Executive Summary 1. INTRODUCTION 1.1 Background: Pandhurna industrial area consist of nearly 34 small and large units which basically consist of Cotton ginning & Processing, Food Processing, Copper Wire, Stone & Gitti etc., providing direct and indirect employment to nearly 5000 people. Pandhurna has good potential for industrial operations such as Ginning, Cotton Seed Oil, manufacturing of food, copper wire etc. Cotton cultivation potential is higher in the area leading to availability of raw material for textile industries. The Department of Industrial Policy and Promotion (DIPP), Ministry of Commerce & Industries (MoCI), Government of India (GoI) has introduced the Industrial Infrastructure Upgradation Scheme (IIUS) with an objective to enhance international competitiveness of domestic industry by providing quality infrastructure through Public Private Partnership (PPP) in the cluster which have greater potential to become globally competitive. The scheme provides for a financial assistance in the form of a grant up to 75% of the project cost, with a ceiling of Rs.50 Crores. The GoI contribution under this scheme is for creation of durable assets. The scheme requires remaining 25% of the project cost to be financed through other sources including contribution from Industries. CLC Textile Park Private Ltd. (Special Purpose Vehicle (SPV) incorporated under the companies Act 1956) has come forward to implement industrial infrastructure under IIUS. Since, the scope of IIUS is limited to physical infrastructure, the gap assessment and project identification for Pandhurna cluster was therefore focused on physical infrastructure. The interventions were identified to meet the requirements of a model industrial cluster/park through field visits, stakeholder consultations, collection and analysis of data, interactions with government agencies and institutions and benchmarking with well developed clusters. 1.2 Proposed Project: The present trend in process industries which consume large quantum of process steam and electric power is to establish co-generation facility which can simultaneously meet M/s Creative Enviro Services, Bhopal ES: 1
the process steam as well as the electrical energy requirements of the plant. However for supplying steam it is preferred that consuming process industries are located in close proximity to the steam turbine. Considering the scattered arrangement of consuming process industries in the proposed textile park it is very difficult to run steam piping all round. Due to this reason it is proposed to install a captive thermal power plant which can generate and supply power to the industries situated in the textile park. The captive power plant will go a long way in improving the overall energy balance of the plant which will in turn improve the economy of operation. Own thermal power generation is most reliable one compared to other type of power plants. In line with the present trend, establishing a captive power generation facility in M/s. CLC TEXTILE PARK PRIVATE LIMITED is expected to substantially improve the overall energy economy. Moreover power tariff of state electricity board is high and is expected to increase further in the years to come; M/s. CLC TEXTILE PARK PRIVATE LIMITED will have to pay a very high cost if the plant power requirements are to be met from the electricity board grid. On the other hand, if power requirements are to be met through the diesel generator sets using Diesel, the prevailing uncertainty with regards to the price of oil due to changing global scenario, and the cost of oil at the present level makes the DG sets based plant power generation also unattractive. In order to reduce the costs of production to sustain the operation in the globally competitive environment, it is essential for M/s. CLC TEXTILE PARK PRIVATE LIMITED to install their own power plant. The plant will be located at Village: Hirawa, Tehsil: Pandurana, District: Chhindwara in the state of Madhya Pradesh. 1.3 Objective of the study: This Environmental Impact Assessment (EIA) study is prepared for obtaining the Environmental Clearance (EC) from Ministry of Environment and Forests (MoEF), Government of India, New Delhi, for the proposed 10 MW Coal based Power Plant. Considering the above points, Environmental Impact Assessment report has been prepared along with Environment Management Plan (EMP) for various environmental components, which may be affected due to the proposed Power Plant. The Risk Assessment and Disaster Management Plan have also been prepared to meet the M/s Creative Enviro Services, Bhopal ES: 2
eventualities during operation of the plant. This EIA Report covers the primary data collected during the period Oct. 2009 to December 2009 covering Post monsoon season. M/s Creative Enviro Services, Bhopal have prepared Rapid Environmental Impact Assessment (REIA) report for the proposed 10 MW Coal based Power Plant at Village: Bihajhar, Tehsil: Bagbahera, District: Mahasamund in the state of Chhattisgarh by incorporating Terms of References (TORs) approved by Ministry of Environment & Forest (MoEF) New Delhi. The report contains detailed description of the following, a. Detailed characterization of status of environment with in an area of 10 km radius from the proposed plant site for major environmental components including air, water, noise, soil, flora, fauna and socio-economic environment. b. Assessment of air emissions, liquid waste and solid waste from the proposed project along with the noise level assessment. c. Pollution control measures proposed to be adopted. 1.4 Environmental Setting: The environmental setting of the proposed plant is given in Table-1. Table-1 - Environmental Setting of the proposed site SL.NO PARTICULARS DETAILS 1 Location Hiwara 2 Latitude (N) 21 0 32 53 3 Longitude (E) 78 0 39 01 4 Nature of Terrain Plain 5 Mean sea level 480m 6 Nearest Town Pandhurna 7 Nearest City Nagpur 8. Nearest Highway N.H.-69, Bhopal-Nagpur Road-0.5 km 8 Distt. Head quarter Chhindwara 9 Nearest Airport Nagpur 9 Total Area i) Built up area TPP ii) Area of Green Belt iii) Open area 36421.704sqm 8093.712 sq. m 12747.402 sq. m. 12580.402sqm 10 Nearest River Jam-8.5km-NNE 11 Surface water Chiklajodi Nalla-1.0km-W Ambaghat Nalla-2.0km-ES Dantpali Nalla 8.0km-E 11 Climatic Condition - (i) Average Rainfall (ii) Maximum Temp. 1600 to 1800mm 40 0 C M/s Creative Enviro Services, Bhopal ES: 3
(iii) Minimum Temp (iv) Average relative Humidity (v) Wind Direction 09 0 C 19 to 86% NNE, N and NE, ESE 2. DETAILS ABOUT THE PROJECT SITE 1. The plant site is located at Tehsil: Pandurana, District: Chhindwara in the state of MP. 2. The nearest railway facility is available at Pandurana, which is about 15.0 Km. from the proposed project site. The nearest airport is Nagpur, which is about 70 km from the proposed project site. 3. Rajana, Hirwa Sendwara, Temni Sani, Meharakhapa, Ghogri shahani, wada, & Chicholi etc., are the near by habitations to the proposed plant. 4. Total land is sufficient for installation is about 9acre 5. The average annual rainfall in the area is 1300 mm. 6. The major crops in the study area are Kappas etc. 2.1 RAW MATERIALS The following will be the raw material requirement for the proposed power plant. Calorific Value of Coal 4214 kcal/kg Heat rate 3485 KCal/Unit (KWatt/Hr) Total Fuel Requirement 3485X10= 34.85 M KCal/hour Coal Consumption 175 TPD Ash Contents in Coal 36.3% Ash Generation (TPD) 65 TPD All the raw materials will be transported through Road under covered trucks only. 2.2 Process Flow of the Power Plant The plant under reference is captive thermal power plant based on co generation cycle catering to the heat and power requirement of the CLC Textile Park. The power plant uses coal as fuel and fluidized bed combustion system of firing coal. The coal is fed mechanically to the boiler bunkers having a storage capacity of 16 hours consumption of coal for the full load boiler output. The coal is then fed to the boiler furnace in the fluidized state with the support of combustion air fed by the forced M/s Creative Enviro Services, Bhopal ES: 4
draught fan (FD Fan). The flue gas thus formed as a result of combustion is led over the heating surfaces and heat recovery surfaces (convection & radiant). The gases are finally evacuated from the boiler to atmosphere through one 63 meter high chimney by the induced draught fan (ID Fan). In the process, the Electrostatic Precipitator (ESP) is interposed in the flue gas path before it escapes through the chimney. The dust in the flue gas is separated in the ESP hoppers and disposed off pneumatically. The emission level through the chimney is maintained at less than 50 mgm/nm 3 level at all times. As a result of heat exchange in the boiler between flue gas and water, the steam is formed and the same is evaporated at 68 ata and 490 deg C. The high pressure high temperature steam from the boiler is sent to one 10.0 MW Steam Turbo generator Set (TG Set) where the heat energy is converted in mechanical energy which in turn gets converted to electrical power by driving the generator. The electric power is generated at 11 KV at generator terminals The turbine is a condensing turbine having one controlled extraction of steam at 65 ata to cater to the steam requirement of the process. A part of this steam is also used for feed water heating to achieve higher cycle efficiency. In order to increase the overall efficiency further, the turbine is provided with an additional bleed point to supply steam for deaeration and feed water heating. The above process meets with the objective of catering the needs of heat and power for the process operations. To keep the various equipment scale and corrosion free, water is treated in the DM Plant and then fed to the power plant as make up water. The feed water is then deaerated and the boiler water concentration maintained within limits by resorting to adequate blow down. The fly ash produced is carried along with the flue gases. ESP is interposed in the flue gas path where the fly ash is separated from flue gases, collected in ESP hoppers and then pneumatically transported to Fly ash storage silo. M/s Creative Enviro Services, Bhopal ES: 5
The steam passed through the turbine is partly extracted at 65 ata to be fed to the process and to HP feed water heater. The steam is then further expanded in the turbine till the bleed point for use in deaeration and feed water heating. The balance steam is finally expanded further to the condenser where it is condensed by circulating cooling water. The cooling water gets heated through 8-10 deg C. This is cooled in the Induced draught cooling tower for reuse as cooling water in the condenser. 2.3 Water and Waste Water: 2.3.1 Water Requirement and Source Total raw water requirement for the plant has been estimated at 1200 M 3 /day including Domestic consumption. This includes water for Make-up water for Cooling tower Makeup for Boiler water, Resin Regeneration water, dust suppression, and domestic water. Water requirement for the proposed project will be met from the water reservoir made by project proponent. Table-2 -Water Consumption S. NO DESCRIPTION UNIT PARAMETERS BOILER MAKE UP WATER 1) Boiler blow down m 3 /hr =(47000 x 2.5%)/1000 = 1.175 2) Treatment plant regeneration m 3 /Day 30.0 Total water requirement for boiler m 3 /Day 58.2 COOLING TOWER MAKE UP WATER 3) Cooling Tower make up m 3 /hr = 2100 x 1.8% =37.8 4) Treatment plant regeneration m 3 /Day 90 Total water requirement for cooling tower m 3 /Day 997.2 5) Service water requirement m 3 /Day 75 Total water requirement for boiler and cooling tower make up together m 3 /Day 1136 2.3.2 Waste Water Generation: Sr. No. The total quantity of effluents generated from the proposed project will be 308 M 3 /day. The following is the break-up of the wastewater generation from the proposed project. Item Effluent Generation (M 3 / Day) Table-3- Effluent Generation: Treatment and disposal M/s Creative Enviro Services, Bhopal ES: 6
A. Domestic 5 Treated through Septic Tanks & Soak pits B. Boiler 13 Will be neutralized through neutralization tanks and mixed with Cooling tower Blowdown and recycles to D.M Plant C. Cooling 280 Neutralized in neutralization pit and afterward passed through pressure filters and go to D.M. plant for mixing with raw water D. Other 10 - E. Horticulture --- --- F. Dust suppression/ Spraying --- --- G. Total 308 --- 2.4 Ash Handling & Disposal Collection/ Transportation: The Ash collected in Hoppers of ESP is pneumatically conveyed to Silo Area for temporary storage. Storage: Ash is pneumatically conveyed to Silos. Silos (2 nos.) 138 cum of capacity are provided for storage of ash. Disposal: It is proposed to use the ash profitably by selling the same for brick manufacturing units & Cement plant. 3.0 SOURCE OF POLLUTION & CONTROL MEASURES 3.1 AIR POLLUTION The flue gases coming from Boilers will pass through state-of-the art Electro Static Precipitator. The particulate matter at the outlet of all the Electro Static Precipitators will be less than 50 mg/nm 3 as per CREP recommendations. These treated gases will be let out into the atmosphere through stack of 63 m height for effective dispersion of pollutants into the atmosphere. The following measures will be taken for control of fugitive emissions Dust extraction system with bag filters & Water Sprinkling system will be provided at material handling & raw material storage areas. All Conveyors will be totally covered with GI sheets to prevent the fugitive emissions. M/s Creative Enviro Services, Bhopal ES: 7
3.2 Water Pollution The total wastewater generated will be 308 M 3 /day. The generated effluent will be treated in well-designed treatment system and treated effluent will be fully recycled within plant premises. No effluent will be discharged outside the plant premises. Effluent Treatment Scheme The effluent generated from the proposed project will be treated in the following manner. The Cooling Tower Blowdown is neutralized in another neutralization pit and afterward passed through pressure filters and go to a Central Monitoring Basin (CMB) from where it will mix with raw water and goes to D.M. Plant. ph of the boiler blowdown will be between 9.5 to 10.5. Hence a neutralization tank of size 3m x 2m x 3 m will be constructed for neutralizing the boiler blow down. The treated Boiler blowdown will be mixed with Cooling tower Blowdown and mixed with treated cooling blowdown in Central Monitoring Basin (CMB) and goes to D.M. Plant. DM plant regeneration water will also be neutralized in the neutralization tank of 2m x 2m x 3m afterward treated effluent will be used for dust suppression and ash conditioning. The domestic effluent is passed through Septic Tanks and Soak pits for the treatment and effluent remains after Soak Pits (if any) will be utilized for Green belt development within the premises. No effluent will be let out of the plant premises. Hence Zero discharge concept will be implemented. A dedicated pipe distribution network will be provided for using the treated effluent for ash conditioning, dust suppression & green belt development. The characteristics of the treated effluent will be in accordance with the CECB Standards for land irrigation. Hence there will not be any impact on ground water quality / surface water due to the proposed Project. 3.3 Solid Waste Management Ash will be generated as the results of operation of proposed power plant. The following table depicted the total quantity of the ash generation: Table- 5 Calorific Value of Coal 4214 kcal/kg Heat rate 3485 KCal/Unit (KWatt/Hr) Total Fuel Requirement 3485X10= 34.85 M KCal/hour Coal Consumption 175 TPD Ash Contents in Coal 36.3% Ash Generation (TPD) 65 TPD M/s Creative Enviro Services, Bhopal ES: 8
3.0 BASELINE DATA 3.1 Ambient air quality Ambient air quality was monitored for RPM, SPM, SO2 & NOx at 08 stations including project site for one season as per MOEF guidelines. The following are the concentrations of various parameters at the monitoring stations. RPM - 34.06 to 46.60 µg/m 3 SPM - 103.21 to 141.21 µg/m 3 SO2-5.96 to 12.83 µg/m 3 NOx - 8.37 to 12.80 µg/m 3 3.2 Water quality Ground water samples were collected at 7 stations along with 4 surface water samples and analysed for various Pysico-Chemical parameters. The water samples are shows that they are suitable for potable purposes. 3.3 Noise levels Noise levels were measured at 8 locations during daytime & Nighttime. The ambient noise level at rural area varied from 35 dba to 65 dba. 4.0 PREDICTION OF IMPACTS 4.1 Prediction of impacts on Air Environment: The proposed emission from proposed project has been considered for prediction of GLC s. The predicted maximum incremental rise in SPM concentrations (24 hourly) will be 22.7 µg/m 3 which occur at a distance of 0.952 m from the origin stack in the down wind direction over the baseline concentrations. The net resultant Ground Level Concentrations of avg. SPM during operation will be 103.21 to 141.21 µg/m 3. The net resultant concentrations of SPM, SO2 and NOX are well within the National Ambient Air Quality Standards (NAAQS) after project commences the operation. Thus, it can be safely stated that due to the proposed plant there will be no adverse impact on the existing ambient air quality. 4.2 Impact on Reserved Forests / Protected Forests Net resultant GLC s are computed for SPM, SO2 and NOx at all the sensitive receptors such as Reserved Forests/Protected Forests. This net resultant GLC s are within the National Ambient Air Quality Standards (NAAQS) for sensitive zones. Hence there will M/s Creative Enviro Services, Bhopal ES: 9
not be any impact on Reserved Forests/Protected Forests, human beings, flora & fauna and animal life due to the proposed expansion. 4.3 Prediction of impacts on water quality The effluent generated from the proposed project will be treated in well-designed effluent treatment scheme and will be used for dust suppression, ash conditioning & green belt development after ensuring the compliance of CECB standards. Hence there will not be any adverse impact on ground water/ surface water due the proposed expansion project. 4.4 Prediction of impacts on noise quality The major noise generating sources in the plant are STG, CFBC Boilers, compressors, etc. All this machinery will be manufactured keeping in view the MoEF/ International Standards on noise levels. 4.5 Prediction of Impacts on Land Environment Quality The effluent will be treated to achieve CECB stipulated standards for on land for irrigation. All the required air pollution control systems will be provided to meet CECB norms. All solid wastes will be disposed / utilized as per CECB norms. Hence there will not be any adverse impact on land environment due to the proposed project. 4.6 Biological Environment All the required Air pollution control facilities for efficient treatment will be provided to comply with CECB norms. Solid wastes will be disposed off as per guidelines. Hence there will not be any adverse impact on flora and fauna due to the proposed project 4.7 Socio - Economic Environment Certainly there will be a scope for employment to local people during construction as well as in operation phase. Hence there will be an all round development of the area. 5.0 ENVIRONMENT MANAGEMENT PLAN 5.1 Environment Management during Construction Phase: During construction, some of the vegetation in the plant premises is required to be cleared. The measures required to be undertaken to minimize the impact on the ecology are: The felling of trees will be kept at minimum; The greenbelt having vegetation density of 2000 trees/ha shall be developed; Construction is restricted to day time only 5.2 Environment Management during Operation Phase: M/s Creative Enviro Services, Bhopal ES: 10
5.2.1 Air Pollution Management Air Pollution Control Equipment - Proposed Power Plant It is proposed to installed an electrostatic precipitator (ESP) having efficiency to reduce particulate emission below 50 mg/ NM 3 Fugitive Emissions To control the fugitive emissions, the following measures are proposed: All the conveyors will be provided with conveyer covers and hoods to offset any trapping of material in wind stream. The height of the chutes at each of the transfer points and the slope of chutes to be considered to avoid dust generation; High efficiency reverse air jet type bag filters are considered to arrest the air borne dust at all the locations where transfer of material from one conveyor to other takes place; Unloading of coal from trucks will be carried out with proper care avoiding dropping of the materials from height. It is advisable to moist the material by sprinkling water while unloading; The sprinkling of water will be done along the internal roads in the plant in order to control the dust arising due to the movement of vehicular traffic; All the workers and officers working inside the plant will be provided with disposable dust masks; Thick greenbelt will be developed around the plant to arrest the fugitive emissions. Air Pollution Control Schemes Adequate and efficient control equipment will be installed in the proposed plant to keep the dust emission at a minimum. The following measures shall be taken: Advance type of Boiler will be installed for the generation of Power, which will control the emissions of SO2. Low NOx burners will be installed to control the NOx emissions below 50 ppm. Further, chimney of 63m height is proposed for adequate dispersion of pollutants. Since, the Coal to be used in the plant, lime injection system will be provided to reduce SO2 pollution. Generation of NOx gases depends to a great extent on the combustion temperature. A well-designed burner system will be installed which limits the temperature to a reasonably low value of NOx generation. 5.2.2 Noise Pollution Management M/s Creative Enviro Services, Bhopal ES: 11
The extensive greenbelt proposed around the boundary of the plant will attenuate the noise emitted by the various sources in the plant. Earplugs will be provided for the personnel working close to the noise generating units as a part of the safety policy. Apart from this, some of the design features provided to ensure low noise levels are as follows: All rotating machinery will be well lubricated and provided with enclosures as far as possible to reduce noise transmission; Provision of silencers will be made wherever possible; The insulation provided for prevention of loss of heat and personnel safety will also act as noise reducers; Necessary enclosures will also be provided on the working platforms/areas to provide local protection in high noise level areas; The workers will be provided with ear plugs; and Plantation in the zone between plant and township would attenuate noise in the residential area. 5.2.3 Water Pollution Management The blow down from the boiler section which is about 2 cum per day will be neutralized through neutralization tanks and mixed with Cooling tower Blowdown and recycles to D.M Plant and the Cooling Tower Blow Down (100 cum per day) will be Neutralized in neutralization pit and afterward passed through pressure filters and go to D.M. plant for mixing with raw water whereas the waste water from resin regeneration which is about 08 cum per day will be Neutralized in neutralization pit and afterward passed through pressure filters and go to D.M. plant for mixing with raw water. Thus the effluent would get finally dispersed into the soil and no further treatment would be necessary. It is thus presented that instead of any additional negative impact on water quality; there will be a positive impact in the water table due to proposed water harvesting techniques. 5.2.4 Solid Waste Management Only ash will be generated from the proposed power plant as a solid waste. Ash handling and storage system is total enclosed and ash will be collected from the ESP of material from One rotary air lock pocket feeder is provided below the ash for every hopper. The ash collected at ESP hoppers is continuously discharged through the rotary feeders to a screw feeder, which is located underneath the rotary feeders. Water will be sprinkled through a water spray nozzle, which is provided in the screw feeders. Water M/s Creative Enviro Services, Bhopal ES: 12
will be sprinkled through a water spray nozzle, which is provided in the screw feeder. Then wet ash will be discharged to trucks for disposal. It is proposed to use the ash profitably by selling the same for brick manufacturing units. The ash is stocked in silo, which has a capacity to store 1-week generation of ash. 5.2.5 Greenbelt Development Due care will be taken to ensure that a greenbelt is developed in and around the plant. All areas devoid of vegetation and having low density will be systematically and scientifically afforested. Proponent has proposed to develop greenbelt on more than 33% of Total area that is as per guideline of CPCB. 5.2.6 Health and Safety Occupation safety and health is very closely related to productivity and good employeremployee relationship. The main factors of occupational health in plant are fugitive dust and noise. Safety of employee during operation and maintenance of equipment and handling of materials are proposed to be taken care of as per regulations. To avoid any adverse affects on the health of workers due to dust, heat, and noise sufficient measures have been provided in the project. The CLC Textile Park (P) Ltd. is conscious of its moral and legal obligation to prevent hazards and to provide healthy working environments. They are proposed to do the following activities: Provision of rest shelters for workers/staff with amenities like drinking water, fans, toilets etc. Provision of personal protection devices to the workers; Rotation of workers exposed to noise premises; Dust suppression of road; and First-aid facilities in the plant area. The management should make annual budget for the safety and health of their employees and provide sufficient facilities in order to effectively implement the health and safety measures. The management shall carry out periodical audit of safety and health with view to ascertaining the effective implementation of policy. M/s Creative Enviro Services, Bhopal ES: 13
Regular medical examination shall be conducted for the employees. The Medical Officers renders timely advice to the Management on preventive measures and safe guards. A safety Committee under MP Factory Rule 1962, under the chairmanship of the Vice President (Mech.) shall be constituted. Emergency Plan duly approved by the Director, Industrial Health and Safety shall be prepared and will be updated periodically. 5.2.7 Institutional Arrangement for Pollution control Environment cell is formed for overall activities for implementation of Environment Management Plan, compliance of statutory requirements as well as interaction with regulatory bodies viz. Chhattisgarh Environment Conservation Board, etc. Table-6 - SUMMARY OF ENVIRONMENTAL MANAGEMENT PLAN AIR Periodical maintenance of pollution control equipments, regular Ambient Air Quality, Stack Monitoring and well developed green belt. WATER Proper sanitary facilities present in the plant to inhibit ground water pollution, oxidation ponds are provided for domestic wastewater management. NOISE Regular Maintenance of machinery & well developed green belt. Provision to provide sound protective devices. SOLID WASTE To take the material in process. BIO-MONITORING Annual medical check up of all employees and various safety measures for employees has been taken. M/s Creative Enviro Services, Bhopal ES: 14