EXECUTIVE SUMMARY PROJECT BACKGROUND DB power (Madhya Pradesh) Limited a fully-owned subsidiary of Bhaskar Group proposes to develop a coal based super critical 2x660 MW Thermal Power Plant at Tehsil- Deosar, District- Singrauli in the state of Madhya Pradesh due to its proximity to coal, rail and water. The site is surrounded by villages Gorgi, Pepal, Mahuagaon and Chhamruch. The plant is planned to be set-up as an independent power producer which will sell power to state distribution and power trading companies. Total land requirement of the project is around 1200 acres. The coal for the project will be sourced from Northern Coal Fields. The location is well connected by railway route through Katni-Singrauli main Rail Line. Water for the project will be drawn from Gopad River flowing at distance of 1.5 kms from the project site. PURPOSE OF THE STUDY As per New Environmental Impact Assessment Notification dated 14th September 2006, establishment of new power plants above 500MW requires Environmental Clearance (EC) from MoEF as category A project before the commencement of ground activity. D B Power (Madhya Pradesh) Limited has appointed GIS Enabled Environment and Neo-graphic Centre, Ghaziabad, Uttar Pradesh to prepare the Environment Impact Assessment report for the proposed 2x660 MW coal-based Thermal Power Plant and to facilitate environment clearance for the same from Ministry of Environment and Forest (MoEF), Govt. of India. In line with the EIA notification 2006, Terms of Reference (TOR) for the proposed plant was issued by Expert Appraisal Committee for Environmental Appraisal of Thermal Power. The purpose of the report is to integrate different environmental factors into project planning and decision making by studying probable changes in the various socioeconomic and bio-physical characteristics, which will result from the proposed project, so as to achieve ecologically sustainable development. The purpose of the study is to identify environmental risks, reduce conflicts by promoting community participation, minimize adverse Environmental Impacts and keep decision makers informed thus laying base for environmentally sound project, such that the benefits shall be observed at all the stages of the Project starting from conceptualization to planning, design, construction, operation and decommissioning.
LOCATION OF THE PROJECT The project site is surrounded by the villages Gorgi, Pepal, Mahuagaon and Chhamrachh and located in district Singrauli of Madhya Pradesh State. The total land requirement for this project is 1200 acres. The details of Project location are depicted in Table 1 and shown in Figure 1 State District Tehsil Surrounded Villages Nature of the Area Project Site Co-ordinates Altitude Seismicity Nearest Railway Station Nearest Air Port Nearest Water body Nearest Road Nearest Highway Nearest Town Ecologically sensitive zones like Wildlife Sanctuaries, National Parks or biosphere Archaeological monuments Socio-economic factors PROCESS DESCRIPTION Table 1.1: Location of the Project Site Features Madhya Pradesh Singrauli Deosar Project Coordinates Gorgi, Pepal, Mahuagaon and Chhamrachh Ground level consist of more than 50% Scrub and Barren Land Latitude- 24º07 01.9 N Longitude- 81º55 18.5 E Geological & Meteorological Features 350 m above MSL Seismic Zone- II Nearby Locations Niwas 6 kms Varanasi- 170 kms Gopad River- 1.5 kms Village road is passing near the Plant Site National Highway 75E- 30 kms Sidhi- 35 kms. No Ecologically Sensitive Area is within 10 km radius No Archeological Monuments within 10 km radius No homestead displacement is proposed at the project site In a Thermal Power Plant, the chemical energy of the fuel (coal) is first converted into thermal energy (during combustion), which is then converted into mechanical energy (through a turbine) and finally into electrical energy (through a generator). The plant configuration is 2 x 660 MW. The commercial operation date (COD) of the first unit is envisaged in 42 months and other unit at 3-month interval thereafter. The complete plant shall be under commercial operation within 45 months from the date of financial closure.
PROJECT FEATURES The brief outline of the features of the plant and allied information are given in Table 2 Item Location of the Plant Table -2 Project Features Main Design Parameters Tehsil- Deosar, District Singrauli, State- Madhya Pradesh Co-ordinate Plant Site: (Figure 2.2) 24º07 01.9 N 81º55 18.5 E Net capacity No. of Units and configuration Technology Ash Pond: 1320 MW 2 x 660 MW Super Critical Pressure at SH Outlet 258 kg /cm 2 Temperature at SH Outlet 571 C Steam Temp at Reheater Outlet (min) 568 C Turbo Generator Turbine Throttle Steam Pressure 247 kg/cm 2 Turbine throttle main steam/ Reheat steam temp (min) Generator Turbine Speed Fuels Main Fuel: Coal Stacks No. of Stacks 1 Stack Height (meter) 275 No. of flue 2 Additional equipment (attachment) Water Annual requirement Cooling System Total Discharge 566 C / 566 C 660 MW (each unit) 3000rpm Requirement 7.652 MTPA Source- Northern Coal Field and Grade - "E/F" Grade, Avg. GCV- 3400 KCal/Kg Electrostatic Precipitator Low NOX burners 55MCM Induced draft cooling system proposed Minimum
LOCATION OF THE PROJECT The proposed site is located in Deosar Tehsil, District Singruali, Madhya Pradesh. The site is surrounded by four villages namely Gorgi, Papal, Mahuagaon and Chhamrachh. Site is well accessible by all weather motorable village roads. It is also well connected by Katni-Sidhi main rail line. These roads and rail line can also be used for transporting the construction materials and TPP equipments to the site during construction. The general conditions applicable to set up a Thermal Power Plant have been adhered to while selecting the present site. The location of the proposed plant is not within 10 km radius from the outer periphery of the following: Metropolitan Cities National Park and wildlife sanctuaries. Ecologically sensitive areas like tropical forests, important lakes, coastal areas rich in coral formation, etc. The chimney does not fall in the landing funnel of nearest airport at Varanasi (170 km). The site is not in the vicinity (10 km) of places of archaeological, religious or tourist importance. Land For a thermal power plant, land is required mainly for the main plant area including input storage areas i.e. coal and water, land for ash disposal, residential township and other requirements such as the corridor for access roads, water pipeline routes, ash disposal routes, transmission corridors etc. The total land required for setting up the 1320 MW plant is 1200 acres including power plant and all its auxiliary systems, ash disposal area and colony Accordingly, the area break-up details for the project are given in Table 3 Table 3: Area Break-up Details S. No. Particulars Area (in Acres) 1. Land for Plant 345 2. Ash Disposal Area 337 3. Green Belt 359 4. Staff Township 59 5. Miscellaneous (Offices, Stores and Other Infrstructures) 100 Total 1200 Four villages, namely Gorgi, Papal, Mahuagaon and Chhamrachh will be affected by the project. However, no homestead displacement is expected. Only Land Oustees are going to be affected by the project. The Rehabilitation and Resettlement of these PAHs will be as per the Madhya Pradesh R&R Policy, 2002. While planning, utmost care has been taken to acquire minimum land for the
project. The plant will be located in such a manner so as to minimize disturbance of the villagers. Water Water requirement of the proposed plant will be met through Gopad river. The plant water requirement is estimated to be 55 MCM per annum. A suitable reservoir will be made on river Gopad to cater the water requirement during lean period. The water will be transported through a dedicated pipeline of about 1400 mm OD with pump house at the source and adequate number of pumping stations. A water reservoir for 15 days storage is proposed in the site to meet the water requirement of the plant. Land allocated for the water reservoir is about 60 acre and it will be located within the plant site. This is required due to the scarcity of water in this region and to ensure that there is continual operation of the plant. S. No. Item Table 4: Water Requirements m 3 /hr Estimated Quantity m 3 /day 1. CW/ Service system make up 5307 120888 2. Plant facilities make up/ Potable water 353 8472 3. Evaporation loss 1990 47760 Total water requirement 6944 166666 Fuel Requirement, Availability and Transportation Coal Coal for the project would be indigenous and will be sourced from Northern Coal Fields on long term basis. The company is also in the process of applying for allotment for more coal blocks in the surroundings. The coal requirement considering a GCV of 3400 Kcal/kg will be about 7.652 MTPA. The coal analysis is given in Table 5. Parameter Table 5: Coal Analysis Values Proximate Analysis ( As Received) 11.9 % Total Moisture 11.9 % Ash 41.5 % VM 22 % Fixed Carbon 24.5 Ultimate Analysis ( Equilibrium basis) Carbon 37.5% Hydrogen 2.1% Nitrogen 0.9% Oxygen 5.6%
Parameter Values Sulphur 0.4% HGI 50 GCV AFT Coal Transportation and Handling System 3300 Kcal/Kg 1200 O C The coal extracted from the linkage coal block (NCL) or captive coal block will be transported to the nearest railway station on the existing Katni- Sidhi main railway line through Indian Railways network. For the project, the envisaged mode of coal transportation from the coalmines to the Niwas Rly Station is by Indian Railway system in BOX-N wagons. The route will be finalized based on the detailed coal transportation study under progress. From this Railway station, the coal will be transported up to the plant site either by road or conveyor belt depending upon the viability of either of the options. Company will also study the feasibility of merry-go-round (MGR) system for transporting coal to the power plant site. The length of MGR or conveyor belt will be between 6-8 kms. Coal received at power plant shall be conveyed to the crusher house for sizing of coal to (-) 20mm. From the crusher house, the crushed coal can either be conveyed directly to the coal bunkers through a series of conveyors or stacked on to the crushed coal stockpiles by means of reversible stacker / reclaimer. 02 numbers of stacker cum reclaimers are envisaged. Coal stockyards shall have crushed coal storage equivalent to 15 days coal consumption at 100% PLF. Dust suppression and service water system shall be provided throughout the coal handling plant. A centralized main CHP control room shall be provided to control and monitor the operations of the entire coal handling system. Auxiliary Fuel Light Diesel oil (LDO) will be used as an auxiliary fuel. LDO will be used for cold startup. The requirement of fuel oil has been estimated to be 2200KL/annum. The secondary fuel will be transported using rake load. The analysis of LDO is given in Table 6. Table 6: Analysis of LDO and HFO S. No. Parameters LDO Values 1. Specification IS-1460 (Latest Revision) 2. Acidity (Inorganic) Nil 3. Ash Content 0.02% (max.) by weight 4. Flash Point (Pensky-Martens, closed) 66 C 5. Pour Point (Winter) 12 C Pour Point (Summer) 18 C
S. No. Parameters LDO Values Power Evacuation 6. Kinematic Viscosity at 38 C 2.5 to 15.7 Centistokes 7. Sediment by weight 0.10% (maximum) 8. Water content by volume 0.25% (maximum) 9. Sulphur by weight 1.8% (maximum) 10. Carbon Residue (Rams bottom) by weight 1.5% (maximum) 11. Gross Calorific Value 10,500 Kcal/kg. 12. Specific gravity 0.85 at 15 C The power evacuation from the power station switchyard will be at 400KV. The evacuation of the power can be done by connecting it to the pooling station of PGCIL. Part of the power will be evacuated by state grid at power plant s generation switchyard which shall be utilized for transfer of power across the state of Madhya Pradesh. Project Cost The total cost of the project including all facilities is estimated to be INR 6238 Crores. PLANT WATER SYSTEM The total estimated water requirement for the proposed TPP shall be around 6944 cum/hr for both the units. As discussed earlier, water requirement for the station is proposed to be drawn from Gopad River flowing at a distance of 1.5 km from plant site. Run-off the river is adequate to support a Thermal Power Generation of the required capacity. Flow in the River however dwindles down in the month of May. However the past records indicate that last ten days of May is the most critical period in the year. To be on the safer side therefore, it has been proposed that a suitable storage may be created by constructing a low barrage on River Gopad for augmenting availability of water during the lean period. With the water quality available, water treatment plant would comprise clariflocculation, sand bed filtration and demineralization. The station would deploy recirculating cooling water system using cooling towers. A cycle of concentration of 4.0 will be considered for the CW circuit. Appropriate acidulation and chemical dozing shall be adopted for this purpose. While utmost care has been taken to maximize the recycle/ reuse of effluents and minimize effluent quantity. The total quantity of treated effluent to be discharged from proposed TPP would be about 40 m 3 /hr (5%) of makeup water requirement). In addition to the systems described above, the oily wastes from fuel oil handling area and main plant area shall be treated using oil water separator and the treated
water shall be led to the tube settler provided for service water waste for further treatment and reuse in service water system. Effluent Disposal The provisions like Ash Water Recirculation Systems (AWRS), Effluent Treatment Plants (ETP), Sewage Treatment Plants (STP) and Closed Cycle CW Systems will ensure that most of the treated effluent is reused inside the plant. Further, implementation of Zero discharge has been explored. This requires consumption of an exorbitantly large quantity of raw water to make high TDS discharge water usable with in the system. The use of discharge water of the order of 40 m 3 /hr for any other purpose like horticulture and green belt development is not possible as these were already considered in reuse and recycling. In-view of this and based on available technology feasibility of zero effluent discharge is not considered. All the treated effluents would be discharged through a single point outlet from Central Monitoring Basin (CMB) / Guard Pond to nearby natural drain. PLANT CONFIGURATION AND LAYOUT The layout of the main plant along with all auxiliary system for the proposed 2x660 MW TPP has been shown in the site layout plan. In planning out of the various facilities, consideration has been given to the following general principles: Least disturbance to existing habitation and vegetation, if any; Flexibility to have future expansion of unit with particular reference to the switch yard; Predominant wind directions as gathered from the wind rose to minimize pollution, fire risk, etc; Raw water intake facilities; Approach road to the power plant from the main highway; Availability of adequate space for fabrication / construction equipment; and Availability of adequate space for labour colony during construction stage. All facilities of the plant are laid out in close proximity to each other to the extent practicable to accommodate them efficiently within the plant boundary. ASH HANDLING SYSTEM It is estimated that the total ash to be generated with coal having 45% ash content is 393 TPH. Out of this, 314.5 TPH of fly ash and 78.5 TPH of bottom ash will be generated. Ash handling plant will consist of bottom ash and fly ash handling systems. Bottom Ash Handling System Bottom ash collected in the bottom ash hopper below the boiler furnaces would be conveyed by scraper conveyors/ Clinker Grinder-Jet pump up to the bottom ash slurry pump house for further disposal in wet form.
Fly Ash (FA) handling system The Fly ash collected in the ESP shall be evacuated through vacuum pump in dry form to a Collector tank. From the collector tank the fly ash shall be disposed off in dry form. In case of emergency, the fly ash from the collector tank could be disposed off in wet / slurry form through Ash slurry pump house. The fly ash from collector tank / buffer hopper would be conveyed pneumatically to FA intermediate storage silos and then to the Final silos. The air would be vented out to atmosphere after passing the same through bag filters to mitigate the environmental pollution. The dry fly ash collected in fly ash silos would be disposed off in dry form through container trucks, Railway wagons or any other means. The final fly ash silos would also be located within the plant boundary. ASH POND Assuming the plant to operate at MCR conditions, about 10.3 M cum of ash (bottom and fly ash) is expected to be produced in 3 years. As per MOEF guidelines, 100% of fly ash shall be utilised after first 3 years period. Accordingly, about 10.3 M cum of ash can be disposed off in the dyke. About 337 acres of land is identified for ash disposal. Therefore, for developing 10.3 M cum of storage capacity, a dyke upto 15 m (max.) height will be required. ASH UTILIZATION PLAN In order to meet the requirement of Gazette Notification for Ash utilization following actions is proposed. The company shall provide system for 100% extraction of dry fly ash along with suitable storage facilities. This will ensure availability of dry fly ash required for manufacture of Fly Ash based Portland Pozzolana Cement (FAPPC), asbestos cement products; ash based building products and other uses of ash. All out efforts shall be made to motivate and encourage entrepreneurs to set up ash based building products such as fly ash bricks / blocks etc. With all the efforts mentioned above, it is expected that fly ash generated at the thermal power stations shall be utilized in the areas of cement, concrete and asbestos cement products manufacturing, bricks manufacturing, road construction, low lying area filling etc. However, in order to prepare realistic road map for 100% Ash utilization, a detailed market study shall be carried out. Based on recommendations of the study, detailed road map for 100% Ash Utilization in line with MoEF Gazette Notification shall be prepared and submitted to regulatory authorities.
FIRE DETECTION / ALARM AND FIRE PROOF SEALING SYSTEM A comprehensive fire detection and protection system is envisaged for the complete power station. This system shall generally conform to the recommendations of TAC (INDIA)/ IS: 3034 and NFPA- 850. The following fire detection and protection systems are envisaged:- Hydrant system for complete power plant covering the entire power station including all the auxiliaries and buildings in the plant area. The system shall be complete with piping, hydrants, valves, instrumentation, hoses, nozzles, hose boxes/stations etc. Automatic high velocity water spray system for all transformers located in transformer yard and those of rating 10MVA and above located within the boundary limits of plant, main and unit turbine oil tanks and purifier, lube oil piping (zoned) in turbine area, generator seal oil system, lube oil system for turbine driven boiler feed pumps, consisting of detectors, deluge valves, projectors, valves, piping, instrumentation etc. Automatic medium velocity water spray system for cable vaults and cable galleries of main plant, switchyard control room, CHP control room and ESP control room consisting of smoke detectors, linear heat sensing cable detectors, deluge valves, isolation valves, piping, instrumentation, etc. Automatic medium velocity water spray system for coal conveyors, coal galleries, transfer points and crusher house consisting of QB detectors, linear heat sensing cables, deluge valves, nozzles, piping, instrumentation, etc. Automatic medium velocity water spray system for un-insulated fuel oil tanks storing fuel oil having flash point 65ºC and below consisting of QB detectors, deluge valves, nozzles, piping, instrumentation, etc. Foam injection system for fuel oil / storage tanks consisting of foam concentrate tanks, foam pumps, in-line inductors, valves, piping & instrumentation etc. For protection of control room, equipment room, computer room and other electrical and electronic equipment rooms, Inert Gas extinguishing system as per NFPA-2001 would be opted. Fire Detection and Alarm System - A computerized analogue, addressable type early warning system shall be provided to cover the complete power plant. Following types of fire detection shall be employed. o Multi-sensor type smoke detection system and photo electric type smoke detection system. o Combination of both Multi-sensor type and photo electric type smoke detection systems. o Linear heat sensing cable detector. o Quartzoid bulb heat detection system. o Infra red type heat detectors. o Portable and mobile extinguishers, such as pressurized water type, carbon-dioxide type, foam type, dry chemical powder type, will be located at strategic locations throughout the plant. Required fire engines and fire station equipments shall be provided. Complete instrumentation and control system for the entire fire detection and protection system shall be provided for safe operation of the complete system.
POLLUTION CONTROL Air Pollution Control Measures Coal consumption in furnace generates suspended particulate matter, sulphur dioxide (SO2) and oxides of nitrogen (NOX) as main air pollutants. Various systems to control air pollution from the combustion of coal are as follows. Electrostatic Precipitator: It is proposed to install high efficiency electrostatic precipitator having an efficiency that limits the outlet emission to 100 mg/nm 3. To ensure the safe and optimum operation of the ESP s, each stream of precipitator would be supervised and monitored by a separate microprocessor based rapper control EP Management System (EPMS). It would also monitor and display the status of ESP stream. NOX Control System: For obtaining the sustained high efficiency and availability of the boiler, it shall be designed for low NOX formation by adopting the appropriate burners. Chimney: One bi-flue chimney of 275 metre height of reinforced concrete shall be provided to facilitate wider dispersion of SO2, NOX and particulate matters after ESP. Coal Dust Suppression System: For the control of fugitive dust emission within and around the coal handling plant, coal dust extraction and suppression systems would be provided. Dust suppression system would be installed at all the transfer points in CHP and at coal stockyard. Dust extraction system would be provided in crusher house. Water Pollution Control Systems An effluent management scheme would be implemented with the objective of optimization of various water systems so as to reduce intake water requirement which would result in lesser waste water discharge. The effluent management scheme would essentially involve collection, treatment and recirculation / disposal of various effluents. Adequate treatment facilities would be provided to all the waste streams emanating from the power plant to control water pollution. This would include cooling towers to control thermal pollution and physico-chemical and biological treatment for other effluents. Efficient operation of these treatment plants would be ensured so that the quality of effluents conforms to the relevant standards, prescribed by the Regulatory Agencies. All the treated effluents would be discharged through a single point outlet from Central Monitoring Basin (CMB). The effluents from the project can be broadly classified into the following broad categories: Thermal discharges from Condenser cooling water. Miscellaneous wastes like Coal Handling Plant waste, Service Waste Water, Oily Waste Water and DM Waste Water. Effluent from ash pond. Sanitary waste from plant and township. The treatment proposed for the above effluents is briefly discussed below: Condenser Cooling System: A closed cycle recirculating condenser cooling system with cooling towers is envisaged to minimise thermal discharges from the plant. However,
periodic blow down from the system would have to be resorted to avoid build-up of TDS. The blow down would be used for ash handling system and excess would be sent to the Central Monitoring Basin (CMB) / Guard Pond for dilution and disposal. Oil Separator for Oily Wastes: Oil separator will be provided to trap oils from effluents arising from oil handling area. Service Waste Water: The service water effluent drains shall be separately routed to a sump and treated in plate separator/ tube settler for treatment of suspended solids. The treated service water would be discharged through the main plant drain to CMB. Neutralization Pit: DM Plant effluents will be neutralized in neutralization pit before routing to the Central Monitoring Basin (CMB) A Central Monitoring Basin / Guard Pond would be constructed to facilitate mixing and dilution to all the above wastes before final discharge. Sewage Treatment Plant for Sanitary Wastes from Plant and Township: The sewage from plant and township would be treated in a sewage treatment plant. It would be provided with extended aeration system to control BOD and suspended solids. Noise Control The major noise generating sources in a thermal power plant are the turbines, turbogenerators, compressors, pumps, fans, coal handling plant etc. from where noise is continuously generated. Acoustic enclosures shall be provided wherever required to control the noise level below 90 db(a). Solid Waste Management Systems Ash Management Ash (Fly Ash & Bottom Ash) is the main solid waste from coal based thermal power plants. The ash handling and disposal systems have been described in Section 2.6 and ash utilization plan has been described in Section 2.7. Management of Mill Rejects Mill rejects will be reused within the plant or sold to out side industries for use (e.g. brick kilns). Unused mill rejects will be disposed off in reject yard.