting at 20% of current generation and rising to 50% from the third year onward.

The report identifies state sector plants, particularly in Uttar Pradesh, Maharashtra, and Telangana, as the key areas requiring improvement, citing logistical constraints, limited local industrial demand, and coordination challenges as the primary barriers.

The featured photograph is for representation only.