PRE-FEASIBILITY REPORT. M/s. NUVOCO VISTAS CORPORATION LTD. ( Formerly Lafarge India Limited) At-Jojobera, Jamshedpur, Dist East Singhbhum Jharkhand

Transcription

1 PRE-FEASIBILITY REPORT On Proposed Installation of 1 X 27 MW Coal Based Captive Power Plant in the Existing 4.6 MTPA Cement Grinding Unit at Jojobera, Dist-East Singhbhum, Jharkhand OF M/s. NUVOCO VISTAS CORPORATION LTD. ( Formerly Lafarge India Limited) At-Jojobera, Jamshedpur, Dist East Singhbhum Jharkhand Prepared by:- APRIL 2017 VISIONTEK CONSULTANCY SERVICES PVT. LTD (An Enviro Engineering Consulting Cell) Plot No. M 22 & M23, Chandaka Industrial Area, Patia, Bhubaneswar-24, Phone No. : visiontekin@yahoo.co.in, visiontekin@gmail.com Visit us at -

2 TABLE OF CONTENT Chapter No DESCRIPTION PAGE NO Chapter-1.0 Executive Summary Introduction Identification Of Project And Project Proponent Need For The Project & Its Importance To The Country Or 2 Region 2.2 Employment Generation Project Description Location Site Selection Technology Selection Raw Material Requirement Water & Power Requirement Waste Generation & Management Site Analysis Connectivity Present Land Use Topography Existing Infrastructure Climatic Data From Secondary Sources Planning Brief Planning Concept Land Use Planning Proposed Infrastructure Green Belt Others Rehabilitation And Ressettlement (R & R) Plan Project Schedule And Cost Estimates Project Schedule Project Cost Analysis Of Proposal 8 Chapter-2.0 Introduction 2.1 Identification Of Project And Project Proponent Description Of Nature Of The Project Need Of The Project And Its Importance To The Country And/Or 10 Region 2.4 Employment Generation 13 Visiontek Consultancy Services Private Limited

3 Chapter-3.0 Project Description 3.1 Type Of Project Location Plant Location Land Requirement Plant Layout Site Selection Technology Selection Selection Recommendation Process Description Mechanical Equipment And System Steam Turbine & Auxiliaries Flue Gas De Sulfurization System (Fgd) Utilities & Services Electrical Equipment And System Power Evacuation And Interconnection System Heat & Mass Balance Raw Material Raw Material Analysis Water & Power Requirewment Waste Geneartion And Its Management Plan Waste Water Solid Waste Noise Levels Schematic Representations Of The Feasibility Drawing Which Give Information Of Eia Purpose. 46 Chapter-4.0 Site Analysis 4.1 General Connectivity Present Land Use Topography Existing Infrastructure Climate Data From Secondary Sources 48 Chapter-5.0 Planning Brief 5.1 Planning Concept Technical Concept Power To Be Produced 49 Visiontek Consultancy Services Private Limited

4 5.1.3 Human Resources Organization Structure Project Engineering Project Conceptualization Project Planning Budgeting Procurement Design And Engineering Project Execution Coordination With Site Management Overall Time And Cost Control Project Site Management Commercial And Financial Services Organizational Structure For Operational Phase Training 52 Chapter-6.0 Proposed Infrastructure 6.1 Industrial Area 53 Chapter-7.0 Rehabilitation And Resettlement (R & R) Plan 55 Chaptre-8.0 Project Schedule & Cost Estimates 8.1 Project Schedule Project Cost Environment Cost 57 Chapter-9.0 Analysis Of Proposal 58 LIST OF TABLE SR. NO DESCRIPTION PAGE NO 1.1 Raw Materials Requirement & Source Background of the Project Project Profile Peak Demand and Peak Met in India Manpower Requirement-Existing Manpower Requirement-Proposed Expansion Land Use Breakup Proposed Configuration Steam Generator Design Parameter 21 Visiontek Consultancy Services Private Limited

5 3.4 Basic Technical Parameters Raw Material Requirement & Source Chemical Analysis Water Requirement Air Quality Environment & Management (Air Environment- Mitigation 44 Measures) Source of air pollution and control measures 4.1 Environmental Setting of the Area Project Cost Expenditure on Pollution Control Measures 57 LIST OF FIGURES SR. NO DESCRIPTION PAGE NO 3.1 Index Map Topo Map (10 Km Radius) (a) Plant Layout-Exisitng (b) Plant Layout- Proposed Expansion Air Cooled Condenser Process Flow Diagram-FGD Process Flow Diagram Heat & Mass Balance 41 Visiontek Consultancy Services Private Limited

6 CHAPTER 01 EXECUTIVE SUMMARY 1 Name of the project Proposed 1 X 27 MW Coal based Captive Power Plant within Existing 4.6 MTPA Cement Grinding Unit at Jojobera, Dist- East Singhbhum. Jharkhand 2 S.No in the schedule Activity 1(d) 3 Registered Office 4 Name of the promoters 5 Area of plant 6 Topo Sheet No 73 J/1 7 Latitude Longitude M/s Nuvoco Vistas Corporation Limited (Formerly Lafarge India Limited) Jojobera Cement Plant P.O. Rahargora, Jamshedpur M/s Nuvoco Vistas Corporation Limited (Formerly Lafarge India Limited) 3.00 Ha (7.41 Acre) within existing premises of.123 Acres (49.77 ha.) Latitude: N Longitude: E 8 Proposed capacity 1x27MW Captive Thermal Power Plant 9 Cost of Project Rs Cr. 10 Man power Requirement 11 Water Requirement Proposed Manpower for CPP 43 Existing Manpower-1347 Total Manpower after proposed expansion : m 3 /day for CPP Source- JUSCO 12 Power Requirement 2000 KW-Startup power Nearest railway station/airport along with distance in kms Nearest Town, City, District Head quarters along with distance in kms. Village penchants, Parishad, Municipal corporation, local telephone nos to be given) body (complete postal addresses with telephone no.s to be given) Tatanagar Railway Station- 4.0 Km WNW Sonari Airport, Jamshedpur 12.5 Km NW Ranchi Airport- 112 Km NW Jamshedpur (approx 6.5 km in NW direction from the plant site) Jamshedpur Notified Area Committee(JNAC) Jamshedpur Visiontek Consultancy Services Private Limited Page 1

7 1.0 INTRODUCTION M/s Nuvoco Vistas Corporation Limited (Formerly M/s Lafarge India Limited) proposes for installing 1 X 27 MW Coal based Captive Power Plant in its existing 4.6 MTPA Cement Grinding Unit within existing plant premises of 123 Acres(49.77 Ha.) and CPP over an area of 3.0 Ha. at Village-Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand. 2.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT M/s Nuvoco Vistas Corporation Limited (Formerly M/s Lafarge India Limited) hereafter refer as NVCL entered the Indian market in Lafarge has 3 integrated units, 2 grinding units & 1 blending units in India: two plants in the state of Chattisgarh (Sonadih and Arasmeta) and grinding units in Jharkhand (Jojobera & Mejia) and cement plant in Chittorgarh. NVCL have cement grinding capacity of 4.6 MTPA at Jojobera & are planning to increase production capacity to 6.6 MTPA. The power demand of the plant at present is met from JUSCO. In view of the high power tariff & plan of JUSCO to increase same in future NVCL is contemplating to have Self Power generation to meet bulk power requirement of the cement grinding plant. 2.1 Need for the project & its importance to the country or Region Indian cement industry is large, growing and with consumption of 185kg/capita/yr in 2011 (compared to global average of ~300 kg/capita/yr) the country itself has the capacity to demand significantly more cement as it develops. In India, Jharkhand has around 40 per cent of the country s mineral wealth such as coal, limestone etc. In addition to the large raw material deposits, the strategic location of Jharkhand, proximity to large markets in southern and central India (providing an opportunity to cater to these markets) and 1805 kms of national highway passing through the State, have made Jharkhand an ideal destination for establishing cement units. Now with the government of India giving push to various infrastructure projects, housing facilities and road networks, the cement industry in India is currently growing at an enviable pace and further growth in the Indian cement industry is expected in the coming years. Therefore, there is an urgent need to increase the production capacity in the country. Visiontek Consultancy Services Private Limited Page 2

8 Hence, the proposal for expansion of Grinding Unit by NVCL will cater the increasing demand of cement in the country and region of Jharkhand. NVCL have cement grinding capacity of 4.6 MTPA at Jojobera & are planning to increase production capacity to 6.6 MTPA. The power demand of the plant at present is met from JUSCO. In view of the high power tariff & plan of JUSCO to increase same in future NVCL is contemplating to have Self Power generation to meet bulk power requirement of the cement grinding plant by installing 1 X 27 MW Coal based CPP. 2.2 Employment Generation Direct and indirect employment will be generated to the local population, the total man power requirement during construction phase for the project will be , out of which 8 are the permanent senior level persons and rest will be the casual workers for construction, erection gardening, packing, cleaning etc. Similarly, during operation expected additional employment to the existing plant will be 43 and total employment after expansion will be PROJECT DESCRIPTION The proposed installation of 1 X 27 MW Coal Based Captive Power Plant based on Conventional Steam Cycle Operating in Rankine Cycle, consisting of 120 TPH CFBC Boiler and 1 no. Turbine 535 ⁰C at 105 Kg/Cm² pressure. 3.1 Location Proposed expansion is within the existing cement grinding unit plant premises located at Village-Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand. Total area required is 3.0 Ha. available within 123 Acres. existing land. The proposed expansion site falls under the Survey of India Toposheet No. 73 J/1 and the buffer zone falls under the Survey of India Toposheet 73 J/2, 73 J/5 and 73 J/6. The Latitude and Longitude of the proposed site is N and E respectively. Visiontek Consultancy Services Private Limited Page 3

9 3.2 Site Selection The total project land area required is 3.0 Ha. available within the existing plant premises of total 123 Acres. The site selection of Power Plant has been based on the following considerations. Plant availability. Cooling Water availability. Compatibility of grid to withstand sudden outage of unit. Operating experience of the set size. Thermodynamic cycle efficiency and specific input consumption viz. fuel, water etc.. Specific investment requirement & cost of generation. 3.3 Technology Selection The proposed expansion is installation of 1 X 27 MW Coal Based Captive Power Plant based on Conventional Steam Cycle Operating in Rankine Cycle, consisting of 120 TPH CFBC Boiler and 1 no. Turbine 535 ⁰C at 105 Kg/Cm² pressure. 3.4 Raw Material Requirement The annual coal requirement considering E/F grade Indian coal for 1 X 27 MW unit is estimated to be about TPD will be consumption) as the proposed coal for the plant would be having an average calorific value of 3200 kcal/kg. Coal would be made available from the nearby mines of Open market purchase. Table.1.1 Raw Material Requirement & Source S. No. Raw Materials Source Coal Based Supercritical Thermal Power Plant Transportation Mode Requirement MTPA 1 Coal Open Market purchase Rail / Road MTPA 2 LDO / HSD IOCL/HPCL/BPCL Local depots Road Approx 80.KLPY Visiontek Consultancy Services Private Limited Page 4

10 3.5 Water & Power Requirement The water requirement for the proposed CPP plant works out to be approximately 360m3/ day. In addition, water requirement for Fuel gas Desulfurization is 216m 3 /day. The total water requirement shall be 576m 3 /day. Agreement made with JUSCO is for 0.5 MGD The water requirement for free- fighting and service application has not been considered because their intermittent requirement and can be met from the cement plant. Start up power of total 2000 KW will be supplied by JUSCO. 3.6 Waste Generation and Management The principal solid wastes would be fly-ash and bottom ash apart from neutralization tank sludge, which would be dried and stored within the Plant. The fly ash and bottom ash generation would be in the range of 43-45% of coal consumption. It will be completely reused in the cement manufacturing process. 4.0 SITE ANALYSIS 4.1 Connectivity The site is well connected to NH - 33 (approx. 8.0 km in NE direction from the plant site) and SH - 6 (approx. 3.5 km in WNW direction from the plant site). Nearest city is Jamshedpur (approx. 6.5 km in NW direction from the plant site). Nearest Airport Ranchi is approx. 112 km in NW direction from the plant site. The site is well connected with communication facilities like telephone, fax, wireless and as such, no constraints are envisaged in this aspect as the tehsil and district headquarters are near to the site. 4.2 Present Land Use Existing plant area is 123 Acres(49.77 Ha.) and the proposed expansion will be done within the existing premises; hence, no additional land is required for the proposed expansion project. 4.3 Topography The topography of the area is not flat and have minor undulations; consisting of series of hummocks having an average elevation of 175 metres. A detailed analysis of slope in the area has been carried out. It has been observed that topography of the area is undulating with a Visiontek Consultancy Services Private Limited Page 5

11 hummock running in the NE-SW direction. The general drainage is parallel to sub parallel. The drainage in surrounding area is dendritic in nature and the drainage density ranges from moderate to poor thus indicating low run-off. 4.4 Existing Infrastructure Total existing plant area is 123 Acres(49.77 Ha.) and the proposed expansion will be done within the existing plant premises area. All basic infrastructure viz. canteen, Administrative building, Store, Sheds are available within the existing plant premises. 4.5 Climatic data from secondary sources The district receives an annual rainfall of 1500 mm. and most of it occurs during the rainy season. Mean annual temperature is above 26 C. The temperature ranges from 16 C in winter month to 44 C in summer months. The Climate of the district is tropical. Average rain fall is 800 mm per year. Average relative humidity being 70%. 5.0 PLANNING BRIEF 5.1 Planning Concept Technical Concept This technical concept indicates the plant capacity, size and type of main machinery, storages, design of systems, plant layout, flow sheets etc. It covers process, mechanical, electrical, instrumentation and civil engineering aspects. The concept has considered quality, pollution control, operation, maintenance and utility services. Process Control, Instrumentation and Automation Integrated & Distributed Microprocessor based, Control & Instrumentation system has been considered for effective control of various process variables. Human Resources Human Resource is the most valuable asset in any industry. The accelerating pace of technology advancement and fierce competition in the market has led to the increasing importance of human resources. Continuous skill updating of the existing human resources and generating new talents in consonance with the needs of the industry are vital for the progress of the industry. Visiontek Consultancy Services Private Limited Page 6

12 5.2 Land Use Planning Total existing plant area is 123 Acres (49.77 Ha.)and the proposed expansion will be done within the existing plant premises area. 6.0 PROPOSED INFRASTRUCTURE The setting up of the thermal power plant, their auxiliary equipments, coal storage areas, electrical power receiving and evacuation substation, administrative buildings is envisaged. 6.1 Green Belt Ha. (Approx. 33 % of total plant area) has already been developed under greenbelt / plantation. 6.2 Others 1. A garland drain around the plant is envisaged to collect surface run-off during rainy season. 2. Drinking water facilities will be provided for employees as well as nearby villagers. 3. Existing road and rail network will be utilized for raw material and final products transportation. However existing road network will be strengthened. 4. Drinking water facilities will be provided for employees as well as nearby villagers. 5. Existing road and rail network will be utilized for raw material and final products transportation. However existing road network will be strengthened. 7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN Proposed expansion will be done within the existing plant premises and no additional land is required for the same; hence R & R is not applicable. 8.0 PROJECT SCHEDULE & COST ESTIMATES 8.1 Project Schedule The unit will be completed in 22 months. An effective project team has been formulated with an experienced Project Manager as its leader. Visiontek Consultancy Services Private Limited Page 7

13 8.2 Project Cost An indicative estimated capital cost of the proposed power plant is Cr. Including the Pre-operative expanses, contingency and interest during construction. 9.0 ANALYSIS OF PROPOSAL The benefits of the proposed unit as follows, 1. Improving and building road network in the adjoining villages. 2. Strengthening local school buildings with playgrounds. 3. Social awareness programme will further improve by the local authority such as sanitation and hygiene, HIV Prevention Program. 4. Through this project, adult education and female education will be provided to the illiterate adults and backward females of the villages in the project surrounding area. Sponsor the education to Poor Students of the Proposed Area. Plus additional jobs generated by local business in the supply of raw materials, finished products and services. Development of the local area in terms of an enlarged market will provide the farmers with a good outlet of their agricultural products to enjoy the price effect, which is likely to be strong enough to offset the impending local inflations through real-balance effect. Thus, the proposed project will be ushered in the social and economic upliftment of the persons living in the vicinity of the Project i.e. of society at large. Visiontek Consultancy Services Private Limited Page 8

14 CHAPTER 02 INTRODUCTION 2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT M/s Nuvoco Vistas Corporation Limited (Formerly M/s Lafarge India Limited) proposes for installing 1 X 27 MW Coal based Captive Power Plant in its existing 4.6 MTPA Cement Grinding Unit within existing plant premises of 123 Acres(49.77 Ha.) and CPP over an area of 3.0 Ha. at Village-Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand. M/s Nuvoco Vistas Corporation Limited (Formerly M/s Lafarge India Limited) hereafter refer as NVCL entered the Indian market in Lafarge has four cement plants in India: two plants in the state of Chattisgarh (Sonadih and Arasmeta) and grinding units in Jharkhand (Jojobera) and cement plant in Chhattisgarh. NVCL have cement grinding capacity of 4.6 MTPA at Jojobera & are planning to increase production capacity to 6.6 MTPA. The power demand of the plant at present is met from JUSCO. In view of the high power tariff & plan of JUSCO to increase same in future NVCL is contemplating to have Self Power generation to meet bulk power requirement of the cement grinding plant. Table 2.1 Background of the Project Sl. No. Description Date 1 Environmental Clearance for Proposed expansion Cement Grinding Unit from 3.4 MTPA to 4.6 MTPA 2 Amendment in Environmental Clearance for Proposed expansion Cement Grinding Unit from 3.4 MTPA to 4.6 MTPA 3 Application for getting EC for proposed expansion of Cement Grinding Unit from 4.6 MTPA to 6.6 MTPA. Issued by MoEF &CC vide F. No. J-11011/638/2008-IA II (I) on dated Issued by MoEF &CC vide F. No. J-11011/638/2008-IA II (I) on dated Applied on Proposal No. IA/JH?IND/57393/2016 MoEF &CC File No. J- Visiontek Consultancy Services Private Limited Page 9

15 11011/638/2008-IA.II(I) 2.2 DESCRIPTION OF NATURE OF THE PROJECT M/s Nuvoco Vistas Corporation Limited (Formerly M/s Lafarge India Limited) proposes for installing 1 X 27 MW Coal based Captive Power Plant in its existing 4.6 MTPA Cement Grinding Unit within existing plant premises of 123 Acres (49.77 Ha.)and CPP over an area of 3.0 Ha. at Village-Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand. Table 2.2 Project Profile Sl. No. Units Production Capacity Existing Unit 1 Cement Grinding Unit 4.6 MTPA Proposed Expansion Unit 1 1 X 27 MW Coal Based CPP 27 MW Proposed Interlinked Project applied for EC 1 Cement Grinding Unit Expansion from 4.6 MTPA to 6.6 MTPA 2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/OR REGION Indian cement industry is large, growing and with consumption of 185kg/capita/yr in 2011 (compared to global average of ~300 kg/capita/yr) the country itself has the capacity to demand significantly more cement as it develops. In India, Jharkhand has around 40 per cent of the country s mineral wealth such as coal, limestone etc. In addition to the large raw material deposits, the strategic location of Jharkhand, proximity to large markets in southern and central India (providing an opportunity to cater to these markets) and 1805 kms of national highway passing through the State, have made Jharkhand an ideal destination for establishing cement units. Now with the government of India giving push to various infrastructure projects, housing facilities and road networks, the cement industry in India is currently growing at an enviable pace and further growth in the Indian cement industry is expected in the coming years. Therefore, there is an urgent need to increase the production capacity in the country. Hence, the proposal for expansion of Grinding Unit by NVCL will cater the increasing demand of cement in the country and region of Jharkhand. Visiontek Consultancy Services Private Limited Page 10

16 NVCL have cement grinding capacity of 4.6 MTPA at Jojobera & are planning to increase production capacity to 6.6 MTPA. The power demand of the plant at present is met from JUSCO. In view of the high power tariff & plan of JUSCO to increase same in future NVCL is contemplating to have Self Power generation to meet bulk power requirement of the cement grinding plant by installing 1 X 27 MW Coal based CPP. Demand-Supply Gap Power Demand Analysis and Justification Of Project India is one of the largest growing economies of the world. It is the fourth largest economy and has shown consistent GDP growth over the past few years. It has been seen from the historical data that the growth in GDP has a direct relation with the sustained growth of all area of electricity Generation, Transmission and Distribution. Therefore to maintain the projected level of growth in country s economy, it is to be ensured that rapid growth in power sector is maintained. Availability of power is one of the major infrastructure requirements for overall development of a nation. Rapid industrial growth, ever increasing demand in domestic, manufacturing and service sectors coupled with progressive extension of power transmission and distribution system have led to the rapid growth of electricity demand. Despite appreciable capacity additions in Power Sector, the demand for power has outstripped the availability in many parts of the country. Unlike the ideal conditions where the system should have some spinning reserves to meet unforeseen outages and surges of demand, Power demand in India has always outstripped the availability. The demand analysis and justification for setting up of a power plant at any part of the country needs to be corroborated with the facts and figures of the existing as well as future demand-supply scenario of the area concern in light of India s perspective. From the below provided monthly report, the deficit and available power details of entire India are provided, in which Gujarat is seen to have 2.1% deficit every month. The demand was 41,184 MW against a supply of 40,331 MW. The demand for power requirement is more and produced power is less. Hence, this project would reduce the deficit to certain extent. Visiontek Consultancy Services Private Limited Page 11

17 Table 2.3 Peak Demand and Peak Met in India Installed Capacity and Production The Proposed expansion project is intends to produce 27 power by installing 1 X27 MW coal based Thermal Power plant. Imports vs. Indigenous production. Since the Project is Power generation, only indigenous production envisaged. The proposed power plant will use the Indian coal supplied from Open Market Purchase. Visiontek Consultancy Services Private Limited Page 12

18 2.4 Employment Generation Direct and indirect employment will be generated to the local population, the total man power requirement during construction phase for the project will be , out of which 8 are the permanent senior level persons and rest will be the casual workers for construction, erection gardening, packing, cleaning etc. Similarly, during operation expected additional employment to the existing plant will be 43 and total employment after expansion will be Table 2.4 Manpower Requirement-Existing Sl. No. Particulars Existing 1 Skilled Semi Skilled / Unskilled 553 Total 1347 Table 2.5 Manpower Requirement-Proposed Expansion Manpower Details Area Manager Engineer Supervisor Technicians Operator & Chemist Total Top Management Operations Maintenance Total People Training of Personnel Training of the required manpower for the proposed project shall be planned, well in advance. The key personnel shall be selected and trained suitably. The training shall be carried out in the following manner: 1. Onsite training during the construction phase of the Project 2. On job training during the commissioning phase of the project. 3. On job training during operation of the plant immediately after commissioning. The training of the key engineering personnel such as Process Engineer, Mechanical Engineer, Electrical Engineer and Instrumentation Engineer shall be carried out in all the facets. Visiontek Consultancy Services Private Limited Page 13

19 The training of the key operating personnel such as boiler operator, mechanic, welder, fitter and electrician shall be suitably carried out during the construction, erection and operation phases. The training program shall include the following aspects among others so as to impart knowledge and training to the key personnel in relevant aspects of the plant design, operation and maintenance: 1. Understanding the functions of various units. 2. Understanding the equipment in respective sections and the 3. Important parts and control in each equipment. 4. The hazards in respective sections and precautions to be taken for safety of the equipment & personnel. 5. Inspection, preparation and start up of equipment in respective sections. 6. Routine operation of respective sections. 7. Shut down procedures for respective sections. 8. Procedure for attending to emergency stoppage due to failure of power, water and air supply. Visiontek Consultancy Services Private Limited Page 14

20 CHAPTER 03 PROJECT DESCRIPTION 3.1 TYPE OF PROJECT NVCL proposed for the expansion of its 4.6 MTPA Cement Grinding Unit by installing 1 X 27 MW Coal based Captive Power Plant with in its existing plant premises over an area of 3.0 Ha. At Village-Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand. 3.2 LOCATION Proposed expansion is within the existing cement grinding unit plant premises located at Village-Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand. Total area required is 3.0 Ha. available within existing 123 Acres(49.77 Ha.) of land. existing land. The proposed expansion site falls under the Survey of India Toposheet No. 73 J/1 and the buffer zone falls under the Survey of India Toposheet 73 J/2, 73 J/5 and 73 J/6. The Latitude and Longitude of the proposed site is N and E respectively Plant Location Figure 3.1 Index Map Visiontek Consultancy Services Private Limited Page 15

21 Figure 3.2 Topo Map (10 Km Radius) Land Requirement The total project land area required is 3.0 Ha. available within the existing plant premises of total 123 Acres. Table 3.1 Land Use Breakup Sl. No. Particulars Area in Ha. Total Area in Existing Expansion Ha. 1 Clinker Grinding Unit CPP Greenbelt/Plantation Railway Siding Total Plant Layout Visiontek Consultancy Services Private Limited Page 16

22 Existing 4.6 MTPA Cement Grinding Unit at Jojobera, Dist- East Singhbhum. Jharkhand Figure 3.3(a) Plant Layout-Exisitng Visiontek Consultancy Services Private Limited Page 17

23 Existing 4.6 MTPA Cement Grinding Unit at Jojobera, Dist- East Singhbhum. Jharkhand Figure 3.3 (b) Plant Layout- Proposed Expansion Visiontek Consultancy Services Private Limited Page 18

24 3.3 SITE SELECTION The total project land area required is 3.0 Ha. available within the existing plant premises of total 123 Acres. The site selection of Power Plant has been based on the following considerations. Plant availability. Cooling Water availability. Compatibility of grid to withstand sudden outage of unit. Operating experience of the set size. Thermodynamic cycle efficiency and specific input consumption viz. fuel, water etc.. Specific investment requirement & cost of generation. 3.4 TECHNOLOGY SELECTION The selected configuration consist of 1 x 27 MW power plant with CFBC boiler with a continuous rating of 120 tph connected to a single turbo-generator of 27 MW nominal capacity. The type of turbine & boiler are discussed below: Pulverised fuel firing (PF) Fluidised Bed Combustion (FBC) Following aspects are considered while selecting the type of fuel firing system: The boiler type and size are to be chosen considering the fact that the coal supply to the power plant can vary in quality, over a period of time. Some of the salient features of PF and FBC types of boilers are given below: PF Boiler The pulverised coal firing gives marginal improvement efficiency compared to fluidized bed firing. However, for a power project with boiler size of 120 tph, PF boilers are not techno-commercially viable. In addition, PF boiler are designed for specific fuel characteristics and cannot accept large variations in coal fuel quality as such are considered for Power plant having fixed mine coal characteristics. In addition, PF boiler operation on petcoke is constrained. Visiontek Consultancy Services Private Limited Page 19

25 Hence, pulverised coal firing option is not considered. FBC In the last two decades, the concept of fluidized bed combustion has been extensively adopted for boilers in our country. As on date, there are more than 400 nos. of fluidized bed boilers upto 450 tph working in World wide. are as follows: Some of the advantages The fluidized bed combustion can work with lower levels of excess air because of the excellent turbulence created by high velocity air steams in the combustion zones. The fluidized bed combustion requires larger size coal particles i.e. approx. 6 to 8 mm as compared to pulverised coal firing and hence consumes lesser auxiliary power. Due to the intense mixing created in the combustion zone, the fluidized bed boilers tolerate much wider variety in the properties of fuel fired as compared to pulverised coal fired boilers. Considering the above, FBC Boiler option is being considered for the proposed Thermal Power Plant Selection Recommendation Based on the above analysis, following configurations shall be adopted for the each units: Table 3.2 Proposed Configuration A Steam Generator a. No. and ratings of Boiler 1 no. with Maximum Continuous rating 120 tph & 540 o C b. Type of Boiler CFBC B c. No. of Boiler fans 2 X 60 % duty for ID & SA & SA Fan d. Type of Atmospheric pollution control system Steam Turbine Generator Electro static precipitators with outlet dust concentration less than 30 mg / Nm 3 & So2 as 100mg/Nm3 by considering FGD a No. and ratings of turbine 1 no. for each unit of inlet parameters,105 kg & 535oC Visiontek Consultancy Services Private Limited Page 20

26 b Capacity 27 MW Max. Continuous rating c No. of controlled extractions 4 nos. 2 HP, 1 MP and 1 LP D Type of exhaust steam cooling With Air Cooled Condenser The proposed expansion is installation of 1 X 27 MW Coal Based Captive Power Plant based on Conventional Steam Cycle Operating in Rankine Cycle, consisting of 120 TPH CFBC Boiler and 1 no. Turbine 535 ⁰C at 105 Kg/Cm² pressure. 3.5 PROCESS DESCRIPTION Mechanical Equipment and System The selection covers selection of Mechanical equipment and system for efficient operation of the power plant Steam Generator The steam generating system for each unit of 27 MW power plant will consist of one no. 120 TPH capacity boiler with all the auxiliaries. The boilers shall be of circulating fluidized bed type, natural circulation, balanced draft, and membrane wall radiant furnace design with three (3) stage super-heaters and inter-stage de-super heater. Table 3.3 Steam Generator Design Parameter Maximum continuous rating (MCR) (T/hr) 120 Super-heater outlet pressure (kg/cm 2 (g)) 110 Super-heater outlet temperature ( o C) Feed water inlet temperature ( o C) at eco inlet 230 Excess air (%) Not more than 25 Boiler outlet flue gas temperature ( o C) Dust concentration at chimney (mg/nm 3 ) 150 (max.) 30 (max.) The steam generator shall be provided with a steam drum and the drum shall be of fusion-welded type. The steam drum shall be with necessary nozzle connections for the Visiontek Consultancy Services Private Limited Page 21

27 steam outlets, safety valves, feed water inlets, down-comers, continuous blow down, level indicators, chemical dosing, sampling connection, drains and vents to assure the required steam purity Furnace The furnace envelope shall be constructed of fully water-cooled membrane/fin welded walls and the construction shall be gas pressure tight. The furnace bottom shall be covered with an air nozzle tube plate, below which the fluidizer air plenum shall be located. The coal / pet coke of properly graded size shall be brought to the furnace through over bed feeding system Super Heater Super-heater system shall be of three (3) stage design with inter-stage desuperheating to achieve the rated steam temperature over 60% to 100% MCR load. The super-heater shall be combination of convection and radiation type. The inter-stage attemperator or a de-super-heater of spray type shall be located between the two super-heater stages, to control the final steam temperature at oC between 60% to 100% MCR load Economizer The economizer shall be located downstream of the super-heaters and evaporator sections. The economizer shall be of bare tube construction, inline arrangement, counter flow type and the economizer shall be designed for inlet temperature of 230 o C Air Heater Air heater shall be arranged as the last heat recovery section downstream of economiser. Air heater shall be recuperative type with flue gas flowing inside the tubes and the combustion air flowing over the tubes. Considering usage of the pet coke the last bank of air heater is corton steel. Visiontek Consultancy Services Private Limited Page 22

28 Draft System The draft system for the steam generator shall be suitable of producing a balanced draft with sub-atmospheric pressure condition in the furnace. The system shall be comprising of: 2 X 60% PA Fan 2X 60% ID Fan 2 X 60% SA Fan HP & LP Dosing System Steam generator shall be with High Pressure (HP) dosing and Low Pressure (LP) dosing system. The HP dosing system shall be based on tri-sodium phosphate dosing and this shall be dosed in boiler water to take care of the ingress of the hardness salts and to increase the boiler water ph. The LP dosing system shall be based on hydrazine dosing and this is dosed in the feed water to scavenge the last traces of oxygen and to increase the feed water ph Blow Down Tank One Continuous Blow Down tank (CBD) and one Intermittent Blow Down tank (IBD) shall be provided for each of the boiler. The flash steam from the CBD tank shall be piped to the de-aerator and outlet of the IBD tank shall be vented to the atmosphere De-Aerator One De-aerator of de-aerating capacity equal to twenty percent (20%) higher than the gross MCR steam generation capacity of boiler with a de-aerated water storage tank of minimum 10 minutes operation Steam Turbine & Auxiliaries Steam Turbine This project envisages 27 MW multi extraction-cum-condensing turbo-generators. Visiontek Consultancy Services Private Limited Page 23

29 The turbine shall be designed for the operation with the inlet steam parameters at 105 ata and 535 deg C and shall be with automatic controlled extraction steam. The turbine shall be horizontal, single cylinder, triple extraction-cum-condensing type. All casings and stator blade carriers shall be horizontally split. The controlled extraction steam from the turbine shall be delivered to the heaters/de-aerators in saturated condition. A de-superheater to bring the steam temperature from the extraction steam temperature down to the required level is envisaged Lubrication System A pressure lubrication and control oil system shall be provided for the turbo-generator unit to supply oil at the required pressure to the steam turbine, gearbox, generator and governing system. The lubrication oil system shall supply oil to the turbine generator under all the load conditions, including the turning gear operation. The oil system shall be with the following: One hundred percent (100%) capacity centrifugal/gear type, main oil pump. One (1) no. of one hundred percent (100%) capacity auxiliary oil pump of centrifugal type, arranged to cut in automatically if the oil pressure falls to a preset value. This pump shall also meet the requirements during the start up and shut down. One (1) no., centrifugal type, DC emergency oil pump to provide adequate lubrication in the event of a failure of the main driven pump. This pump also shall cut in automatically at a preset value of the oil pressure. Emergency gravity lube oil system comprising of overhead tank with SS lining and complete interconnecting SS oil piping. 2x100% capacity (one working and one standby) water-cooled air coolers. 2x100% duty oil filters Turbine Governor The turbine governing system shall be electro-hydraulic type, designed for high accuracy, speed and sensitivity of response. The governor shall ensure controlled acceleration of the turbo generator and shall prevent over-speed without tripping the unit Visiontek Consultancy Services Private Limited Page 24

30 under any operating condition or in the even of maximum load rejection. The governor shall be configurable in the field. The governing system shall have the following important functions: Speed Control Over Speed Control Low Control Steam Pressure Control The governing system shall be digital governor with all parameter control from plant DCS system Air Cooled Condenser The waste heat produced in the thermal process of the plant has to be transferred to the atmosphere by using adequate cooling system. Environmental concern and climatic conditions are the main factors in the selection of the most suitable power station process. Since water availability is concern as such to save natural resources & to have sustained generation Air cooled Condenser is considered with Air Cooled Condenser approx. 90% of the water is saved. The basic Configuration of Air cooled condenser is as follows Figure 3.4 Air Cooled Condenser Visiontek Consultancy Services Private Limited Page 25

31 Turbine Control The turbine control shall be through the centrally located Distributed Control System. The control system shall provide redundancy for key functions by use of separate sensors and monitors. alarming. local shall be : The control system shall include all the standard control monitoring and In addition to centralized monitoring, some of the essential parameters mounted in Inlet steam pressure temperature and flow Controlled extraction steam pressure and temperature Exhaust steam pressure, temperature and flow Lube oil header pressure Control oil header pressure Steam turbine/generator speed indicator Steam turbine/generator stop push button Turbine back propose control Emergency shutdown push button Flue Gas De Sulfurization System (FGD) Wet limestone scrubbing systems are designed for high SO2 removal efficiencies that are needed to meet the desired outlet SO2 level. As well as the wet limestone process is controlled based on SO2 in a closed loop operation, in which fresh water is added to the system only as makeup water for water lost by evaporation and lost with the gypsum flakes. The flue gas is brought into contact with the limestone slurry in a spray tower. Chemical reaction of limestone with SO2 in the flue gas produces gypsum, which must be removed continuously from the scrubbing loop. Theses gypsum solids are separated in a hydro cyclone and then dewatered in a Rotary Vacuum Drum/Belt Filter to produce semi dry Gypsum which can be used in Cement industries Process Control The primary functions of a wet limestone FGD process control To bring SO2 emission within the required limits To achieve optimum limestone utilization and energy consumption To achieve continuous and reliable operation Visiontek Consultancy Services Private Limited Page 26

32 Exhaust Gas Control The exhaust gases from boiler shall enter the FGD plant through Diverter Valve OR Guillotine damper and the Booster Fan shall provide the necessary head for overcoming the pressure drop through FGD plant. The speed of the Booster Fan is varied to maintain the set pressure at inlet of Booster Fan. FGD can be bypassed by using Guillotine Dampers by closing the Dampers (i.e. open to existing chimney) under any of the following conditions Booster Fan is off Boiler is unhealthy Lime Slurry Preparation The process water flow to slurry tank is regulated by Flow Control Valve to maintain steady level in Slurry Preparation Tank with input signal from Level Transmitter. The process water flow to Slurry Preparation Tank is measured using the Water Flow Meter and the flow signal is used for modulating the rotary limestone feeder through the variable speed drive. The process water flow for slurry preparation is diverted to either of the Slurry Preparation Tank through pneumatically actuated isolation valves Limestone Feed Control Pump Limestone slurry feed rate is one of the factors that determines the extent of limestone dissolution in the Oxidation Tank and thus ph of the slurry in the tank, which in turn affects the SO2 removal. The ph level can be used in a simple feedback control loop to regulate the flow of limestone feed to the Oxidation tank. Value of ph 7 is considered as neutral, less than 7 is acidic & 7 to 12 as alkaline All operational systems control the limestone feed rate with a feedback loop using ph as the controlled variable. A ph electrode probe activates a signal that regulates the VFD of Pump to control the rate of limestone feed. For ph control, dip-type electrode probes, which are inserted into a in-line, flowthrough probes, located in a section of piping. Flow-through sensors must be removed and kept wet if the sample line is drained when the Plant is shut down. Visiontek Consultancy Services Private Limited Page 27

33 Colour of Gypsum In FGD process the Gypsum is generated from reaction of SO2 (pollutant) and alkali reagent (Limestone, CaCO3) in presence of Water. The exhaust gases going to FGD process are from ESP exhaust; hence it also contains fly ash particles in the range of 50 to 150 mg/nm3 (depending upon the ESP Performance). These fly ash particles being insoluble in water goes into gypsum as impurity. Hence, colour of Gypsum in FGD Process is uncontrollable factor. The colour of Gypsum can be brownish gray and the whiteness cannot be predicted or guaranteed even if the whiteness of limestone is known and assured Utilization of FGD Gypsum in Cement Production The whiteness of Gypsum should be minimum 90% to make it suitable for use in cement production. Hence whether FGD Gypsum can be utilized in cement or not is a matter of experience and can be confirmed only after actual FGD Gypsum is produced from the FGD Plant. However, it is evident that the FGD Gypsum having purity around 65-70% (comparable or higher than mined gypsum) is 100% utilized in grey cement production. Visiontek Consultancy Services Private Limited Page 28

34 Figure 3.5 Process Flow Diagram-FGD Visiontek Consultancy Services Private Limited Page 29

35 Figure 3.6 Process Flow diagram Utilities & Services Ash Handling The ash generated from the above shall be about 18 T / hr. maximum while using washery rejects. Out of this 30% is expected to be Bed Ash and rest 70% shall be Fly-ash to be collected from Boiler EP/ Economizer/ Cyclone. The details of quantity are as furnished below:- Fly ash shall be transported pneumatically with the help of dense phase pneumatic to the fly ash silo from Economizer, Cyclone and EP. The fly ash from the silo shall be used in PPC cement production inside plant. Bed Ash will be collected from overflow spouts into ash cooler hoppers. Ash from the hoppers, after sufficient cooling will be discharged through ash vessel of pneumatic conveying system to bed ash silo. bed ash shall be disposed through trucks. Visiontek Consultancy Services Private Limited Page 30

36 Flyash silo has been considered of capacity of 300m 3. Bed ash silo has been considered of capacity 100m 3. Water System Raw intake system of the plant shall be from the JUSCO (water supplier).the water shall only be used for the input to RO/ DM plant, auxiliary circuit for generator cooling, lube oil cooler, cycle water make up. Source of Water System JUSCO (Water supplier) shall be used for water requirement of the power plant. Dematerialized water system To cater to the make-up water requirement of the steam generator turbine cycle, a dematerialized water of 12 m3/hr capacity is required. To meet operation requirement, start-up and load throw lot of venting is there. To overcome such requirement the RO water reserve of above 200m3 is proposed at plant. Compressed air system Compressed air is required for meeting the needs of various mechanical equipment s and for instruments. A Centralised compressor is envisaged for this economizing the overall cost. The compressors shall be fitted with all auxiliaries like receivers, dryers, moisture and oil separators and also necessary control panels. The compressor dew point shall be restricted to - 20 C. Outlet from service air compressor shall be routed to various areas like steam generator, TG Hall extension, coal handling etc. In addition to this separate compressor for cleaning and other miscellaneous purposes. HP & LP Piping The piping for the Power Plant has been divided as follows :- Power cycle piping Low pressure utility piping Cooling water piping Fire water piping Compressed air piping Visiontek Consultancy Services Private Limited Page 31

37 Power cycle piping The power cycle piping of each unit shall consist of mainly the following: Main stream piping from generator to turbine inlet Interconnection between main steam piping and auxiliary steam header through a Pressure Reducing and DE superheating Station (PRDS) Boiler feed water pump suction piping Boiler feed water suction piping and common feed water header Boiler feed water pump recirculation piping Condensate extraction pump discharge piping Condensate extraction pump suction piping Heat Exchanger piping Boiler blow down piping Low pressure utility piping Raw Water R.O Plant Water Cooling water piping Heat Exchanger for Main Plant Area Heat Exchanger for Compressed Air System Fire fighting piping For fire Hydrants Compressed air piping Instrument air Service air Fire protection system Fire protection in the proposed power plant is envisaged for the following purposes: Early Detection Alarm Suppression of Fire The entire fire protection shall be designed to meet above requirement effectively and quickly as per the guidelines set out by the Tariff Advisory Committee. Visiontek Consultancy Services Private Limited Page 32

38 For detection of fire, necessary smoke and heat detectors and manual call buttons with centralised zonal control room have been envisaged. Suitable alarm system shall also be provided along with detection system. Fire protection system shall consist of: Fire Hydrants Portable Fire Extinguishers Heat sensing cable for cable trays Spray system for power transfer & lube oil system The hydrant system shall consist of one electric driven water pump and one diesel engine driven standby pump along with necessary length of hose to be laid around vulnerable points. Various water pumping points shall be provided along the length of hose as per requirement. Portable fire extinguishers shall consist of a combination of different type of extinguishers like foam type, CO2 type etc. Air conditioning Air conditioning has been considered for the following Control room Group level controller and Electronic panel room UPS panel room SWAS room Based on estimated heat load, the capacity of air-conditioning unit works out to: 20 TR for controller and electronic panel room 15 TR for Control room 5 TR for UPS room and SWAS room Based on the heat load, operational ease, flexibility and reliability of the system air cooled package type is being considered. Ventilation The Pressurise & ventilation system for turbine building is provided to evacuate the heat liberated from the operating equipment and to prevent ingress of atmospheric dust. For effective draft, induced draft ventilation system shall be provided for turbine building by installing sufficient roof exhausters. All the air entering the turbine building shall rise through various floor grills/gratings and the hot air shall finally be exhausted through roof exhausters. Visiontek Consultancy Services Private Limited Page 33

39 For switchgear/mcc room, clean air is required for protection of the equipment. Air filters are used in supply air and dampers are provided to maintain positive pressure of 3-4mmWG inside the room. In order to have controlled atmosphere, the ventilation system shall consist of : Air intake louvers viscous and fine filters Centrifugal blower Electrical Equipment And System Generator The Generator will be coupled to the steam turbine and shall match with turbine maximum output. The Generator will be of 6.6 KV, 3 phase, 50 Hz, 0.8 p.f. (lap), Class F insulation for Stator and Rotor with temp. rise limited to Class B. The Generator shall be with brush-less excitation. The excitation system will have automatic voltage regulator to maintain steady generator terminal voltage under varying load conditions. HT switchgear 6.6 KV single bus switchboards shall be provided at power plant. 6.6 KV switchgear will be motor operated vacuum circuit breaker. The Circuit Breaker shall be used for synchronizing purpose and providing unitized protection for Generator, Station Transformer and Outgoing Feeders. Switchgear shall be located in Electrical Room with Air Conditioned system. 6.6 kv bus duct Connection from 27 MW Generators to 6.6 KV Switchboard will be through 6.6 KV Bus bar segregated in sheet steel suitable for Indoor installation as required by Layout consideration Outgoing feeder and auxiliary transformer will be connected to 6.6 KV Switchgear by armoured Aluminum conductor XLPE cable. Visiontek Consultancy Services Private Limited Page 34

40 0.415 kv motors Generally, motors shall be squirrel cage induction motors suitable for 0.415KV +10%, 50 Hz +3%, Class F insulation with temperature rise limited to Class B. Motor for boiler feed pump, ID, SA fan,pa fans & ACC fans shall be suitable VVVF Drives. Neutral grounding resistor (NGT) For 6.6 KV system, low resistance grounding is envisaged so as to facilitate selective clearance of ground circuit earth fault current. The ground resistance of Generator shall restrict earth fault current. Neutral grounding transformer / neutral grounding resister is envisaged. Control and relaying For protection of the equipment against abnormal condition, adequate protective relay shall be considered. Proper discrimination will be provided to isolate the faulty elements incase of any fault. LT auxiliary transformer 3 nos. LT auxiliary transformers of 2000KVA, 6.6/0.415 KV ONAN have been envisaged for supplying power-to-power plant LV auxiliaries at each location. 415V auxiliary distribution Secondary of Auxiliary Transformer to 415 V Power Control Center shall be through bus-duct. LT switchboard shall be fully draw-out, motor operated circuit breaker with necessary protection features to facilitate safe operation and easy maintenance. Section-wise distribution to plant LT load shall be made through down stream MCC. DC system A 110V DC system is envisaged for the Plant DC shall cater to DC loads of HV, LV switchgear, AVR, relay system and DC emergency lighting Alarm and annunciation of the plant condition during emergency Emergency lube oil pump for turbine UPS system Redundant mode UPS with its own battery will be provided to feed following loads: Burner Management System Turbine Supervisory Instruments Visiontek Consultancy Services Private Limited Page 35

41 Plant Communication System DCS System Fire Alarm System Station illumination system An efficient illumination system is necessary to ensure safety of operating personnel. Suitable numbers of lighting panels are envisaged. Power to same shall be fed from main lighting board. Metal Halide Lamps shall be used for Indoor/Outdoor illumination. Provision shall also be kept for emergency 24V AC/110 V DC lighting in key areas. For outdoor lighting, photocell / PLC based control lighting has been considered. Plant communication system Communication system shall be provided in plant for quick communication among operating personnel in field and CCR of power plant. Multi-channel communication with paging/private mode is envisaged with necessary interface. Adequate stations for each zone shall be provided Power Evacuation and Interconnection System Mode of Operation Thermal Power Plant shall be operated in: Isolated mode Parallel mode with JUSCO GRID Isolated Mode It is possible to operate system in isolated mode wherein proposed power plant shall supply power to plant auxiliaries & Cement plant load. The start up shall be trough dedicated DG sets. However it is preferred to operate Power plant in parallel with Utility Grid to take care of Shock load during starting of big drives. The Configuration has also advantage as distribution system is not effected at Cement Plant. Parallel Mode Under this mode of operation, generator shall be operating in parallel with UTILITY GRID at 33 KV. The synchronization of the UTILITY GRID supply forward and back synchronization shall be carried at power plant. The switchgear at main sub-station is of suitable for parallel operation. Visiontek Consultancy Services Private Limited Page 36

42 Power transfer from Power plant to sub-stations The proposed interconnection between thermal power plant and the power evacuation shall be by stepping up power from 6.6 kv to 33 kv using power transformer of 35/40 MVA. Synchronising facilities Synchronization shall be carried out from power plant control room. The load management and control shall also be carried from the power plant. Necessary synchronization check relay, double voltmeter, double frequency meter etc. shall be provided in the control room. Table 3.4 Basic Technical Parameters Sn. Parameter Uni Data Sn Parameter Un Data A Steam Turbine t. it Generation MW 1 x 27 0 Deaerator No 1 1 capacity 2 No of Generating units No 1 11 Deaerator Storage time min Generating voltage kv FW temp at o C 230 economizer Steam pressure at ata Type ofcep -- 2x100% the Turbine (1w+1s) 5 Steam 6 Type Temperature of Condenser cooling 7 Turbine exhaust pressure o C Dumping % 30 Air 15 system Hot well Nos 2 x 100% Cooled pump Condense ata r Governor Woodward B LP heater No 1 17 TG vibration monitoring system HP heater No 2 18 Sox / Nox emission BOILER Bentley Nevada make ppm / 200ppm Visiontek Consultancy Services Private Limited Page 37

43 1 2 Type of boiler CFBC 10 Coal Bunker capacity(stor age hours) No of boilers No 1 11 Bunker SS Liner m3 2X 300 (20 hours) 2mm thk SS lining at bunker conical portion Nos 2 x60% VFD 3 Boiler MCR TPH No of SA Steam temp at o fans C 4 SH outlet 540± 5 13 No of PA Nos 2 x60% 5 Pressure at SH ata No of ID Nos 2 x60% Super heated % ESP outlet 30 6 temperature emission mg/nm 3 control range SPM Sn. Parameter Unit Data Sn. Parameter Unit Data 7 Flue gas temp at APH out oc Fuel Analysis kcal/k grefer Chapter Fuel to be used Guaranteed fuel Pet Coke / coal/any combinatio n Pet Coke / Coal 17 Sulphur capture C Oil firing System 1 LDO/ HSD tank Nos 1 4 Type of pumps % >95 with FGD Screw/cen trif ugal type 2 Capacity of tank kl 25 5 Duty Unloadin g /Transfer 3 Number of pumps Nos 2x100% (1w+1s) 6 Oil burner req capacity for HAG % 20 of Boiler capacity D BFP Visiontek Consultancy Services Private Limited Page 38

44 1 No of Boiler feed pumps 2 Method of start/voltage No 2 x 100% (2w+1s) 3 Type of pump Ring section type, multi VVVF 4 Type of Balancing Disc/ Drum E 1 2 AIR COOLEDCONDENSER Type A- Frame, Dir. air cooled No. of ACC assembly 4 Design ambient Temp 1 no. 5 Turbine Back Pressure oc 45 ata F 1 Fin Type Serpentine 6 Fans VVVF AUXILLARY COOLING TOWER Type of cooling tower Induced draft, Cross flow, 2 Capacity 450 m3/hr 7 6 Range o C 8 No of ACW pumps 1W + 1S 3 No of Cells (1w + 1S) 1W+1SB 8 Type of ACW Pumps Horizontal o C 4 Temp of Hot water 4 9 Type of fills Gridtype Sn. Parameter UnData Sn. Parameter Unit Data it 5 G 1 Inlet cooling water temp WATER SYSTEM DM water tank capacity oc Basin construction RCC m3 2 DM plant capacity 1X12 m3/hrs DM plant configuration DMF- SBA- SAC- MB Visiontek Consultancy Services Private Limited Page 39

45 H I 1 INSTRUMENT AIR Type of compressors 2 No of compressors 3 Air dryer type 1 EOT CRANE Capacity of main hook Non-lub screw 2 x 100% Adsorpti on / refrigera T 40 4 No. of Air receiver 2 m3 1x10m3 main plant 1x5mr3 service air 1x3m3 CHP Capacity of Aux hook T 5 J FUEL HANDLING 1 Coal reclaimin 2 Secondary crusher capacity TPH 125 1X125T PH 4 Out put size from secondary crusher 5 Primary screen capacity mm 6 to 8 1X125 TPH 3 K Coal input size for secondary crusher ASH HANDLING mm 75 6 Secondary screen capacity 1 Type of system Fly ash silo Pneumat ic 5 Bed ash disposal No. of 2 capacity m Ash Bed ash silo Conveyin Bed ash 3 capacity M outlet L AC / VENTIALTION temperature 1 M Turbine hall, ventilation FIRE PROTECTION Sn. Parameter Un it Dry Type/ Wet Type Data 5 Sn. Electrical switch gear room, Control room,i/o room Parameter 1X125 TPH Dry 2 x 100% (1W+1 C 200 Un it Centralize AC Data Visiontek Consultancy Services Private Limited Page 40

46 1 Fire detection system As per local regulati on 2 Hydrant system N CHIMNEY No of chimney 1 3 Chimney 1 construction 2 Height of Chimney m Min 90 4 Chimney mtr Diameter O TG Building Elevator Required m Required RCC As required 3.6 HEAT & MASS BALANCE Figure 3.7 Heat & Mass Balance 3.7 RAW MATERIAL The annual coal requirement considering E/F grade Indian coal for 1 X 27 MW unit is estimated to be about million tonnes (MTPA) as the proposed coal for the plant would be having an Visiontek Consultancy Services Private Limited Page 41

47 average calorific value of 3200 kcal/kg. Coal would be made available from the nearby mines of open market purchase. Table.3.5 Raw Material Requirement & Source S. No. Raw Materials Source Coal Based Supercritical Thermal Power Plant Transportation Mode Requirement MTPA 1 Coal Open market purchase Rail / Road MTPA 2 LDO IOCL/HPCL/BPCL Local depots Road 80KLPY Raw Material Analysis Table 3.6 Chemical Analysis Sl. No. Parameter Unit Value Proximate Analysis 1 Fixed Carbon % Volatiule Matter % Ash % 45 4 Moisture % 10 Ultimate analysis 1 Carbon % Hydrogen % Oxygen % Moisture % 10 5 Sulphur % Nitrogen % Ash % Fuel Gross Calorific Value Kcal/Kg 3200 Visiontek Consultancy Services Private Limited Page 42

48 3.8 WATER & POWER REQUIREWMENT The water requirement for the proposed CPP plant works out to be approximately 360m3/ day. In addition, water requirement for Fuel gas Desulfurization is 216m 3 /day. The total water requirement shall be 576m 3 /day. Agreement made with JUSCO is for 2472 m³/day. The water requirement for free- fighting and service application has not been considered because their intermittent requirement and can be met from the cement plant. Table 3.7 Water Requirement Sl. No. Particulars Quantity in m³/day Existing Plant 1 Process Drinking & Greenbelt 470 Proposed Expansion 1 1 X27 MW CPP Glue Gas Desulfurization Plant 216 Total WASTE GENEARTION AND ITS MANAGEMENT PLAN Waste Water Water would be required for steam generation and condenser cooling purpose. The hot water would be taken to cooling towers and after cooling it would be recycled back for condenser cooling. The cooling tower blow down would be taken to Common Monitoring Basin (CMB). DM plant regeneration waste water would be taken to neutralization pit and then to Common Monitoring Basin. Boiler blow down would be taken to CMB. The quality of water from CMB would be checked and then it would be used for coal dust suppression and ash handling. Run-off water generated from coal stockyard would be collected in sump followed by settling tank where the coal dust particulates would be separated out and clear water would be stored in surface impoundments for reuse within the plant. The water used for ash conveying to ash pond would be recycled back after solids settling in the ash pond. No waste water would be discharged outside the plant premises. Visiontek Consultancy Services Private Limited Page 43

49 The plant sanitary waste water including canteen effluent would be treated in a sewage treatment plant for separation of floating oil and reduction of BOD and the treated effluent would be partly used for plant greeneries, road washing etc. and the balance would be taken to the pond Solid Waste The principal solid wastes would be fly-ash and bottom ash apart from neutralization tank sludge, which would be dried and stored within the Plant. The fly ash and bottom ash generation would be in the range of % of coal used. It will be completely reused in the cemen manufacturing process. Table 3.8 Air Quality Environment & Management (Air Environment Mitigation Measures) Source of air pollution and control measures Sl.No SOURCES POLLUTANTS MITIGATIVE MEASURES Coal Handling Section 1. Transfer Points/Junction House Fugitive Dust All transfer points will be fully enclosed with provision for access doors. Spillages will be periodically removed. Dry fog dust suppression system would be provided. Air borne dust at all transfer points will be extracted through dust extraction system to the bag filters. 3. Belt Conveyers Fugitive Dust All the belt conveyers will be covered and it will be connected to Bag Filter. 4. Weigh feeder discharge 5. Raw materials hoppers Power Plant Crusher House & Bunker Fugitive Dust Fugitive Dust Fugitive Dust The weigh feeder vents will be connected to bag filters. The vents of the hoppers will be connected to dust extraction system i.e. bag filter. dust extraction system i.e. bag filter & Bunker Ventilation System will be provided. 1 Boiler PM ESPs would be provided to control the emissions. Dry low NOx burners(dlnb) would be installed for control of NOx. ROADS Visiontek Consultancy Services Private Limited Page 44

50 1. Internal Roads Fugitive Dust The internal roads will be made of Concrete/ Black topped. Manual sweeping/vacuum sweeping will be carried out regularly followed by water sprinkling NOISE LEVELS The noise generation from the power plant can be broadly categorized into two type s viz. Area and Point sources. All the equipment used can be categorized as point sources and the vehicular traffic movement can be treated as area source. All the equipment is designed to comply with the International Norms, Rules and Stipulations on not exceed 75 db (A). All these noise generating equipment will be within the buildings and the presence of workers at these equipment is either not required or Intermittent. People required for intermittent work near high noise generating equipment will be provided with earplugs and their working hours in these areas will be regulated. The noise levels at the periphery of the plant will be well within the stipulated norms of noise pollution. Visiontek Consultancy Services Private Limited Page 45

51 3.11 Schematic representations of the feasibility drawing which give information of EIA purpose. Visiontek Consultancy Services Private Limited Page 46

52 4.1 General CHAPTER-04 SITE ANALYSIS M/s Nuvoco Vistas Corporation Limited (Formerly M/s Lafarge India Limited) proposed for the expansion of its 4.6 MTPA Cement Grinding Unit by installing 1 X 27 MW Coal based Captive Power Plant with in its existing plant premises over an area of 3.0 Ha. At Village- Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand. 4.2 Connectivity The site is well connected to NH - 33 (approx. 8.0 km in NE direction from the plant site) and SH - 6 (approx. 3.5 km in WNW direction from the plant site). Nearest city is Jamshedpur (approx. 6.5 km in NW direction from the plant site). Nearest Airport Ranchi is approx. 112 km in NW direction from the plant site. The site is well connected with communication facilities like telephone, fax, wireless and as such, no constraints are envisaged in this aspect as the tehsil and district headquarters are near to the site. 4.3 Present Land Use Existing plant area is ha and the proposed expansion will be done within the existing premises; hence, no additional land is required for the proposed expansion project. S. NO. PARTICULARS Table 4.1 Environmental Setting of the Area DETAILS (with approximate aerial distance & direction from the plant site) 1. Nearest Town / City Jamshedpur (6.5 km in NW direction) 2. Nearest National Highway / State Highway o SH- 6 (3.5 km in WNW direction) o NH - 33 (8.0 km in NE direction) 3. Nearest Railway station Tatanagar Railway Station (4 km in WNW direction) 4. Nearest Airport Ranchi Airport (112 km in NW direction) 5. National Parks, Wildlife Sanctuaries, Biosphere Reserves within 10 km radius No National Park, Wildlife Sanctuary, Biosphere Reserve exists within 10 km radius of plant site. Visiontek Consultancy Services Private Limited Page 47

53 S. NO. PARTICULARS 6. Reserve Forests (RF) / Protected Forests (PF) within 10 km radius 7. River / Water Body (within 10 km radius) DETAILS (with approximate aerial distance & direction from the plant site) Patches of RF and PF exist in North to NE direction within 10 km radius study area. o Hitkujuri Nala (3.5 km in S direction) o Harkarjuriya Nala (4.5 km in SSE direction) o Subarnarekha River (5.5 km in NNE direction) o Kharkai River (7.0 km in WNW direction) o Dimna Jhor (7.0 km in N direction) o Dudh Nala (8.0 km in SSE direction) o Garra Nala (8.0 km in SSE direction) 8. Seismic Zone Zone III [as per IS 1893 (Part-1): 2002] 4.4 Topography The topography of the area is not flat and have minor undulations; consisting of series of hummocks having an average elevation of 175 metres. A detailed analysis of slope in the area has been carried out. It has been observed that topography of the area is undulating with a hummock running in the NE-SW direction. The general drainage is parallel to sub parallel. The drainage in surrounding area is dendritic in nature and the drainage density ranges from moderate to poor thus indicating low run-off. 4.5 Existing Infrastructure Total existing plant area is ha and the proposed expansion will be done within the existing plant premises area. All basic infrastructure viz. canteen, Administrative building, Store, Sheds are available within the existing plant premises. 4.6 Climatic data from secondary sources The district receives an annual rainfall of 1500 mm. and most of it occurs during the rainy season. Mean annual temperature is above 26 C. The temperature ranges from 16 C in winter month to 44 C in summer months. The Climate of the district is tropical. Average rain fall is 800 mm per year. Average relative humidity being 70%. Visiontek Consultancy Services Private Limited Page 48

54 CHAPTER 05 PLANNING BRIEF 5.1 Planning Concept Technical Concept This technical concept indicates the plant capacity, size and type of main machinery, storages, design of systems, plant layout, flow sheets etc. It covers process, mechanical, electrical, instrumentation and civil engineering aspects. The concept has considered quality, pollution control, operation, maintenance and utility services Power to be produced Electric power of total 27 MW will be generated which will be used in existing plant Human Resources Human Resource is the most valuable asset in any industry. The accelerating pace of technology advancement and fierce competition in the market has led to the increasing importance of human resources. Continuous skill updation of the existing human resources and generating new talents in consonance with the needs of the industry are vital for the progress of the industry. The human resource requirement for the project, organization structure and HR Strategies for success of the project is hereby defined Organization Structure An organization structure has been developed for the management of the Project. The project will be headed by Managing Director who will be the overall in charge and Project will be implemented by experienced Project Leader with a core team having extensive experience in thermal power plant execution and operation. The entire project activities have been divided into four broad functions, Project Design, Engineering and coordination Project Execution and site management. Project commercial services Project financial services Visiontek Consultancy Services Private Limited Page 49

55 Each of the above functions is headed by a Functional Head having substantial exposure and experience in management of large thermal power projects. 5.2 Project Engineering The basic engineering of the project will be done with in house resources for which an organization structure has already been put in place. The Detailed Engineering for the project will be done with the help of experienced Designers and Consultants in the following areas Environmental Impact assessment. Geo Technical Soil Investigations and site survey Civil Structural Design Mechanical Plant Design Electrical and Instrumentation Systems Design Project Conceptualization This would consist of formulating the project, defining the project objectives and scope, examining the preliminary feasibility with respect to markets, location, infrastructure, environmental conditions and aspects, social infrastructure etc Project Planning Preparing overall plans and schedules and identifying resources requirement for various activities related to the project Budgeting This activity entails working out a detailed budget for the defined project scope, taking necessary approvals and sanctions as per company s policies, and controlling all activities, to ensure that the project is completed within the sanctioned budget amount Procurement The procurement function would consist of developing detailed specifications for the required plant, machinery and equipment and services, evaluation of bids, coordination with bidders and provide support for finalization of contract. Visiontek Consultancy Services Private Limited Page 50

56 5.2.5 Design and Engineering This function starts with the selection of consultants, development of basic engineering, concepts, plant layout, general arrangement drawings and floor plans, civil design of structures, mechanical and electrical designs etc Project Execution This activity will consist of developing specifications for site works related to civil mechanical, electrical and other installation work, tendering activities and evaluation and selection of various contractors, and developing works contract Coordination with Site Management Coordination with site management shall be done on regular and ongoing basis, to ensure continuous flow of construction drawings and interactions with consultants and suppliers Overall Time and Cost control Develop and implement management reporting system, periodic review of the project schedule and other objectives and initiate preventive and corrective action Project Site Management The organization for the site management function will be headed by a Project Manager who will be overall responsible for all the site functions. The technical functions will be divided into three groups i.e. Civil, Mechanical and Electrical and Instrumentation each headed by highly experienced Personnel and assisted by a group of Engineers and Supervisors. Personnel for highly specialized nature of work will be drawn from the supplier of respective equipment. It is also proposed to deploy experienced personnel from power plant Operations during the project implementation so as to facilitate the transition from project to operations phase. A separate team of commissioning Engineers will be deployed who would eventually be responsible for the operation of the plant. The Project Manager will also be assisted with adequate numbers of personnel for materials management, accounting and administration Visiontek Consultancy Services Private Limited Page 51

57 functions. The materials management function will be responsible for Receipt, Storage and issue of various plant and machinery. The administration function will be responsible for Safety, HR&IR, Liaoning and Security Commercial and Financial Services The Procurement and Logistics functions will be carried out with the help of in-house resources. The commercial functions will comprise of a) Procurement and Ordering. b) Inspection and Expediting and c) Logistics management. 5.3 Organizational Structure for Operational Phase The organizational structure that would be required for the Plant operations has been given due consideration. The total man power requirement for the project will be during construction phase, The total requirement of manpower including management staff and workmen for complete operations and maintenance of the power plant unit will be about 43. The manpower requirement has been planned keeping in view the following: Smooth & efficient running of the plant with optimum manpower. Capacity utilization with optimum energy consumption. Effective coordination Rational distribution of responsibilities The organizational development would be started from the project phase itself as those involved with the project would also be trained for Operations Training The training, be it induction training or on the job training for skill up-gradation, will be given due importance. The sources for training will be Main machinery suppliers In house training programs On the job Training Visiontek Consultancy Services Private Limited Page 52

58 6.1ndustrial Area (Processing Area) CHAPTER 06 PROPOSED INFRASTRUCTURE Following infrastructure will be provided as following: Workshop The mechanical and electrical workshop will be provided to take care of the regular maintenance/ repair jobs in the plant. Machinery stores A store building needed for storing tools, spare parts, consumables, etc. Open area for storing machinery and construction materials for the proposed plant. Cranes, Monorails and Pulley blocks Adequate sized maintenance cranes/ hoists, monorails and pulley blocks at all suitable locations at the plant for ease of maintenance and operation. Bags go down Space will be provided in the packing plant area for the storage of bags. Parking Adequate parking space will be provided in the plant premises for the parking of vehicles. (i) (ii) (iii) Residential Area (Non-processing area) Manpower hired is from the local village and / or nearby city; hence, no residential facility is envisaged. Green Belt ha (approx. 33 % of total plant area) has already been developed under greenbelt / plantation. Social Infrastructure Proposed expansion project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure. Visiontek Consultancy Services Private Limited Page 53

59 (iv) Connectivity The site is well connected to NH - 33 (approx. 8.0 km in NE direction from the plant site) and SH - 6 (approx. 3.5 km in WNW direction from the plant site). Nearest city is Jamshedpur (approx. 6.5 km in NW direction from the plant site). Nearest Airport Ranchi is approx. 112 km in NW direction from the plant site. (v) (vi) Drinking Water Existing drinking water requirement is 470 KLD and additional 130 KLD water will be required for proposed expansion; thus, total drinking water requirement after expansion will be 600 KLD, which is being / will be sourced from JUSCO. Sewage Treatment System Domestic wastewater generated from unit is being / will be treated in existing STP of 140 KLD and treated water is being / will be utilized in greenbelt development / plantation. (vii) Industrial Waste management Water used for cooling at various stages of cement manufacturing is being / will be partially subjected to evaporation and partially recycled; hence, no waste water is being discharged from the unit. (viii) Solid Waste Management Dust collected from various air pollution control equipments is being / will be recycled back to the process. Sludge generated from STP is being / will be used as manure in greenbelt development/ plantation. Visiontek Consultancy Services Private Limited Page 54

60 CHAPTER 07 REHABILITATION AND RESETTLEMENT (R & R) PLAN Proposed expansion will be done within the existing plant premises and no additional land is required for the same; hence R & R is not applicable. Visiontek Consultancy Services Private Limited Page 55

61 CHAPTER 08 PROJECT SCHEDULE & COST ESTIMATES 8.1 Project Schedule The project will start only after obtaining Environmental Clearance and other clearances from statutory authority. Project will be completed in 22 months period after getting all the regulatory approvals. 8.2 Project Cost The total project cost including IDC, financing charges is estimated at Rs Cr for the 1 x27 MW capacity. Table 8.1 Project Cost S.no Estimated Cost Of The Project Particulars Estimated cost in Rs. Cr 1 Land & site Development Buildings and others civil Structures Plant & Machinery Technical know-how Fees Expenses on training Miscellaneous Fixed Assets Pre-Operative Expenses Provision of Contingency Working Capital 0.67 TOTAL Visiontek Consultancy Services Private Limited Page 56

62 8.3 Environment Cost Table 8.2 Expenditure on Pollution Control Measures S. No. Particulars Estimated cost in Rs. Lac Recurring cost in Rs. Lac/Annum 1 Air pollution control Water & Noise Pollution Occupational Health Environmental Monitoring & Measurement 5 Green Belt TOTAL Visiontek Consultancy Services Private Limited Page 57

63 CHAPTER 09 ANALYSIS OF PROPOSAL Proposed expansion project will result in growth of the surrounding areas by increasing direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure. Special emphasis on financial and social benefits are being/ will be given to the local people including tribal population, if any, in the area. Development of social amenities will be in the form of medical facilities, education to underprivileged and creation of self help groups. Jharkhand state will get revenues in terms of taxes and local people will get direct & indirect employment. Business opportunities for local community will be available like transport of cement to market, fly ash transport from power plant, maintenance & house-keeping contract work etc. Visiontek Consultancy Services Private Limited Page 58

64 Visiontek Consultancy Services Pvt. Ltd. (An Enviro Engineering Consulting Cell) Committed For Better Environment