NOTE ON ENVIRONMENTAL IMPACTS DUE TO USE OF PET COKE IN ADDITION TO COAL IN KILN OF CEMENT PLANT AND BOILERS OF CAPTIVE POWER PLANTS

Transcription

1 NOTE ON ENVIRONMENTAL IMPACTS DUE TO USE OF PET COKE IN ADDITION TO COAL IN KILN OF CEMENT PLANT AND BOILERS OF CAPTIVE POWER PLANTS FOR AMENDMENT IN ENVIRONMENTAL CLEARANCE (EC Granted : MoEF letter no. J- 0/66/009-IA II (I) dated Submitted under Clause 7(ii) Chanda Cement WksPlot No., Ghugus Industrial area (MIDC), Chandrapur Taluka and District, Maharashtra Prepared By < B.S. ENVI-TECH (P) LTD. SECUNDERABAD-50007

2 TABLE OF CONTENTS Para No Fig Fig Fig 3 Table Table Table 3 Title Introduction Present Proposal Need F Use of Pet Coke Environmental Benefits of Usage of Pet Coke Project Cost Project Description Cement Plant Captive Power Plant Fuel-Requirement, Quality Availability & Transptation Environmental Impacts Air Environment Solid Waste Generation Conclusion LIST OF FIGURES Predicted ground level concentration of PM0 due to use of pet coke in kiln of cement plant and boiler of captive power plant Predicted ground level concentration of SO due to use of pet coke in kiln of cement plant and boiler of captive power plant Predicted ground level concentration of NO x due to use of pet coke in kiln of cement plant and boiler of captive power plant LIST OF TABLES 50 High 4-hourly average ground level concentrations of PM0 50 High 4-hourly average ground level concentrations of SO 50 High 4-hourly average ground level concentrations of NO x

3 .0 INTRODUCTION ACC Ltd is operating Chanda Cement Wks (CCW)at Chanda Cement WksPlot No., Ghugus Industrial area (MIDC), Chandrapur Taluka and District, Maharashtra. ACC Ltd have been granted Environmental Clearance (EC) vide Ministry of Environment &Fest(MoEF) vide Letter No.J-0/66/009-IA II(I) dated 4th July, 009 Production Details Existing Capacity the Plant Cement, MTPA 0.90 Cement Clinker, MTPA (Intermediate Product) Captive Power 5 Plant, MW EC granted f of Expansion capacity of the plant Capacity of the plant after Expansion ACC-CCW obtained all statuty approvals from the State Pollution Control Board and the plant is in operation with the following capacity. a. Cement Plant 3.8 MTPA b. Clinker.38 MTPA c. Captive Power Plant 40 MW (5+5 MW).0 PRESENT PROPOSAL ACC proposes to use Petcoke in addition to coal in the Kiln of cement plant and boilers of Power plant due to inadequate coal supply. Present proposal is f obtaining Amendment in Environmental Clearance from MoEF&CC f use of Petcoke as much as possible in addition to Coal in cement plant and captive power plant. A comparison of the statement showing the key parameters f EC granted and EC amendments sought is given below

4 S. Particulars No. Existing Environmental Clearance (EC) CEMENT PLANT Capacity of.3mtpa Kiln Cement 3.8 MTPA Capacity Fuel Coal 3 Heat Input 00 % by coal 4 Quantity of Fuel, TPD* Coal Net Calific value of fuel (Kcal/ Kg of fuel) Sulphur content in fuel (%) 3500 (coal) max. (Coal) 7 a) Max. PM in stack flue gases Kg/Hr Coal 34.0 b) Mg/Nm3 50 Proposed EC Remarks Amendment.3MTPA No Change 3.8 MTPA No Change Petcoke in addition to coal as much as possible 00 % by Petcoke Or 00 % by coal Or Combination of Petcoke and Coal Pet coke 569 TPD (max) Or Coal 300 TPD (max) 3500 (coal) 8000 (Pet Coke) 0.40 max. (Coal) 6.0 % max. (Pet Coke) Use of pet coke in addition to coal Pet coke 0.5 Coal Complying with new emission standard while usage of Petcoke, Coal. Overall decrease in dust emission load. 0.5 Use of Petcoke in addition to coal Petcoke Coal will be used in any appropriate proption - -

5 S. Particulars No. 8. a) Existing Environmental Clearance (EC) Max. SO in stack flue gases Kg/Hr Coal b) Mg/Nm3 9. Max. NOx in stack flue gases a) Kg/Hr b) Mg/Nm Coal Proposed EC Remarks Amendment Pet coke Coal (Permitted 000) Complying with new emission standard while usage of Petcoke, Coal. Pet coke 9.6 Coal Complying with new emission standard while usage of Petcoke, Coal. 9.6 CAPTIVE POWER PLANT 5 MW AFBC Capacity of 5 MW 5 MW Power plant Number of Boilers Type of Atmospheric AFBC boiler Fluidised Bed Combustion (AFBC) Number of Steam Turbines Fuel Mix Heat Input 00 % by coal (53% by Coal + 47 % by petcoke) No Change No Change No Change No Change Use of Petcoke Or 6 Fuel requirement (tones per day)* Coal 304 (max) 00 % by coal Fuel Mix Use of Petcoke (56 - Coal + and there will be 60 Petcoke) Or reduction in the overall fuel mix

6 S. Particulars No a) b) 0. a) b) c). Net Calific value of fuel (Kcal/ Kg of fuel) Sulphur content in fuel (%) Existing Environmental Clearance (EC) 3500 (coal) Proposed EC Remarks Amendment Coal quantity due to usage of high calific value petcoke (coal) 8000 (Pet Coke) 0.40 % max %max. (Coal) (Coal) 6.0 % max. (Pet Coke) Max. PM in stack flue gases Kg/Hr Coal 6.05 Fuel Mix No Change 6.05 Coal Mg/Nm 50 No Change Max. SO in stack flue gases Kg/Hr Coal 0. Fuel Mix 7.58 after 75 % SO capture by limestone injection Coal after 8.0% SO capture by limestone injection 835 Mg/Nm3 <600 Complying with new emission standard while usage of Petcoke, Coal. fuel mix Limestone Injection, firing 6.54 injection f TPD control of Coal firing emissions.88 complying with new emission nms Max. NOx in stack flue gases

7 S. Particulars No. Kg/Hr Existing Environmental Clearance (EC) Proposed EC Remarks Amendment Coal 60.5 Fuel Mix Coal Mg/Nm Ash Generation.6 Total Ash Fly Ash generation (tpd) 97.8 Bottom Ash generation (tpd) Complying with new standard 6. with fuel mix Or 3. with coal.0 with fuel mix (9 % ash Includes ash generated from lime injection 00% fly ash will be used in in fuel mix) cement Or manufacturing 97.8 with process Coal 4. ( % bottom from fuel mix ash will be firing and reused as raw 3.6 mix ingredient bottom ash in cement due to manufacturing limestone process injection) 5.98 ( Boiler stack height (M) 80 M Reduction in the emission level from firing coal and.66 bottom ash due to limestone injection) 80 M No Change. Stack height requirement is 50.6 m as per CPCB nm. However the same stack heights of 80m will be maintained

8 S. Particulars No. 4. Particulate Matter emission (mg/nm3) CAPTIVE POWER Capacity of Power plant Number of Boilers 3 Type of boiler 4 5 Number of Steam Turbines Heat Input 6 Fuel requirement (tones per day)* 7 Net Calific value of fuel (Kcal/ Kg of fuel) Sulphur content in fuel (%) 8 9. a) Existing Environmental Clearance (EC) <50 Proposed EC Remarks Amendment <50 PLANT 5 MW CFBC 5 MW 5 MW No Change High efficiency ESP (nos) provided No Change No Change Circulating CFBC Fluidised Bed Combustion (CFBC) No Change 00 % by coal Use of Petcoke % by petcoke Or 00 % by coal Combination of petcoke & coal Coal 504 (max).8 Petcoke Or Coal 3500 (coal) 00 No Change Use of Petcoke and there will be reduction in the overall fuel mix quantity due to usage of high calific value petcoke (coal) 8000 (Pet Coke) 0.40 % max % max. (Coal) (Coal) 6.0 % max. (Pet Coke) Max. PM in stack flue gases Kg/Hr Coal 6.55 Fuel Mix No Change 6.55

9 S. Particulars No. Existing Environmental Clearance (EC) 50 b) Mg/Nm3 0. Max. SO in stack flue gases a) Kg/Hr Coal b) Mg/Nm3 76 c) Limestone Injection, TPD -. Max. NOx in stack flue gases Kg/Hr Coal Mg/Nm3. Ash Generation Fly Ash Proposed EC Remarks Amendment Coal No Change Fuel Mix 78.6 after 95 % SO capture by limestone injection 78.6 kg/hr % - Coal after 53. % SO capture by limestone injection <600 Complying with new emission standard while usage of Petcoke, 00 % Limestone Petcoke firing injection f control of SO Coal firing complying with 8.7 new emission nms 00 % petcoke firing Coal Complying with new standard with pet coke firing with coal firing with 00% fly ash

10 S. Particulars No. generation (tpd) Existing Environmental Clearance (EC) Proposed EC Remarks Amendment will be used in (.76 from cement petcoke firing manufacturing and due process to limestone injection pet coke firing with coal firing (3.30 from coal firing and 4.78 due to limestone injection Bottom Ash generation (tpd) (0.44from petcoke firing and bottom ash due to limestone injection Or 00% bottom ash will be reused as raw mix ingredient in cement manufacturing process 73.8 ( Boiler stack height (M) 5 4. Particulate Matter emission <50 from coal firing and.58 bottom ash due to limestone injection) 5 <50 No Change. Stack height requirement is 5.85 m as per CPCB nm. However the same stack height of 5m will be maintained No Change High efficiency

11 S. Particulars No. (mg/nm3) Existing Environmental Clearance (EC) Proposed EC Remarks Amendment ESP ( nos) provided * Fuel quantity may vary depending upon the calific value of fuel. Overall Emissions Due To Use Of 00% Pet coke, biomass in addition to Coal In Kiln Of Cement Plant And Boiler Of Captive Power Plants S. Paramet Existing Environmental Proposed EC Amendment Remark No er Clearance (EC) Kiln 5 5 Total Kiln 5 5 Total MW MW MW MW (AF (CF (AF (CF BC) BC BC) BC Air Partic decrease Emission ulate In s, Kg/hr Matter overall Sulph emission ur s Dioxid 6 e Oxide s of Nitrog en Kiln 5 5 Kiln 5 5 MW MW Cumul MW MW Cumul (AF (CF ative (AF (CF ative BC) BC BC) BC Ground Partic decrease Level ulate 4 4 in Concentr Matter ations Sulph ground level (µg/m3) ur concentr Dioxid ations e Oxide s of Nitrog en Note : decrease increase *Sulphur Dioxide Control By limestone stone injection in boiler 3.0 NEED FOR USE OF PET COKE Due to uncertainty in the availability of coal linkage and rising prices of impted coal, it is proposed to use petcoke as much as possible in addition to coal depending upon its availability f which approval from MoEF&CC is being sought. The proposed fuel, i.e. Pet Coke is waste from the refinery, readily available in Indian market. F the

12 above Kiln/CPP, the conversion to pet coke as an alternative fuel is envisaged due to the following reasons: ) Petroleum coke (Pet coke) is a carbonaceous solid derived from oil refinery coke units other cracking processes. The chemical composition of petroleum coke is mostly elementary Carbon (usually over the 85% C dry with sulphur content of about 8.5 % (max)) with high heating value and very little ash content (usually less than - %). ) Compared to other low ash coals, pet coke has advantage in terms of bed material inventy. In spite of having low ash content, the bed material requirement is minimum, since limestone and its reacted products (gypsum) act as the bed material. 3) Use of Pet Coke in cement Kiln will facilitate use of sub-grade limestone to the optimum extent resulting in production of high quality clinker. 4.0 ENVIRONMENTAL BENEFITS OF USAGE OF PETCOKE CEMENT PLANT Use of Petcoke in the cement environmental benefits listed below industry results in various Petcoke is a refinery waste which is having a high calific value. Usage of Petcoke at CCW provides waste disposal solution to the refinery thereby helps conserving virgin natural resources. In case of 00 % availability & usage of Petcoke there will be reduction of approx. 0. to 0.5 % of gypsum usage which will results in resources conservation. Low particulate matter and fugitive emission as the ash content in Petcoke is negligible. There will not be any change in Sulphur-di-oxide (SO) emissions from kiln as limestone is the main component of the kiln feed and sulphur in the fuel (Petcoke) gets absbed in the process.

13 CAPTIVE POWER PLANT The pet coke based captive power plant will ensure supply of power at a competitive cost, providing greater flexibility and viability to the ACC Manufacturing operations in an environmentally responsive manner. The project will result in following environmental and economic benefits: ) Generation of power at a competitive cost compared to power generated by using impted coal. ) Utilization of industrial waste thus resulting in fossil fuel conservation. 3) Limestone injection in Boiler will greatly minimize SO emission from the stack (>95 % reduction and to meet new environmental nms of <600 mg/nm3). 4) Solid wastes viz. Fly Ash and Bottom Ash generated from the CPP will be reused/ recycled in the cement plant located within the premises. 5.0 PROJECT COST No additional project cost is involved. 6.0 PROJECT DESCRIPTION: Cement Manufacturing unit of Chanda Cement Wks is a fully integrated cement plant suppted with captive power plant and captive mining of limestone. Fuel is used in the following areas of cement plant complex a. Kiln of Cement Plant b. Boilers of Captive Power plant Presently fuel used is coal f which all clearances were obtained. Due to non availability of coal, it is now proposed to use pet coke as a fuel f Kiln and CPP. The pet coke is proposed to be brought to site by rail/ road. In case of road transpt, pet coke will be brought in high capacity covered trucks to avoid spillage. Pet coke requirement f the project (Kiln and CPP) will be about million TPA. It is proposed to inject limestone into the boiler to

14 control SO emission. The limestone requirement is about 0.06 million TPA. 6. CEMENT PLANT CCW proposes to use pet coke due to uncertainty in the availability as well as rising prices of coal/impted coal. Use of pet coke in InLinecalciners (ILC) is viable as the kiln is already equipped with InLineCalciner (ILC). In-line calciners generally have lower NOx emissions than separate-line calciners (SLC), since all of the kiln exhaust gases must pass through the calciner. In an ILC, the fuel is injected into the kiln riser below where the tertiary air enters at the base of the calciner. This so-called reduction zone, designed f a particular gas retention time, has an oxygen deficient atmosphere that promotes NOx reduction. The process of clinker production in kiln systems creates favourable conditions f use of pet coke due to high temperatures, long residence times, an oxidising atmosphere, alkaline environment, ash retention in clinker, and high thermal inertia which ensure that the fuel s ganic part is destroyed and the inganic part, including heavy metals is trapped and combined in the product. No additional machinery is required f firing of Petcoke in kiln. No additional pollution control equipment will be required f control of Particulate matter, SO and NOx. 6. CAPTIVE POWER PLANT To increase the thermal efficiency, a pre-heater f the fluidizing air and combustion air, and a boiler feed water heater, are installed SO emission is reduced by injection of limestone in the combustion chamber. Limestone Feed and Control Mechanism Sulphur capture in boiler happens by injecting Limestone along with fuel. The fuel and Lime mixture enters into combustion chamber through multiple feed points located in furnace front close to the bottom primary zone. Limestone undergoes decomposition by taking heat from the hot bed material (endothermic) and converts into

15 Calcium Oxide (CaO).This process is called Calcination. The calcined Limestone being pous in nature gets entrained in flue gas and enters the top section of furnace where the mixture of Oxygen and Sulphur Dioxide reacts with Calcium Oxide and converts into Calcium Sulfate (CaSO4).This Process is called Sulfation. This process is an exothermic reaction. Thus, the Limestone converts gaseous SO emission to solid Calcium Sulfate and gets removed from the system. Attributing higher particle residence time and recirculation, the Sulphur capture efficiency in boilers can be achieved to almost 80 % in AFBC boiler and 95 % in CFBC boiler. The amount of limestone that is required f a given amount of fuel depends on the sulphur content of fuel mix i.e coal/petcoke/coal+petcoke. An increase in sulphur dioxide emissions will necessitate an increase in the amount of limestone that is required f a given fuel flow to the furnace. The limestone demand is a function of the main fuel flow. An increase in fuel flow demand will result in a cresponding increase in the limestone demand to provide the demand signal to the Limestone Variable Rotary Feeder. 7.0 FUEL-REQUIREMENT, TRANSPORTION: QUALITY AVAILABILITY & It is envisaged that pet coke required f the project will be transpted through rail/ road. During road transpt pet coke will be brought in closed trucks. Limestone available inside the plant will be used. PET COKE QUANTITY: Considering pet coke with gross calific value (GCV) of 8000 kcal/kg and plant load fact of 00%, the annual pet coke requirement f CPP wks out to be about 0.37 Million Tonnes and 0.07 million Tonnes f Cement Plant.

16 FUEL QUALITY (PET COKE): Pet coke f the project will be available either from Indian refineries/impted. During road transpt, pet coke will be brought in high capacity covered trucks. The proximate and ultimate analysis of pet coke to be used f the captive power plant& Kiln, are as follows: Heating Values Calific Value 8000 kcal/kg Ultimate Analysis (weight %) Moisture 4.50 Ash 0.84 Carbon Hydrogen 3. Nitrogen.37 Sulphur 6.00 Oxygen.69 Proximate Analysis (weight %) Moisture 4.5 Ash 0.84 Volatile Matter 0.60 Fixed Carbon Source :ACC Ltd Because of the extremely low ash (<%) and high sulphur content of pet coke (6.0%), limestone is used in the majity of bed materials of the fluidized boilers using pet coke. Limestone sizing is critical not only f efficient sulphurcapture but also f effective fluidization and fuel mixing thereby unifm temperatures and heat transfer is attained. Limestone will be sourced from the captive mine situated adjacent to the cement plant. Limestone of approx. 45% CaO content will be used f CPP f desulphurization. PET COKE HANDLING PLANT: The pet coke handling will be done in the same system designed f coal.

17 8.0 ENVIRONMENTAL IMPACTS Environmental impacts due to use of pet coke in the Cement plant and power plant has been wked out and presented below under each environmental component. There will be no change in water and wastewater components of the plant due to use of Pet coke 8.AIR ENVIRONMENT The emission details along with emission parameters f Coal and Petcokeare given below. EMISSION DETAILS (EC OBTAINED) Location Height Temp- OC M CEMENT PLANT *Raw 4 40 Mill/Kiln CAPTIVE POWER PLANT +CPP 40 Boiler stack- 5 MW 80 +CPP 40 Boiler stack- 5 MW 5 Dia- Velocity of flue gas Flow rate m3/hr M M/sec Emissions from stacks (gm/sec) (Max.) PM SO NOx #8. # $46.65 $0.94 *emissions are based on operating values PM = 50 mg/nm3, SO = 750 mg/nm3 and NOx - 83 mg/nm3 in case of kiln + emissions are based on PM=50 mg/nm3, #SO = 835 mg/nm3and $SO = 79 mg/nm3, and #NOx = 500 mg/nm3 and $NOx = 300 mg/nm3 in case of power plant

18 EMISSION DETAILS (EC REQUESTED) Location Height Temp- OC M CEMENT PLANT *Raw 4 40 Mill/Kiln CAPTIVE POWER PLANT +CPP 40 Boiler stack- 5 MW 80 +CPP 40 Boiler stack- 5 MW 5 Dia- Velocity of flue gas M M/sec Flow rate m3/hr Emissions from stacks (gm/sec) (Max.) PM SO NOx *emissions are based on operating values PM = 30 mg/nm3, SO = 750 mg/nm3 (permitted 000 mg/nm3) and NOx mg/nm3 in case of kiln + emissions are based on PM=50 mg/nm3, SO = 600 mg/nm3 and NOx 300 mg/nm3 in case of power plant The emission load in terms of Kg/hr (both from cement plant kiln and power plant is given below : Kg/Hr Particulate Matter Sulphur Dioxide Oxides of Nitrogen EC granted EC requested Coal Fuel mix/ Petcoke/ Coal GROUNDLEVEL CONCENTRION The ground level concentration due use of petcoke in kiln of cement plant and CPP computed using AERMOD model (EPA recommended model) is given below :

19 Ground Level Concentrations (ug/m3) Particulate Matter Sulphur Dioxide Oxides of Nitrogen EC granted EC requested Coal Fuel mix/ Petcoke/ Coal Predicted ground level concentration of PM0, SO and NOx due to use of petcoke in kiln of cement plant and boiler of power plant are shown in Fig - to Fig High 4-hourly average ground level concentrations of PM0, SO and NOx are given in Table to Table 3. AIR POLLUTION CONTROL MEASURES The change in pollution control equipment due to use of pet coke in kiln and power plant are given below : POLLUTION CONTROL EQUIPMENT EC Granted Sl. Location / Unit Type of No. Equipment Control of Particulate Emissions Kiln/Rawmill Bag house no Boiler CPP ESP 3 nos Control of SO Kiln/Raw mill Boiler CPP Control of NOx emissions Absption in Kiln - EC Requested Type of Equipment Remarks Bag house no No change ESP 3 nos No change Absption in kiln Optimization of raw mix and process parameters will be done f efficient absption of SO in kiln atmosphere. Limestone injection at boiler

20 Sl. Location / Unit No. Kiln/raw mill Boilers CPP EC Granted Type of Equipment Low NOx burner and Low NOx Calciner AFBC/CFBC Boilers EC Requested Type of Equipment Remarks Low NOx burner and Low NOx Calciner No Change AFBC/CFBC Boilers, Biomass will be used Biomass will be used Note: Results of Pet Coke Trial Run conducted by NCCBM at 33 Kilns showed that there is no increase in SO, NOx and PM in kiln while the Pet Coke was used. CONTROL OF PARTICULE MTER Cement plant:pollution control equipment f control of particulate emission specified above are designed f meeting outlet emissions below 30 mg/nm3. Captive Power plant:due to the very low ash content in Petcoke, there will be low particulate matter emission in power plant and the outlet emissions will be well below 50 mg/nm3 CONTROL OF SULPHUR DIOXIDE Cement Plant The combustion zone of the kiln with the presence of high lime dust acts as a scrubber combining to fm calcium sulfate preventing much of the potential SO from the emission gas stream. The combustion of Sulfur: S + O SO The fmation of Calcium Sulfate: CaO + SO + ½ O CaSO4 Captive Power Plant Fluidised Bed Combustion (FBC) Technology is ideal f pet coke firing because its long burning process ensures complete combustion of the low volatile pet coke. The technology also captures a large amount of Pet Coke's sulphur during the combustion process. The vigous

21 mixing of the fuel, limestone and ash particles during the lowtemperature fluidized process allows the FBC to cleanly and efficiently burn almost any combustible material, while minimizing the fmation of NOx and optimizing the capture of SO as the fuel burns. The combustion temperature is well below the melting point of the fuel's ash, which allows tominimize the crosion and fouling issues experienced in conventional boilers. CONTROL OF OXIDES OF NITROGEN Cement Plant: The kiln is equipped with InLineCalciner (ILC). In-line calciners generally have lower NOx emissions than separate-line calciners, since all of the kiln exhaust gases must pass through the calciner. In an ILC, the fuel is injected into the kiln riser below where the tertiary air enters at the base of the calciner. This so-called reduction zone, designed f a particular gas retention time, has an oxygen deficient atmosphere that promotes NOx reduction. The kiln at Chanda is equipped with 6 stage preheater along with ILC calciner. Already Low Nox burner and Low Calciner are in place and NOX emissions will be within the emission limit. Captive Power Plant:NOx emissions are low in FBC boilers and Additionally, to reduce NOx to an extent of 0 %, process optimization and use of Biomass will be done. 8.SOLID WASTE GENERION The solid waste generation is mainly ash from the power plant. The ash generation from the plant with use of coal and petcoke is given below. Maximum ash generation from the power plant is 33.6tpd (from fuel ash and limestone injection)with coal firing. With use of fuel mix in 5 MW power plant and 00 % petcoke in 5 MW power plant, the ash generation will reduce to 6 tpd(from fuel ash and limestone injection). Only dry ash handling system is adoptedand the ash is sted in silos. Transptation of Ash in dry fm from the hoppers to stage silos is done through pneumatic conveying. 00% ash will be utilized f manufacturing of Ptland Pozzolana Cement (PPC). The

22 bottom ash of FBC boilers will have minimum unburnt carbon and thus will be used in cement raw mix. SOLID WASTE GENERION (T/DAY) EC EC Requested Granted 5 MW Captive Power Plant Fuel Coal Fuel mix Or Coal Total Ash.6 6. with fuel mix Or 3. with coal Fly Ash with fuel mix (9 % ash generation (tpd) in fuel mix) Or 97.8 with Coal Bottom Ash (0.50 from fuel mix generation (tpd) firing and 3.6 bottom ash due to limestone injection) 5.98 (4.3 from coal firing and.66 bottom ash due to limestone injection) 5 MW Captive Power Plant Fuel Coal Pet Coke Or Coal Ash Generation with pet coke firing with coal firing Fly Ash with pet coke firing generation (tpd) (.76 from petcoke firing and due to limestone injection with coal firing (3.30 from coal firing and 4.78 due to limestone injection Bottom Ash generation (tpd) (0.44 from petcoke firing and bottom ash due to limestone injection Or 73.8 (70.70 from coal firing and.58 bottom ash due to limestone injection) utilization Total ash will be utilized in cement manufacturing process Total ash will be utilized in cement manufacturing process

23 9.0 CONCLUSION ACC CCW proposes to obtain Amendment in EC f use of petcoke in addition to coal as alternative fuel in Kiln of cement plant and Boilers of power plant. Use of Pet coke will not result in increase of SO and due to complete absption by the limestone in Kiln. Use of Petcoke in the cement environmental benefits listed below industry results in various ) Generation of power at a competitive cost compared to power generated by using impted coal. ) Utilization of industrial waste thus resulting in fossil fuel conservation. 3) Limestone injection in Boiler will greatly minimize SO emission from the stack (>95 % reduction and to meet new environmental nms of <600 mg/nm3). 4) Solid wastes viz. Fly Ash and Bottom Ash generated from the CPP will be reused/ recycled in the cement plant located within the premises. 5) Lowering CO emissions FBC technology adopted enables use of pet coke in the boiler and injection of limestone which controls the sulphur dioxide emission by 80 % in AFBC and 95 % in CFBC boilers meeting outlet concentration of 600 mg/nm3. AFBC boiler use less excess air (3 to 5%) and use staged combustion (fuel and air are combusted in multiple stages) thus low NOx in each stage of combustion. NOx emissions are low in CFBC boilers due to low temperatures. There will be decrease in pollution load with pet coke usage as lime injection in boiler is proposed f capturing the sulphur dioxide. The comparison statement of pollution load and cresponding Groundlevel concentrations are shown below:

24 Overall Emissions Due To Use Of 00% Pet coke, biomass in addition to Coal In Kiln Of Cement Plant And Boiler Of Captive Power Plants Parameter Air Emissio ns, Kg/hr Particul ate Matter Sulphur Dioxide Oxides of Nitrogen Existing Environmental Clearance (EC) Kiln 5 5 Total MW MW (AFB (CFB C) C Proposed EC Amendment Kiln 5 MW (AFB C) MW (CFB C Total Remar k decreas e In overall emissio ns Ground Level Concentrations (µg/m3) Kil n Particula te Matter Sulphur Dioxide Oxides of Nitrogen MW (AFB C) 5 MW (CFB C Cumulati ve Kil n MW (AFB C) 5 MW (CFB C Cumulati ve decrease in ground level concentratio ns Note : decrease increase *Sulphur Dioxide Control By limestone stone injection in boiler There will be no change in water and wastewater components of the plant due to use of Pet coke. Solid waste generated from limestone injection will be totally used in the cement plant Amendment in EC proposal facilitates use of petcoke in Kiln and Boiler. Use of Pet Coke in cement Kiln facilitates use of sub-grade limestone to the optimum extent resulting in production of high quality clinker In view of the above, ACC-CCW requests MOEF&CC to consider the above aspects and issue the amendment in Environmental clearance f use of Pet coke in addition to coal in kiln of cement plant and boiler of captive power plant ***

25 Table Predicted 50 high 4-hourly Average Ground Level Concentration Of Particulate Matter Due To Use Of Pet CokeIn Kiln Of Cement Plant And Boiler Of Captive Power Plants RANK CONC c.990c.868c.085b.07894b.06337c.0579c.0487c.03477c.0756c.0490c.000c.0556c.0059b.0080c.0085c b c c c c c c c c (YYMMDDHH) RECEPTOR (XR,YR) OF (UTM COORDINES) ( , ) ( , ) ( , ) 6054 ( , ) 6054 ( , ) ( , ) ( , ) ( , ) 6054 ( , ) ( , ) 6054 ( , ) ( , ) ( , ) 6054 ( , ) 6054 ( , ) ( , ) 6054 ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) 6054 ( , 0586.) ( , 0586.) TYPE RANK CONC c 0.965c c 0.930b 0.99c 0.903c c c c c c b 0.893b c c 0.880c c c b c c c c b (YYMMDDHH) RECEPTOR (XR,YR) OF (UTM COORDINES) ( , ) 6054 ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , 0586.) ( , ) 6054 ( , ) ( , 0586.) 6054 ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) 6054 ( , ) TYPE

26 RANK Table Predicted 50 high 4-hourly Average Ground Level Concentration Of Sulphur Dioxide Due To Use Of Pet CokeIn Kiln Of Cement Plant And Boiler Of Captive Power Plants CONC c c c c c c.63546c.3496c.70486c.5804b.39305b.0078c c c 0.493c c c b c c b c c 9.404c (YYMMDDHH) RECEPTOR (XR,YR) OF (UTM COORDINES) TYPE ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , 0586.) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) RANK CONC c c b 9.030c c c c c c c c 8.38c c 8.35c 7.84c c c c b b c b c (YYMMDDHH) RECEPTOR (XR,YR) OF (UTM COORDINES) TYPE ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , 0586.) ( , 0586.) ( , ) ( , 0586.) ( , ) ( , ) ( , ) ( , ) ( , ) ( , )

27 Table 3 Predicted 50 high 4-hourly Average Ground Level Concentration Of Oxides of Nitrogen Due To Use Of Pet CokeIn Kiln Of Cement Plant And Boiler Of Captive Power Plants RANK CONC c.5760c.3883c.03694c.0c c 0.490c 0.033c c 8.984c 8.64c 8.384c 8.74c b c 7.70c b b c c b c c c (YYMMDDHH) RECEPTOR (XR,YR) OF (UTM COORDINES) TYPE ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , 0586.) ( , ) ( , ) ( , ) ( , ) RANK CONC c 6.703c 6.86c c 6.858c c c c c 5.993c b c c b c 5.576c c c c b 5.65c b 5.075c (YYMMDDHH) RECEPTOR (XR,YR) OF (UTM COORDINES) TYPE ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , ) ( , 0586.) ( , ) ( , 0586.) ( , ) ( , ) ( , ) ( , )

28 Fig Predicted Ground Level Concentration Of Particulate Matter Due To Use Of Pet Coke In Kiln Of Cement Plant And Boiler Of Captive Power Plant WINDROSE

29 Fig Predicted Ground Level Concentration Of Sulphur Dioxide Due To Use Of Pet Coke In Kiln Of Cement Plant And Boiler Of Captive Power Plant WINDROSE

30 Fig 3 Predicted Ground Level Concentration Of Oxides of Nitrogen Due To Use Of Pet Coke In Kiln Of Cement Plant And Boiler Of Captive Power Plant WINDROSE

31