Accord Energy Corporation India Pvt. Ltd.

Transcription

1 Accord Energy Corporation India Pvt. Ltd. PRE-FEASIBILITY REPORT ON ENVIRONMENTAL ASPECTS OF PROPOSED INCREASE IN CAPACITY 2 x 150 MW to 2 x 180 MW OF EXISTING ENVIRONMENTAL CLEARANCE ( J-13012/107/ 2009-IA-II (T) dated 18/05/2011 ) at Sirupuzhalpettai Village, Gummidipoondi Taluk, Thiruvallur District, Tamil Nadu. October 2014

2 CONTENTS 1.0 EXECUTIVE SUMMARY INTRODUCTION THE PROPOSED PROJECT PROJECT LOCATION LAND USE RAW MATERIALS CONSUMPTION FUEL TRANSPORTATION PROCESS DESCRIPTION RAW WATER REQUIREMENT ENERGY CONSUMPTION WORK FORCE WASTE & WASTE MANAGEMENT Air Pollution Waste Water Management Solid Waste Management SITE ANALYSIS, PLANNING & REHABILITATION AND RESETTLEMENT PROJECT SCHEDULE & COST ESTIMATION CONCLUSION Fig 1.0 Fig 2.0 Fig 3.0 Project Location. 4 Plant Layout...5 Route Map i

3 1.0 EXECUTIVE SUMMARY It is proposed to increase the capacity of 2 x 150 MW to 2 x 180 MW. The 2 x 150 MW coal based thermal power plant was issued Environmental Clearance vide letter # J-13012/107/ 2009-IA-II (T) dated 18/05/2011. Present Status The entire Land Acquisition is complete, and is awaiting issue of Consent to Establish from TNPCB, which is in the final stages of issue. Financial closure is also in the final stages, and is expected by December Construction will commence after obtaining Consent to Establish from TNPCB. Project Location The location of the project is at Sirupuzhalpettai Village, Gummidipoondi Taluk, Thiruvallur District, Tamil Nadu. The plant site is devoid of any forest land. There are no areas of ecological sensitivity or notified bio diversity area or wildlife sanctuary etc. within 10 kms radius of the plant site. Pre-feasibility Report 1 Accord Energy - Gummidipoondi

4 Products & Capacity Increase in capacity of Thermal Power generation using imported coal from 2 x 150 MW to 2 x 180 MW. The 2 x 150 MW Thermal Power Plant was already issued Environmental Clearance. Raw Material Requirement The raw material used will be 100% Imported Coal. Raw Water Requirement & Source Main Condensate is based on Air Condensate Cooling. The daily make water required for 2 x 180 MW will be 150 KLD, whereas the daily water make-up as per Environmental Clearance issued for 2 x 150 MW was 802 KLD. This conservation of water is possible due to use of fin fan coolers for Turbine Generation Cooling. About 150 KLD will be the daily make-up after recycling 192 KLD of treated waste water in the 2 x 180 MW unit. Water will be sourced from Ground / Harvested Rain Water. Solid Waste Generation & Method of Disposal The total Ash generation will increase by TPD by augmentation to 2 x 180 MW compared to 2 x 150 MW. Fly ash will be completely disposed & Bottom ash will be stored in ash dyke. Man Power There will be no increase in manpower owing to augmentation of capacity from 2 x 150 MW to 2 x 180 MW ie it will be 50 Employees as was originally proposed. Project Cost Project cost will remain the same at Rs.1950 Crores as was originally proposed. Pre-feasibility Report 2 Accord Energy - Gummidipoondi

5 2.0 INTRODUCTION India's Electricity Act 2003 introduced structural changes to the power industry, permitting private investment for the first time since This allowed power producers to sell power directly to industrial consumers under the Group Captive model. Key features of the Group Captive and Merchant model are Group Captive Bilateral arrangements with consumers / traders / utilities Offering reliable, consistent power supply, even during peak periods Attractive prices relative to alternative tariffs Merchant Sales with traders directly Flexibility and risks of spot pricing Returns dependent on available pricing Limited to one day future trading 3.0 THE PROPOSED PROJECT The present proposal is for increase in capacity to 2 x 180 MW of the originally proposed 2 x 150 MW, the environmental clearance for which was obtained vide letter # J-13012/107/ 2009-IA-II (T) dated 18/05/ PROJECT LOCATION The proposed augmentation from 2 x 150 MW to 2 x 180 MW is located at Sirupuzhalpettai Village, Gummidipoondi Taluk, Thiruvallur District, Tamil Nadu, wherein the Environmental Clearance for 2 x 150 MW has already been obtained. The project location is as shown in Fig.1.0 and the Plant Layout of the project is as shown in Fig 2.0. Pre-feasibility Report 3 Accord Energy - Gummidipoondi

6 Fig 1.0 Location Map Pre-feasibility Report 4 Accord Energy - Gummidipoondi

7 Fig 2.0 Plant Layout Pre-feasibility Report 5 Accord Energy - Gummidipoondi

8 5.0 LAND USE The Augmentation of Capacity ie from 2 x 150 MW to 2 x 180 MW is within the same site, wherein the Environmental Clearance for 2 x 150 MW has already been obtained. Hence there is no change in land use. The land however was a dry rainfed, and moreover was vacant, barren, with no activity. There were also no Rehabilitation or Resettlement Issues. 6.0 RAW MATERIALS CONSUMPTION The Marginal increase in coal consumption will be as follows. for 2 x 150 MW for 2 x 180MW Additional Coal requirement (ie from 300 MW to 360 MW) 3600 TPD 3815 TPD* 215 TPD *Heat Rate : 2341 Kcal/KWh. Characteristics of Coal S. No. Particulars Imported Coal 1 Gross Calorific Value 5300 k cal/kg 2 Moisture 9 % 3 Ash 9 % 4 Fixed Carbon 19 % 5 Sulphur 1.2 % 6 Volatile Matter 35.8 % 7.0 FUEL TRANSPORTATION The existing road, viz. NH-5, SH-52 will be used for coal transportation. Imported Coal will be shipped by sea and unloaded at Ennore Port and then will be transported by road by 40T capacity container. The route map from Ennore Port to Plant Site is as shown in Fig 3.0. As per latest amendment of MoEF Minutes of Meeting of the 34 th meeting of re-constituted Expert Appraisal Committee (Thermal) held on 10 th & 11 th October, 2011, Coal will be transported by road only for a period upto 4 years of date of Commissioning, after which the rail transportation will be implemented. Pre-feasibility Report 6 Accord Energy - Gummidipoondi

9 Fig 3.0 Route Map Pre-feasibility Report 7 Accord Energy - Gummidipoondi

10 8.0 PROCESS DESCRIPTION Upgradation of capacity of the power plant from 2 X 150MW (MCR) to 2 X 180MW (MCR) Accord Energy Corporation India Pvt. Ltd at Sirupulalpettai Village, Gummidipoondi Taluk, Thiruvallur District, Tamil Nadu was originally finalised as 2 x 150MW Maximum Continuous Rating (MCR) with a capacity to produce 2 x 180MW at Valve Wide Open condition (VWO). Accordingly the equipments were sized as given below: Sl.No. Description Parameters 1 Boiler and its auxiliaries 535tph with a reheater capacity of 477.4tph. 2 Steam turbine generator 150MW (MCR);180MW (VWO) Heat rate: 2125 Kcal/kWh (MCR) 2135 Kcal/kWh (VWO) Generator sized for 150MW. 3 Air cooled condenser 370tph of steam flow 4 Generator transformer 176MVA 5 MS, CRH and HRH piping Designed to carry steam equivalent to 150MW 6 Boiler feed pumps Sized for a steam generation of 580tph. During the technical meetings with the turbine suppliers,bhel/skoda/siemens, it was understood that the turbine could be modified to generate 2 x 180MW on a continuous basis with a heat rate of 2015Kcal/kwh, by redesigning the turbine and upgrading the generator equivalent to 180MW. This has the following advantages: a. Keeping the majority of the systems same, there is a possibility of generating 30MW more in each. b. Much lower heat rate to generate higher capacity with less coal consumption c. Time required is the same d. Better utilisation of the investment made on the transmission line e. The clearances already obtained, will remain the same except an amendment for augmentation capacity at 2 x 180 MW Hence, it was decided to go ahead with this proposal. Pre-feasibility Report 8 Accord Energy - Gummidipoondi

11 The increase in capacity necessitated the following changes: Sl.No. Description Parameters for 2 x 150MW MCR 1 Boiler and its 535tph with a reheater auxiliaries capacity of 477.4tph each 2 Steam turbine generator 2 x 150MW (MCR);180MW (VWO) Heat rate: 2125 Kcal/kWh (MCR) 2135Kcal/kWh (VWO) Generator sized for 2 x 150MW. Revised parameters for 2 x 180MW MCR 580 tph with a reheater capacity of 510tph each 2 x 180MW (MCR): Heat rate: 2015Kcal/kwh Generator sized for 2 x180mw 3 Air cooled condenser 370tph of steam flow each 400 tph of steam flow each 4 Generator transformer 176MVA each 220MVA each 5 MS, CRH and HRH piping Designed to carry steam equivalent to 2 x 150MW 6 Boiler feed pumps Sized for a steam generation of 535 tph each Designed to carry steam equivalent to 2 x 180MW Sized for a steam generation of 580 tph each 9.0 RAW WATER REQUIREMENT Source of water will be Harvested Rain Water / Ground Water. Sufficient draft is available, the total water requirement for 2 x 180 MW on daily makeup will be 150 KLD. Clearance from Central Ground Water Authority has already been obtained for drawl of 1300 KLD of Ground Water. Water Consumption for 2x150 MW Water Consumption for 2x180 MW (As per Environmental Clearance) (Daily Make-up) 802 KLD 150 KLD Main Condensate is based on Air Condensate Cooling. There will be reduction of water consumption by 652 KLD for 2 x 180 MW compared to 2 x 150 MW due to use of fin fan coolers for Turbine Generator. About 150 KLD will be the daily make-up after recycling 192 KLD of treated waste water. Pre-feasibility Report 9 Accord Energy - Gummidipoondi

12 Water Balance Diagram All Values are in KLD From Bore well / Rain Water Harvesting Reservoir 285 Boiler Feed Blowdown Coal Dust Suppression/ Ash Quenching Neutralization Pit Reject Tank 340 ETP/RO Total Raw D M Plant Domestic 1.6 Septic Tank 1.6 Dispersion Trench Pre-feasibility Report 10 Accord Energy - Gummidipoondi

13 10.0 ENERGY CONSUMPTION It is a proposed augmentation of power generation facility and hence the auxiliary power requirement will be met internally WORK FORCE There is no increase in work force required for increase in capacity from 2 x 150 MW to 2 x 180 MW, and will remain the same as was originally proposed for 2 x 150 MW WASTE & WASTE MANAGEMENT 12.1 Air Pollution The Stack height will remain the same at 220 Metres, the calculation of which is as follows. The daily consumption of coal for 2 x 180 MW is around 3815 Tonnes imported coal The rate of SO2 emission due to usage of coal is calculated as given below Sulphur content = 1.2 % S = (3815 x 1.2 /100) = T/D SO2 = x 2 T/D = T/D =3815 kg/hr SO2 emission = 3815 kg/hr = g/s Stack height calculation: H = 14 Q 0.3 Where, H = height of the Stack Q = SO2 Concentration in Kg/hr. Hence H = 14 x (3815) 0.3 = 14 x = m Pre-feasibility Report 11 Accord Energy - Gummidipoondi

14 The stack height proposed to be constructed is however 220 metres, after considering stack lossess, available draft etc at chimney bottom with reference to minimum gas velocity of 21 m/sec at the top of chimney to design the height of the chimney. Stack Emission Characteristics 2 x 150 MW 2 x 180 MW Single Chimney Twin Flue Single Chimney Twin Flue Material of Construction RCC RCC Stack attached to Boiler 1 Boiler 2 Boiler 1 Boiler 2 Stack height (m) Flue diameter (m) Volume Flow Rate (m 3 /s) Velocity of flue gas (m/s) Temperature of flue gas ( o C) Flue gas specific volume ( kg / m³) Fuel Consumption (Kg/s) Sulphur content (% w/w) Emission rate NOx (g/s) Emission rate SO2 (g/s) Emission rate SPM (g/s) The following environmental protection or pollution control systems have already been considered for mitigation of impacts on Air Environment. 220 m tall stack to emit flue gas. Space provision for retrofitting FGD (Flue Gas Desulfurisation) systems. High efficiency ESPs to reduce SPM level in the exhaust gas to <50mg/Nm³. Dust suppression and extraction system at Handling Plant area to Control Fugitive Emission. Green belt development and afforestation in the plant and ash disposal areas. Pre-feasibility Report 12 Accord Energy - Gummidipoondi

15 A minimum water depth will be maintained in the ash pond to prevent fugitive dust emission. Use of bagfilters at all transfer points. Use of limestone to limit SO2 emission. High efficiency Electrostatic Precipitator of 99.9% are provided for limiting SPM concentration in the flue gas to less than 50 mg/nm³. The tall stack of 220 m height based on maximum SO2 concentration in the flue gas is provided for natural dispersion at high elevation so that ground level concentration are within acceptable limits. The emission of NOX, is reduced by burning fuel at a lower temperature and shortening the throughput time of the fuel. NOX is also controlled by operating at low excess air. Fugitive Emissions To control fugitive emissions from process units in the plant, the following measures will be carried out. Tarring of roads inside the factory. Preventive maintenance of valves and other equipments. Green belt on all sides within the project boundary, and community plantation around the unit with help of local area development authorities have already been done. Ambient air quality and stack/fugitive emissions monitored regularly. In-plant training provided to the plant personnel on operation and maintenance of dust collectors, techniques of dust emission measurements, particle size analysis etc. Effective operation and maintenance of pollution control system is ensured to contain the emissions/keep them within the CPCB limits Pre-feasibility Report 13 Accord Energy - Gummidipoondi

16 A good house keeping consisting of simple, obvious task of cleaning up spills, removing accumulations around processing equipment and in general keeping things neat and clean form a part of normal operation and maintenance procedure Measures for arresting fugitive dust emissions along with the envisaged pollution control equipments are adequate and will help to have a healthy and cleaner environment inside the plant thereby improve the productivity and the efficiency of the workers as well as that of plant machinery Waste Water Management Waste Water Generation in KLD For 2 x 150 MW For 2 x 180 MW Boiler Blow Down * D.M. Plant Regeneration Waste Domestic Sewage * Reduction in blowdown due to reduced water consumption by use of Fin Fan Coolers for Turbine Generator. The entire waste water is reused and recycled thus ensuring zero discharge Solid Waste Management The Ash generation will increase by TPD upon augmentation of capacity from 2 x 150 MW to 2 x 180 MW. Solid Waste For 2 x 150 MW (TPD) For 2 x 180 MW (TPD) Additional Quantity of Solid Waste Generation (TPD) Fly Ash Bottom Ash Total Pre-feasibility Report 14 Accord Energy - Gummidipoondi

17 13.0 SITE ANALYSIS, PLANNING & REHABILITATION AND RESETTLEMENT The augmentation of the capacity from 2 x 150 MW to 2 x 180 MW is within the same site, wherein the Environmental Clearance for 2 x 150 MW has already been obtained. There is no Rehabilitation and Resettlement issue PROJECT SCHEDULE & COST ESTIMATION The construction of 2 x 180 MW Power plant will be started upon obtaining Amendment in Environmental Clearance from MoEF and Consent to Establish from TNPCB. The scheduled to be commissioned in 24 months from the date of receipt of Consent to Establish from TNPCB. The project cost will be Rs.1950 Crores as was originally envisaged for 2 x 150 MW CONCLUSION The proposed augmentation will result in better utilization without any modification to the majority of existing systems. The impact will be marginal, however, adequate measures already proposed to mitigate negative impacts, and thus aid positive impacts. Pre-feasibility Report 15 Accord Energy - Gummidipoondi