Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia

Transcription

1 Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia MONITORING REPORT Version: 1.1 Date: 24 th Aug 2007 Verified Emission Reductions (VERs): 1 st July th March 2007 Hindustan Zinc Limited Chanderiya Lead-Zinc Smelter P.O. Putholi, Chittorgarh Rajasthan VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 1

2 1. Project Activity Project Description The project activity has been proposed by Hindustan Zinc Limited, a member company of Vedanta Group, at its Chanderiya smelting unit in Rajasthan. HZL had only a pyro process based manufacturing unit till 2005, when another unit, based on hydro process was commissioned.the total installed capacity at Chanderiya smelting unit is 275,000 tons per annum (TPA) of refined zinc. In order to meet the power requirement of different units, HZL commissioned a 2X77 MW coal based captive power plant. The project activity is 9.4 MW waste heat recovery based power plant which is supplying electricity generated for its internal operations. The electricity in the absence of project activity would have been imported from the captive power plant. The purpose of the project activity is to recover waste heat from the flue gas generated in zinc roaster. The heat recovered is being used in the waste heat recovery boilers (WHRB) for generating high pressure steam which is then expanded for driving turbines for generating electricity. Hence the Project activity is utilizing waste heat recovered from flue gas produced in roaster unit for generating electricity. Roaster is the main heat intensive unit of Hydro processing plant wherein raw zinc concentrate gets oxidized to form zinc oxide, liberating hot flue gases with following characteristics. Reactions in roaster unit are exothermic and produce enough heat to continue reactions. Except for the initial start ups there is no fuel required in roaster unit. (478.1 KL of Light Diesel Oil (LDO) was consumed during April July 2006). During the start up operations of the roaster unit there will be water circulation in the waste heat recovery boilers but no generation of steam in the WHRB. The waste heat recovery boiler is of unfired type. There is no auxiliary fuel firing in the start ups of the waste heat recovery boiler hence there shall not be any project emissions due to fossil fuel firing in the project activity. The project activity of HZL assists in achieving the above components of sustainable development as follows: Social well being Employment opportunities have been created both during construction and operation stages by the project activity. Skilled people have been appointed for operating and maintaining the power unit. These employment opportunities would have not been created in absence of the project activity. Economic well being The project activity is effectively utilizing the waste gases for generating electricity. Generation of electricity in waste heat recovery based power turbine has reduced power supply to hydro processing unit from coal based captive power unit which in turns results in increased profitability of captive unit hence ensuring economic well being. Environmental well being VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 2

3 The project activity is helping global environment by avoiding the generation of greenhouse gases in coal based captive power unit. It is also resulting in avoidance of thermal pollution in the vicinity that would have occurred due to waste gas emissions at high temperature. Technological well being Electricity generation from waste heat recovered from zinc roaster has not been implemented in Indian Zinc industry. Self sufficiency for meeting the power requirement has made the project a role model to be followed in Indian zinc industry. 2. Project Commissioning Start date of commercial operation: 01 July CDM registration details Date: 31 March 2007 Reference No: 0855 PDD version & date: Version 2.0, 26 th Dec 2006 Methodology: Consolidated baseline methodology for waste gas and/or heat and/or pressure for power generation Reference: Approved consolidated baseline methodology ACM0004/Version 02, Sectoral Scope: 1, 03 March 2006 For Details on validation report please refer to web link Monitoring Details The emission reduction measurement is as per approved methodology ACM0004 version 2. The methodology requires the project participant to monitor the following: Net electricity generation from the proposed project activity; Data needed to calculate the emissions factor of captive power generation. The project activity will have the monitoring of the generation of the total electricity generated and the auxiliary electricity consumption thereby enabling the calculation of the net electricity supplied to the facility. The data is monitored for the period 1 st July 2005 to 30 th March The following table details out the data parameters to be monitored for the emission reductions estimation from the project activity. VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 3

4 5. Project Parameters used to determine the Emission Reductions ID Data type 1. EG gen Quantita tive 2. EG aux Quantita tive Data variable Total Electricity Generated Auxiliary Electricity Data unit Measured (m), calculated or estimated (e) Recording Frequency Propor tion of data to be monito red How will the data be archive d? (electro nic/ paper) MWh/yr m Continuous 100% Electroni c/paper MWh/yr m Continuous 100% Electroni c/paper Comment Monitoring location: meters at plant and DCS will measure the data. Manager In-charge would be responsible for regular calibration of the meter, which would be carried out annually. Monitoring location: meters at plant and DCS will measure the data. Manager In-charge would be responsible for regular calibration of the meter, VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 4

5 which would be carried out annually. 3. EG y Quantita tive Net Electricity supplied MWh/yr c (EG gen - EG aux ) Continuous 100% Electroni c/paper Calculated from the above measured parameters. 4. EF CO2,i Emissio n factor CO2 emission factor of the fuel used for captive power generation tc/tj National Sources or IPCC default yearly 100% Electroni c Emission factor of the coal used at the project has been calculated based on monitored coal specific parameters like fixed carbon percentage and NCV value. 5. Eff captiv e Efficienc y of captive power plant Energy efficiency of captive power generation % Measured yearly 100% Electroni c/paper Efficiency of captive power generation shall be taken highest of the following three values. 1. Efficiency measured prior to project implementation 2. Efficiency monitored. 3. Design Efficiency of VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 5

6 captive power generation. All the data mentioned above would be archived for two years after the crediting period. The line diagram for Power generation and auxiliary consumption are as below Boiler Steam WHR auxiliary consumption TG Auxiliary Meter ( ) Gross Power meter (50301/3-1704) MCC VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 6

7 Description of formulae used to estimate project emissions (for each gas, source, formulae/algorithm, emissions units of CO2 equ.) Project emissions due to project activity are calculated as follows: PE y = Σ Q i x NCV i x EF i x 44/12 x OXID i = 0 tco 2 Where: PE y : Project emissions in year y (tco 2 ) Q i : Mass or volume unit of fuel i consumed (t or m 3 ) NCV i : Net calorific value per mass or volume unit of fuel i (TJ/t or m 3 ) EF i : Carbon emissions factor per unit of energy of the fuel i (tc/tj) OXID i : Oxidation factor of the fuel i (%) Description of formulae used to estimate baseline emissions (for each gas, source, formulae/algorithm, emissions units of CO2 equ. BE electricity, Y = EG y * EF electricity y Where: EG y Net quantity of electricity supplied to the manufacturing facility by the project during the year y in MWh, and EF y CO2 baseline emission factor for the electricity displaced due to the project activity during the year y (tco2/mwh). Monitored Results Estimation of Emission Reductions Baseline Emissions Month Gross electricity generation (MWh) Auxilliary electricity consumption (MWh) Net Electricity generation (MWh) Emission Factor (tco2/mwh) Baseline Emissions (tco2) Jul Aug Sep Oct Nov Dec Jan Feb VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 7

8 Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Total Project emissions Project Month Emissions (tco2) Jul-05 0 Aug-05 0 Sep-05 0 Oct-05 0 Nov-05 0 Dec-05 0 Jan-06 0 Feb-06 0 Mar-06 0 Apr-06 0 May-06 0 Jun-06 0 Jul-06 0 Aug-06 0 Sep-06 0 Oct-06 0 Nov-06 0 Dec-06 0 Jan-07 0 Feb-07 0 Mar-07 0 Total 0 VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 8

9 Emission Reduction Month Baseline Emissions (tco2) Emission reductions (tco2) Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Total Total Emission reductions for the period 01 July March 2007 are VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 9

10 Annex-1 BASELINE ESTIMATIONS (EF Calculations as per PDD) Emission Factor Approach suggested in Approved Consolidated Methodology ACM0004 is used to estimate the grid emission factor for the project activity. The baseline scenario for the project activity has been taken as supply from the existing coal based captive power plant. The baseline emission factor for captive power plant has been computed using the following formula: EF captive, y = (EF CO2,i x 44 x 3.6 TJ)/(Eff captive X 12 X1000 MWh) where: EF captive, y Emissions factor for captive power generation (tco2/mwh) EF CO2, i CO2 emissions factor of fuel used in captive power generation (tc/tj) Eff captive Efficiency of the captive power generation (%) 44/12 Carbon to Carbon Dioxide conversion factor 3.6/1000 TJ to MWh conversion factor In order to estimate the captive power generation efficiency, project participants have chosen the following option: Option A (Refer ACM0004 / Version 02, 03 March 2006) Use the highest value among the following three values as a conservative approach: 1. Measured efficiency prior to project implementation 2. Measured efficiency during monitoring 3. Manufacturer nameplate data for efficiency of the existing boilers HZL has chosen option-a for calculating efficiency of captive power generation. The highest value amongst the following three values shall be chosen for efficiency calculation. 1. Efficiency of captive power plant has been calculated by dividing output energy from the plant by total energy input of the fuel prior to implementation of the project activity. Month Efficiency April May June Average VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 10

11 2. Efficiency of the captive power plant shall be calculated based on actual monitoring as shown below. Month Unit -1 Unit -2 Jul % 27.9% Aug % 28.3% Sep % 33.6% Oct % 30.4% Nov % 28.8% Dec % 29.7% Jan % 30.6% Feb % 28.7% Mar % 29.1% Apr % 29.6% May % 32.3% Jun % 30.4% Jul % 31.3% Aug % 30.9% Sep % 31.4% Oct % 31.3% Nov % 32.7% Dec % 33.3% Jan % 33.7% Feb % 34.6% Mar % 32.4% Weighted Efficiency 31.4% 31.0% Average efficiency % On the basis of monitored results the efficiency of CPP is calculated on monthly basis, individually for both the units, which is then used to calculate the average efficiency of the CPP. 3. Design efficiency of the captive power generation has been used. VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 11

12 Out of the above three values design efficiency has the highest value and has been chosen as conservative value for emission factor calculations. The table below shows the values of emission factor of fuel and efficiency of captive power generation. S.No Parameter Comment Value 1. Emission factor of fuel used in captive power generation Mixed of Indian and Indonesian coal has been used. Emission factor has been calculated based on the weighted average data for fixed carbon percentage and NCV tc/tj 2. Efficiency of captive power generation. value. Efficiency has been calculated ex ante, highest of the following three values have been chosen as conservative estimate. 2 a. Efficiency prior to project implementation % 2 b. Efficiency monitored % 2 c. Design Efficiency % The design efficiency of is the highest value and has taken as the efficiency for estimating baseline emissions ex-ante. Hence Emission Factor shall be as given: EF captive, y = (EF CO2,i x 44 x 3.6 TJ)/(Eff captive X 12 X1000 MWh) EF captive, y = (19.57 * 44 * 3.6 ) / (35 % * 12 * 1000) = tco 2 /MWh VER Monitoring report Waste heat recovery based power plant at Hindustan Zinc Limited, Chanderia Page 12