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Annexure 1 BCEL-Ketnamallee

List of Annexure Annexure I Location Map Annexure II Plant Layout Annexure III Process Description Annexure IV Treatment / disposal of solid waste & liquid effluents Annexure V Water Balance Diagram Annexure VI Ground Water Clearance Annexure VII Stack Emission Characteristics Annexure VIII Fugitive Emissions – Material Handling & Storage Annexure IX Ambient Noise Levels


Annexure I

Location Map


Annexure II

Plant Layout


Annexure III

Process Description


Process Description – 5 MW Boiler Bhatia Group has established a Coke Oven Plant at Ketnamalli Village,

Gummidipoondi Taluk, Thiruvallur District in Tamil Nadu with a Capacity of 3.36

lac tonnes per annum. The plant enjoys a strategic location, being in close proximity

to the bustling Ennore Port on one side and consumers, the company’s end product

has found favour with nearly all the blue chip steel manufacturing units, various

consumer industries, foundries, and other industries in Southern India.

The plant comprises of running 4 Coke Oven battery of 157 (73 + 84) ovens. The

batteries are at tandem and the hot gas outlet is connected to 50 M Steel chimney /

50 M refractory brick chimney, with a damper and duct arrangement for gas

extraction for Boiler. Coking Coal is imported from various sources and the product

is marketed locally. Each battery of coke oven unit generates exhaust gas of about

48000 cu. m per hour at 900 deg. C in each.

Through futuristic technology, BCEL Group utilize is waste heat from the coke oven

plant to generate power.


Existing Process flow Diagram:

Proposed Process Flow Diagram:

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Plant System Description:- At present the Power generations in the 24 MW Power plant is 18 MW – 19 MW only

due to reduction in availability of Coke Oven gas from the coke oven batteries.

Hence the management has decided to add an additional steam generation facility

by installing ~ 25 TPH CFBC boilers to meet the 100% power generation in 12 MW

power plant. However 25 TPH CFBC boilers shall be integrated with the 2 x 12 MW

under operation. So that even during shutdown of any boiler, the steam shall be

available for power generation.

Thus BCEL intends to set up an additional 25 THP boiler in their existing plant in

Gummidipoondi, Tamil Nadu. The BCEL has installed the power plant of 2 x 12 MW

capacities is intended to always provide a constant power for export to TNEB Grid,

after consuming the auxiliary power requirement for the coke oven plant and power

plant auxiliaries.

Present Plant Capacity at BCEL: Unit - 1 No. of WHRB`s Installed : 02 Nos. Steam Generation capacity : 20 x 2 TPH per boiler No. of Turbine : 01 No. Commissioned Plant Capacity : 12.0 MW Present steam generation : 37.5 TPH Present power generation : 8.0 MW Gap in power generation : 4 MW. (Normal Condition) Unit – 2 The unit -2 power plant. No. of WHRB`s Installed : 02 Nos. Steam Generation capacity : 47.5 TPH No. of Turbine : 01 No. Commissioned Plant Capacity : 12.0 MW Present Power Generation : 10.0 MW Gap in Power Generation : 2 MW


Fuel Source and Consumption for 25 TPH Boiler

Type of Fuel 100% Imported Coal

GCV of Imported 4000 Kcal/Kg

Fuel Consumption for Boiler @ Imported Coal

5.42 TPH 130 TPD

Fuel Consumption at 100% PLF 0.04745 MTPA

Fuel Consumption at 85% PLF 0.04033 MTPA

Coal Storage days at site 7 days

Support Fuel & Source Light Diesel Oil (LDO) from nearest Oil Depot

Ash Generation

Type of Fuel 100% Imported Coal

Ash Qty in Primary Fuel 7.1%

Ash Generation 9.23 TPD

Plant Equipment Boiler & Auxiliaries

Boiler Circulating Fluidized Bed Combustion (CFBC)

Type Natural Circulation, Single Drum, Semi Outdoor Type Unit Designed for firing 100% Imported Coal / Coke Fines.

Steam Parameters Boiler Flow - 25 TPH Pressure - 71 kg/cm² Temperature - 490 ± 5°C

Fuel Handling System

Type of Fuel Imported Coal / Coke Fines

Design Capacity 30 TPH for 6 hours operation with bucket elevator

Ash Handling System

Bottom Ash Manually disposal system through trucks

Fly Ash Dense Phase Pneumatic Conveying System


Chimney

No. & Type of Chimney One (01) & RCC

Height of Chimney 60 meters

Electrostatic Precipitators (ESP) Steam generating unit shall be installed with one (1) electrostatic precipitator.

Electrostatic Precipitator will have minimum Two (02) fields in series for collection

of fly ash. The ESP will have a collection efficiency of around 99.91%. The outlet dust

concentration will be limited to 50 mg/Nm3 as per the latest regulation of Central

Pollution Control Board. ESP will be provided with suitable capacity for storing ash

collected in at least one (1) shift operation of the Boiler at 100% MCR.

Electrostatic Precipitator (Typical)

Flue gas temp. at ESP inlet 140°C

Flue gas temp. at ESP outlet 138°C

Outlet dust concentration at outlet of ESP 50 MG/Nm³ (max.)

Efficiency 99.91% approx.

Number of Precipitator One

Number of gas paths Single (01) stream

No. of Fields Two (02)

The coal to be fired in the boiler has Sulphur content of 1%. The minimum chimney height from the point of view of SO2 emission, as per CPCB standard, works out to about 60 meters. Particulate emission from the plant will be controlled within 50 mg/Nm³ by the use of electrostatic precipitators having the efficiency of the order of 99.91% and more. There will be no significant heat pollution of atmosphere as the hot flue gases, at outlet temperature of ESP is about 140 Deg. C, will be released at a sufficient height through the chimney and will be dispersed with the prevailing winds at that height. Existing Demineralized plant can be utilized for proposed 25 TPH CFBC boiler make-up. The quantity of boiler blow down very less, hence Liquid wastes from boiler area will be connected with existing neutralizing pit. Regeneration effluents will be treated by acid/alkali to meet CPCB standards for effluent discharge.


As far as coal dust suppression is concerned, water spraying arrangement will provided at suitable locations such as crusher house, loading & unloading facilities. In addition, water sprinklers will be provided in coal storage area to suppress the coal dust emission. The blowing of dry ash in the process of ash removal, particularly during the dry season, also represents a pollution hazard. Adequate dust suppression measures will be employed in the silo zone where the dry ash is proposed to be stored before dispatch. Ministry of Environment and Forests has stipulated that new power plants should develop ash utilization plan to use fly ash progressively. It is proposed to design fly ash collection system in dry form in silos for disposal. The dry ash is proposed to be mainly utilized to cement plants for the manufacture of Pozzolona cement or other construction material. It is planned to dispose the generated ash from power plant to cement plant, which is located at near to the proposed plant. Adequate acoustic measures will be provided in the plant so as to keep the noise levels below the acceptable values. Other provisions for pollution on line monitoring and control to ensure compliance with the requirements of the Tamil Nadu State Pollution Control Board will be made.


Annexure IV

Treatment / Disposal of Solid Waste & Liquid Effluents


Solid Wastes A small quantity of solid waste generated at present is coke breeze, about 10560 TPA which will be used in the Steel industries. Ash From proposed 5 MW coal fired power plant about 9.23 TPD total ash will be generated. Out of which 7.38 TPD of Fly ash and about 1.82 TPD of Bottom ash. Fly ash will be handled by Dense Phase Pneumatic Conveying System and disposed to the Cement Manufacturers & asbestos sheet manufactures . Bottom ash will be handled Manual disposal system through trucks and stored in Ash dykes. Waste water generated Description of effluent generated Qty (KLD) Industrial (Blow down) 42.00 Sewage 18.00 Total 60.00 The cooling water blow down is again recycled for Quenching & hence there is no discharge of effluent. The sewage is treated in 20 KLD Capacity Sewage Treatment Plant (STP), the treated sewage is used for greenbelt development within the plant premises. Sludge from STP will be used as manure for greenbelt within the plant premises.


Annexure V

Water Balance Diagram


Water Balance Diagram All values are in KLD

Proposed

Exiting

Raw

Water

Coke Quenching

WHRB Boiler

Make –up

Auxiliary cooling

Domestic

Consumption

Cooling pond/

settling tank

208

Cooling pond II

Proposed

Guard Pond

42

STP

Green Belt

86

10

20

28

3

16

363

Bore well

250

42

D.M. Plant Regeneration

5 5 D.M. Plant Regeneration

25 TPH Boiler Make-up

18 Boiler Blow down 6

Evaporation Loss

12

14

Greenbelt 210


Annexure VI

Ground Water Clearance


Annexure VII

Stack Emission Characteristics


Stack Emission Characteristics Bhatia International Limited

Stack No 1 2 3 4

Material of Construction Refractory Bricks

Refractory Bricks

MS MS

Stack attached to Coke Oven Battery I

Coke Oven Battery II

WHRB 1 & 2

D.G. Set 320 KVA

Stack height Above the ground level, in m

40.0 40.0 50.0 9.5

Stack top Round or Circular

Circular Circular Circular Circular

Inside dimensions of the stack at top, mm

3000 3000 1300 150

Gas quantity – m3/hr 48000 48000 96000 2000

Flue gas temperature, oC 925 925 170 300

Exit velocity of the gas, m/s 2.51 2.51 20.1 30.86

Emission concentration, mg/m3

SO2 --- --- --- 52

NOx 1.0 1.0 --- 15

SPM 18.2 18.2 18.2 73

Emission rate, g/s

SO2 --- -- --- 0.0289

NOx 0.00084 0.00084 --- 0.0083

SPM 0.0153 0.0153 0.647 0.0406


Bhatia Coke and Energy Limited

Stack No 5 6 7 8*

Material of Construction Refractory Bricks

Refractory Bricks

MS RCC

Stack attached to Coke Oven Battery III &

WHRB 3

Coke Oven Battery IV &

WHRB 4

D.G. Set 500 KVA

Boiler (25 TPH)

Stack height Above the ground level, in m

50.0 50.0 9.5 60.0

Stack top Round or Circular

Circular Circular Circular Circular

Inside dimensions of the stack at top, mm

3000 3000 150 1200

Gas quantity – m3/hr 48000 48000 2000 89500

Flue gas temperature, oC 925 925 300 140

Exit velocity of the gas, m/s

2.51 2.51 30.86 22.0

Emission concentration,

mg/m3

SO2 --- --- 52 245.77

NOx 1.0 1.0 15 553.10

SPM 18.2 18.2 73 0.006

Emission rate, g/s

SO2 --- -- 0.0289 6.11

NOx 0.00084 0.00084 0.0083 13.75

SPM 0.0153 0.0153 0.0406 0.00015

*Proposed


Annexure VIII

Fugitive Emissions – Material Handling & Storage


Coal Handling & Preparation Truck loading hopper/Manual unloading hopper will be provided with dust suppression system to avoid nuisance of coal dust. Bagfilters system is provided in the crusher (Impactor) house. Settling pond to collect all the waste water from various units and stock pile through 150 mm dia outlet drains have been provided. The removal of sludge will have through monorail mounted grab bucket operated electrically, locally. This coal fine sludge is reclaimed to the coal stream. The belt conveyor system envisages Belt conveyor on closed gallery type system with continuous hooding device along the length of belt conveyor. This eliminates pollution to atmosphere besides causing any spillage in turn causing any loss. Further,

• Coal stock yard will be provided with water sprinkler • Coal conveyed in closed gantry conveyor from stock yard to Boiler House • Coal Crusher / Pulverisor carried out in closed conveyor • Fly Ash pneumatically conveyed to ash silo • From silo Fly Ash unloaded in closed trucks to Cement Factories / Asbestos

Cement Sheet Manufacturing Companies • Bottom ash stored in dyke with water column


Annexure IX

Ambient Noise Levels


Ambient Noise Levels Location Noise Level – dB(A)

Leq Min Max

At Entrance Gate 58.2 41.6 62.5

Near Eastern Boundary of unit 47.2 41.6 58.3

Near Coal Crusher House 49.7 41.6 60.9

Near Security watch tower 54.7 41.6 74.3

Adjacent to staff quarters 52.7 44.1 78.4

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