Jakarta, CNBC Indonesia \u2014 PT Pupuk Kalimantan Timur (Pupuk Kaltim)\nhas successfully used fly ash and bottom ash (FABA) from its coal-fired\nboiler operations as a more efficient alternative raw material, adding\nvalue to the production process. The innovation has two benefits:\nreducing FABA waste and saving on clay used as a filler and binder in\nNPK Fusion production.<\/p>\n
As well as serving as a filler, FABA acts as an anti-caking agent,\nhelping to maintain product quality and supporting the binding of\nnutrients in each fertiliser granule.<\/p>\n
Pupuk Kaltim President Director Rafli Yandra said using FABA had\nimproved raw-material efficiency and helped manage waste by making\nbetter use of material that had not previously been fully utilised. The\ninitiative is one of the company\u2019s efforts to reduce waste-management\ncosts and improve production efficiency. Reusing FABA can also create\nadded value by putting residual material classified as hazardous waste\nfrom combustion to use.<\/p>\n
\u201cThrough this innovation, Pupuk Kaltim continues to strengthen its\ncommitment to sustainable industrial practices. The use of FABA is part\nof the company\u2019s efforts to optimise resources, support production\nefficiency and maintain the sustainability of fertiliser supplies to\nstrengthen national food security,\u201d Rafli said, as quoted on Monday (14\nSeptember 2026).<\/p>\n
In this initiative, FABA\u2014primarily fly ash\u2014is moved from temporary\nstorage to the NPK Fusion production facility at Plant 7. The fly ash is\nthen mixed with clay using a wheel loader. The mixture is fed into a\nhopper and processed with NPK raw materials including urea, rock\nphosphate, DAP, KCl and brucite.<\/p>\n
The mixture is then fed into a rotary drum granulator, where steam\nand water help form fertiliser granules. After granulation, the product\nis dried at around 55\u201365\u00b0C, then cooled and screened. Undersized and\noversized material is recycled before the product is coated, weighed and\nbagged.<\/p>\n
A total of 66,180 tonnes of FABA has been reused. The programme is\nnow targeting a utilisation capacity of 15,000 tonnes a year, or 75,000\ntonnes over five years.<\/p>\n
Pupuk Kaltim previously processed FABA into concrete blocks, paving\nblocks and soil-stabilisation materials. In 2021, the company obtained a\npermit to use FABA as a substitute material in construction and soil\nstabilisation.<\/p>\n
For soil stabilisation, a mixture of FABA and cement is used to\nimprove the load-bearing capacity of soil, particularly soft ground. The\ninnovation significantly increased bearing capacity, as the cementing\nreaction produced harder granules better able to withstand loads.<\/p>\n
In 2022, the company\u2019s coal-fired boiler units, with a capacity of 2\n\u00d7 220 metric tonnes an hour and electricity output of 96.6 MW, generated\naround 35,000 tonnes of FABA. Of this, approximately 34,000 tonnes was\nprocessed into alternative construction and soil-stabilisation\nmaterials.<\/p>\n
The use of FABA, particularly bottom ash, can also support\nbiodiversity restoration, including as a manufactured material for\nartificial coral reefs. These structures can be useful in coral-reef\nrehabilitation.<\/p>\n
Pupuk Kaltim\u2019s use of FABA is part of its Reusing Our Ash to Improve\nthe Sea Ecosystem (RAISE) programme. Before RAISE was introduced,\nselecting and growing coral seedlings attached to artificial structures\ntook around six months.<\/p>\n
After RAISE was implemented, observations showed that coral\nattachment and seedling growth could take around four months. The\nobservations were subsequently corroborated through monitoring by third\nparty Reef Check Indonesia.<\/p>\n
\u201cThe innovation in processing FABA waste is a pioneer in turning coal\nwaste into a useful commodity under circular-economy principles. It is\nhoped that this will help create a better environment for the company\nand the wider community,\u201d Rafli said.<\/p>\n
Thanks to the innovation, Pupuk Kaltim was nominated for an ASEAN GRC\nAward at the ASEAN Risk Awards 2025. The achievement reflects the\ncompany\u2019s commitment to governance, risk and compliance (GRC), as well\nas sustainable social and environmental responsibility as an integral\npart of its corporate identity and culture.<\/p>", "url": "https:\/\/jawawa.id\/newsitem\/pupuk-kaltim-turns-coal-waste-into-added-value-1792565462", "image": "" }, "sponsor": "Okusi Associates", "sponsor_url": "https:\/\/okusiassociates.com" }