NLC INDIA LIMITED PRE FEASIBILITY REPORT 2x660 MW SUPER-CRITICAL LIGNITE BASED POWER PLANT AT MUDANAI DISTT. CUDDALORE, TAMILNADU NOVEMBER 2016 DESEIN PRIVATE LIMITED CONSULTING ENGINEERS DESEIN HOUSE, GREATER KAILASH-II NEW DELHI 110 048
NLC INDIA LIMITED INDEX S.NO. DESCRIPITION SHEET NO. 1.00.00 Introduction and Background 1-2 2.00.00 Site Selection and Feasibility Studies 3-4 3.00.00 Project Highlights and Technical Features 4-9 4.00.00 Environmental Aspect 10-13
NLC INDIA LIMITED Sheet - 1 1.00.00 Introduction and Background Electricity is a basic human need and essential requirement for all facet of our life. Power development is one of the key infrastructure elements for the socio-economic growth of the country. The entire Indian Economy hinges on the availability of reliable and quality power at competitive rates to rural India for its overall growth and to Indian Industry to make it globally competitive. NLC India Limited (a NAVRATNA CPSU) is engaged in mining and power generation since its inception and has contributed to the social and economic development of the country for over 5 decades. NLCIL is presently having lignite mining operations in Neyveli (Tamilnadu) and Barsingsar with associated power generation units of 3289 MW capacity. NLCIL is also owning and operating a 2X500 MW coal based station at Tuticorin (in Joint Venture project with TANGEDCO, Tamil Nadu).. NLCIL has the advantage of vast expertise in both mining and power sectors giving it a unique position for setting up of cost effective power projects. In addition to operation of Mine-I, Mine-IA and Mine-II, NLCIL had initiated action for development of Mine-III and 2x500 MW lignite fired thermal power project. Accordingly, NLCIL had appointed M/s Desein Private Limited as a consultant for preparing the Feasibility Report. The proposal for seeking approval of Terms of Reference (TOR) of Environmental Impact Assessment (EIA) study was submitted vide proposal no. IA/TN/THE/53173/2016 to Ministry of Environment & Forests (MOEF). In response, MOEF has informed that as per the Ministry of Power s O.M. dated 13.11.2009, the 13th Plan (01.04.2017 onwards)
NLC INDIA LIMITED Sheet - 2 capacity addition will be through supercritical units only. Hence, necessary action may be taken accordingly. The consultant was accordingly advised to examine the feasibility to revise the project configuration from 2x500 MW to 2x660 MW taking in to account all relevant aspects including availability of basic inputs like land, water & fuel and availability of proven technology & equipment suppliers for lignite based Super Critical Steam Generator units etc. Various rounds of discussions were held with all prospective equipment suppliers to ensure adequate competition in tendering process. The above points have been suitably addressed and hence the present proposal is for implementation of 2x660 MW Lignite based super critical units at Mudanai (Neyveli) in Cuddalore District of Tamil Nadu. It is worthwhile mentioning that the proposed plant would be the first lignite fired 660 MW Supercritical Unit in India. Numerous references of installed units of lignite fired Supercritical plants are found outside the country in Germany, USA, Japan & China as given below: LIGNITE BASED SUPER CRITICAL THERMAL POWER PLANTS IN OPERATION Sl. No. Name of the Plant Country Capacity 1. LIPPENDORF TPS GERMAN 2 X 920 MW 2. BOXBERG TPS GERMAN 1 X 900 MW 3. SCHWARZE TPS GERMAN 2 X 800 MW 4. MEHRUM TPS GERMAN 1 X 660 MW 5. MATSUURA TPS JAPAN 2 X 1000 MW 6. MANL TPS USA 2 X 1100 MW 7. NIEDERAUSSEM GERMAN 1 X 1000 MW 8. NEURATH TPS GERMAN 2 X 1100 MW 9. BAICHENG CHINA 2 X 660 MW 10. HUANENG JIUTAI CHINA 2 X 670 MW
NLC INDIA LIMITED Sheet - 3 2.00.00 Site Selection and Feasibility Studies The present project site near village Mudanai was selected by the site selection team of NLCIL for development of 2x500 MW lignite based project after examining four alternative site based on the following considerations: 1. Availability of suitable & adequate land 2. Availability of reliable source of water 3. Availability of road and railway access 4. Environmental aspects 5. Availability of infrastructural facilities 6. Conformity to Siting Criteria of MOEF The Site Selection Committee Report is placed at Annexure-I. The salient details of alternative sites are briefly elaborated below: Site-I Near Village Kolliruppu The site is on the western side of the village Kolliruppu adjacent to upcoming Neyveli New Thermal Power Project (NNTPP) of NLC India Ltd., and comprises of about 200 acres of land in possession of NLCIL. As the land area is only 200 acres, the site is not considered suitable. Site-II Near Village Mudanai The site is on south west side of Thermal Power Station-II (TPS-II) near village Mudanai and comprises of about 608 acres of land in possession of NLCIL. The site is in close vicinity of Mine-II & III so the lignite could be fed through conveyor system. There is an under-utilized ash dyke of the TPS-II and water reservoir of TPS-II near the site-ii, which could be used
NLC INDIA LIMITED Sheet - 4 for the proposed TPS-II 2 nd expansion project. The plant area and associated facilities could be accommodated within the land in possession of NLCIL. The site elevation is 50m to 57 m MSL. The site is therefore considered suitable. Site-III Near Village Marungur The site is located at a distance of approx. 12 kms. South West of TPS-II. There is no land in possession of NLCIL. The entire land is fertile agricultural land and will pose lot of problem in acquisition. Further, it will require crossing of river Manimutharu for transportation of Lignite through conveyor system. Hence, this site was not considered suitable. Site-IV Near Village Kammapuram The site-iv is located at a distance of 8.5 kms. South of TPS-II and comprises of 1452.98 acres of land for which administrative approval was accorded by Govt. of Tamil Nadu. NLCIL has plan for augmentation of Mine-II from 15 MTPA to 18.75 MTPA. It is learnt that this 1452.98 acres land will be required for additional external dump area. Hence this site is not considered suitable for for TPS-II 2 nd expansion project. 3.00.00 Project Highlights and Technical Features In line with the observations of MOEF and considering the feasibility aspect brought out at 1.0 above, it is proposed to adopt Ultra Supercritical technology. The advantages of supercritical technology are listed below: Higher plant efficiency Less Fuel Consumption
NLC INDIA LIMITED Sheet - 5 Less Infrastructure Investment for Fuel Transport / Storage and Ash Disposal Less Emission (CO2, SOx, NOx, Dust/Ash) Less Auxiliary Power Consumption of plant auxiliaries. Less Water Consumption (No need of continuous blow down in case of once through boiler.) Lower operating costs Greater operating flexibility Location The site is on south west side of Thermal Power Station-II (TPS-II) near village Mudanai and comprises of about 608 acres of land in possession of NLCIL. The nearest airports are at Trichy Airport at a distance of 150 kms. And Chennai airport at a distance of approx. 200 KMs. Nearest railway station at Uthangal Mangalam on Vridhachalam- Cuddalore section is at a distance of 1.5 kms. Land Requirement The plant & associated facilities including green belt, ash disposal and Townships of the project is proposed to be accommodated within the land under possession of NLC India Limited. The overall plant layout is shown in the Plot Plan placed at Annexure-II. Capacity : 2X660 MW - Present proposal Mode of Operation : Base Load Fuel : Lignite from the basket of captive mines comprising of Mines I, IA, II & the proposed Mine-III
NLC INDIA LIMITED Sheet - 6 Lignite Availability and Transportation The daily Lignite requirement for 2x660 MW units shall be about 32280 tonnes. Annual Lignite requirement for the plant shall be around 10 MTPA considering PLF of 85% and the same is proposed to be met from nearby mine blocks of NLCIL. The envisaged mode of Lignite transportation from the proposed mine is by belt/ piped conveyor system as the site chosen is very close to the mine block. Cooling Water Source, Requirement and Commitment Consumptive make-up water requirement of the project shall be 3400 m3/hr with ETP Recovery and 4221 m3/hr without ETP Recovery. Makeup water from the source shall be pumped to an in-plant raw water reservoir having storage capacity of about 10-15 days to take care of emergencies. Presently, Natural Draft Cooling Towers NDCT have been proposed for the project. It is envisaged to adopt Cycle of Concentration in such a way to achieve zero discharge of plant s treated effluents to any water body outside the project area. Steam Generator Technology The Steam Generators (SG) shall be super-critical, once through type, water tube, direct pulverized lignite fired, top supported balanced draft furnace, single reheat, radiant, dry bottom type, suitable for outdoor installation. The gas path arrangement shall be single pass (tower type) or two pass type rated to deliver approx. 2100 t/hr of superheated steam at 270 kg/cm2(a) & temperature of 603±5ºC with feed water temperature of about 305ºC at the economizer inlet. The reheat steam temperature would be of 610±5ºC.
NLC INDIA LIMITED Sheet - 7 The SG would be designed to handle and burn HFO/Light Diesel Oil (LDO) as secondary fuel up to 30% SG MCR (maximum continuous rating) capacity for flame stabilization during low-load operation. For unit light up and warm up purposes, light diesel oil (LDO) would be used with air atomization. Steam Turbine Technology The steam turbine shall be tandem compound, single reheat, regenerative, condensing, multi cylinder design with separate HP, separate IP and separate LP casing(s) OR combined HP-IP and separate LP casing(s), directly coupled with generator suitable for indoor installation. Turbine shall be capable of operating continuously with valves wide open (VWO) to swallow 105% of EMCR steam flow to the turbine at rated main steam and reheat steam parameters. The steam turbine generator shall also be capable of delivering at generator terminals at least 105% of rated output (Guaranteed Output) without any constraints with all the valve wide open, rated steam condition and condenser pressure as optimized by TG supplier targeting lowest heat rate with 0% makeup. Lignite Handling System External Lignite Handling System (ELHS) shall comprise of two (2) identical & parallel streams of around 3000 TPH rated capacity each to deliver Lignite from mines to the power plant site. In view of long distance ( 10.5 km), Pipe Conveyor / Belt Conveyor System may be envisaged for lignite transportation. Possibilities of having lignite crushing facilities and the crushed lignite stockyard at the mine end shall be examined in detail during FR formulation stage.
NLC INDIA LIMITED Sheet - 8 Internal Lignite Handling System (ILHS) consisting of two (2) identical & parallel streams to operate at rated capacity of around 3000 TPH each are envisaged for the proposed Power Plant to cater to the fuel requirements of 2X660MW Units i.e. Unit 1&2. Beneficiary States The project is being set up to supply power to home state of Tamil Nadu & other willing beneficiaries. Project Implementation Schedule Commercial Operation Date (COD) of the first 660 MW units is envisaged in 48 months from the zero date and second unit at an interval of 6 months thereafter. The zero date shall be reckoned as the date of main plant award. Associated Transmission System (ATS) Clearance The power generated from the project will be evacuated through 2 nos. D/C 400 KV transmission lines up to the nearest 400 KV Pooling Substation of Central Transmission Utility i.e. Power Grid Corporation of India Limited (PGCIL). Unit start-up power requirements shall be met by back charging of one of 400 kv transmission line. The present provisions for power evacuation are tentative and shall be reviewed based on the finalized ATS of the project by PGCIL. Commitment from PGCIL shall be obtained for the necessary infrastructure for power evacuation from the proposed generating station, by erecting transmission lines as deemed fit and necessary.
NLC INDIA LIMITED Sheet - 9 Project Financing The overall debt-equity ratio proposed is 70:30. Equity will be financed through internal resources and the debt portion is proposed to be financed from Domestic Commercial Borrowings. Indicative Project Capital Cost The indicative project capital cost of the proposed 2x660 MW project shall be as under: Cost of Project including IDC Cost per MW Rs. 9240 Crores Rs. 7.00 Crores The above estimated cost is of the order cost without any detailed estimation of bill of quantities for the purpose of Pre-Feasibility Report only. However, the detailed cost estimates and financial analysis will be carried out during Detailed Project Feasibility Report stage based on the site specific data. Conclusion On analysis of all aspect involved for the development of the project, it is concluded that: It is technically feasible to establish 2x660 MW units based on Supercritical Technology at the site identified for the project considering the availability of infrastructural facilities subject to tying up of basic inputs and obtaining the statutory & non statutory clearance of the concerned authorities.
NLC INDIA LIMITED Sheet - 10 4.00.00 Environmental Aspect A Draft Environmental Impact Assessment report for this project will be prepared based on the TOR prescribed by MOEF. Tamil Nadu State Pollution Control Board will then be approached for conducting Public Consultation. Thereafter, the EIA report will be finalized incorporating public hearing minutes & action plan for its submission to Ministry of Environment & Forests (MOEF) for obtaining Environmental Clearance (EC), in accordance with the procedure laid down in the MOEF Notification dated 14th September 2006 and its further amendment dated 01st December 2009. All relevant notifications in respect of environmental protection measures/ guidelines including the December 2015 notification shall be fully complied. Air Pollution Control System High efficiency electrostatic precipitators (ESPs) will be installed to limit the particulate emission to 30 mg/nm3 to facilitate wider dispersion of particulate and gaseous pollutants. A twin flue chimney of appropriate height will be provided for wider dispersion of pollutants. On-line equipment will be provided for monitoring of stack emissions. To control NOx emission, supercritical boilers having advanced low NOx generation system will be installed. In addition, Selective Catalytic Reduction (SCR) system will be installed to limit the NOx emission as per latest environmental guidelines. FGD system will be installed in flue gas duct to the chimney as per latest environmental stipulation. The design and layout of steam generator and its auxiliaries will take into account wet flue gas desulphurisation (FGD) system to be installed taking suction from duct after ID fan and feeding the
NLC INDIA LIMITED Sheet - 11 desulphurised flue gases back to the chimney with provision for bypassing the FGD system. For control of fugitive dust emissions within and around coal handling plant, dust extraction/ suppression systems would be provided. Dust suppression system shall also be provided in the coal stock yard. Noise Pollution Control Systems The major noise generating sources in a thermal power plant are the turbines, turbo-generators, 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). Wherever required, the workers shall be provided with protective equipment such as ear plugs and ear muffs. Solid Waste Management Systems Ash will be the major solid waste generated from the power project. An ash management scheme shall be implemented consisting of dry collection of ash, supply of ash to entrepreneurs for utilization and promoting ash utilization to maximum extent and safe disposal of unused ash. Ash utilization. The proposed expansion project is based on lignite as fuel, which contains low ash (approximately 5 to 8%) and hence the ash disposal burden is quite less compared to a coal fired power station. Moreover Neyveli is located in southern region surrounded by many cement industries and there are many cottage industries who manufacture fly ash bricks, window/ door frames, paver blocks using the ash. In fact 100% ash utilization is achieved in the existing stations of NLCIL. Hence Emergency
NLC INDIA LIMITED Sheet - 12 Ash Dyke of 125 Acres developed for TPS II is envisaged to be used for this expansion project. Water Pollution Control System An effluent management scheme, consisting of collection, treatment, recirculation and disposal of effluents shall be implemented in order to optimize the makeup water requirement as well as liquid effluent generation. The liquid effluents shall be collected and treated/ recycled as per the following design philosophy: The sludge from clarifiers of water PT Plant shall be collected in a sump/ pit and shall be treated in order to extract most of the water from the sludge for reuse & solid particles in the form of semi-solid shall be dispose of suitably either for land fill or in the bottom ash dyke. The waste effluents from neutralization pits of DM plant and condensate polishing plant shall be collected in the common neutralization pits and neutralized before pumping to dispose of in bottom ash dyke along with bottom ash slurry. Similarly service water waste from different parts of the power plant such as ESP, BTG area etc. shall be dispose of in bottom ash dyke along with bottom ash slurry. Oily waste from the power plant shall be collected & treated in oil water separator in order to separate oil. Clear water shall also be dispose of in bottom ash dyke along with bottom ash slurry. Re- circulating type cooling water (C.W) system with cooling towers, with C.W. blow down from cold water side to ensure no thermal pollution. The blow down shall be led to central monitoring
NLC INDIA LIMITED Sheet - 13 basin after treating through clarifiers/ tube settlers, filters, UF filters & RO, the RO permeate shall be reuse in CW make up. The sludge from clarifiers/ tube settlers, & RO reject shall be disposed of in bottom ash dyke along with bottom ash slurry. Lignite particle settling pond shall be provided to remove lignite particles from lignite handling plant waste. Decanted water shall be pumped back to the lignite dust suppression system An independent plant effluent drainage system would be constructed to ensure that plant effluents do not mix with storm water drainage. Efficient operation of various treatment schemes shall be ensured so that the quality of treated effluent from CMB conforms to relevant standards, prescribes by regulatory agencies. The sewage from plant and township shall be treated in a sewage treatment plant. The treated sewage conforming to prescribed standards shall be utilized for plantation to the extent possible. Description of the Environment In order to identify the environmental impacts due to the construction and operation the project and associated facilities, an EIA study is proposed to be undertaken to establish baseline environmental status for various environmental attributes within the study area. The major environmental disciplines to be covered in the EIA report includes ambient air quality, water quality, noise, soil, ecology (terrestrial and aquatic), land use, geology, hydrology and demographic & socio-economic conditions.
NLC INDIA LIMITED Sheet - 14 Annexure 1
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NLC INDIA LIMITED Sheet - 19 1 KOLLIRUPPU 2.MUDANAI 4.KAMMAPURAM 3.MARUNGUR
NLC INDIA LIMITED Sheet - 20 Annexure 2