note on due to use of pet coke in addition to...

NOTE ONENVIRONMENTAL IMPACTS

DUE TO USE OF PET COKE IN ADDITION TO COALIN

KILN OF CEMENT PLANT AND BOILERS OF CAPTIVEPOWER PLANTS

FORAMENDMENT IN ENVIRONMENTAL CLEARANCE

(EC Granted : MoEF letter no. J- 11011/166/2009-IA II (I) dated 14-07-2009

Submitted under Clause 7(ii)

AT

Chanda Cement WorksPlot No.1, Ghugus Industrial area (MIDC),Chandrapur Taluka and District, Maharashtra

Prepared By

< B.S. ENVI-TECH (P) LTD.

SECUNDERABAD-500017

TABLE OF CONTENTS

Para No. Title1.0 Introduction2.0 Present Proposal3.0 Need For Use of Pet Coke4.0 Environmental Benefits of Usage of Pet Coke5.0 Project Cost6.0 Project Description6.1 Cement Plant6.2 Captive Power Plant7.0 Fuel-Requirement, Quality Availability & Transportation8.0 Environmental Impacts8.1 Air Environment8.2 Solid Waste Generation9.0 Conclusion

LIST OF FIGURES

Fig – 1 Predicted ground level concentration of PM10 due to use of petcoke in kiln of cement plant and boiler of captive power plant

Fig – 2 Predicted ground level concentration of SO2 due to use of petcoke in kiln of cement plant and boiler of captive power plant

Fig – 3 Predicted ground level concentration of NOx due to use of petcoke in kiln of cement plant and boiler of captive power plant

LIST OF TABLESTable – 1 50 High 24-hourly average ground level concentrations of PM10

Table – 2 50 High 24-hourly average ground level concentrations of SO2

Table – 3 50 High 24-hourly average ground level concentrations of NOx

1.0 INTRODUCTION

ACC Ltd is operating Chanda Cement Works (CCW)at ChandaCement WorksPlot No.1, Ghugus Industrial area (MIDC), ChandrapurTaluka and District, Maharashtra. ACC Ltd have been grantedEnvironmental Clearance (EC) vide Ministry of Environment&Forest(MoEF) vide Letter No.J-11011/166/2009-IA II(I) dated 14thJuly, 2009

ProductionDetails

ExistingCapacity ofthe Plant

EC granted forExpansioncapacity of theplant

Capacity of theplant afterExpansion

Cement, MTPA 0.90 2.46 3.8Cement Clinker,MTPA(IntermediateProduct)

0.864 2.0 2.318

Captive PowerPlant, MW

15 40 40

ACC-CCW obtained all statutory approvals from the State PollutionControl Board and the plant is in operation with the followingcapacity.

a. Cement Plant – 3.8 MTPAb. Clinker – 2.318 MTPAc. Captive Power Plant– 40 MW (15+25 MW)

2.0 PRESENT PROPOSAL

ACC proposes to use Petcoke in addition to coal in the Kiln of cementplant and boilers of Power plant due to inadequate coal supply.Present proposal is for obtaining Amendment in EnvironmentalClearance from MoEF&CC for use of Petcoke as much as possible inaddition to Coal in cement plant and captive power plant.

A comparison of the statement showing the key parameters for ECgranted and EC amendments sought is given below

S.No.

Particulars ExistingEnvironmentalClearance (EC)

Proposed ECAmendment

Remarks

CEMENT PLANT1 Capacity of

Kiln2.31MTPA 2.31MTPA No Change

CementCapacity

3.8 MTPA 3.8 MTPA No Change

2 Fuel Coal Petcokein addition tocoal as muchas possible

Use of pet cokein addition tocoal

3 Heat Input 100 % by coal 100 % byPetcokeOr100 % by coalOrCombinationof Petcokeand Coal

Use of Petcokein addition tocoal

4 Quantity ofFuel, TPD*

Coal –1300 Pet coke –569TPD (max)OrCoal – 1300TPD (max)

Petcoke or Coalwill be used inany appropriateproportion

5 Net Calorificvalue of fuel(Kcal/ Kg offuel)

3500 (coal) 3500 (coal)or8000 (PetCoke)

-

6 Sulphurcontent infuel (%)

0.40 max. (Coal) 0.40 max.(Coal)or6.0 % max.(Pet Coke)

-

7 Max. PM in stack flue gasesa) Kg/Hr Coal – 34.20 Pet coke -

20.52 orCoal -20.52

-

b) Mg/Nm3 50 30 Complying withnew emissionstandard whileusage ofPetcoke, Coal.Overall decreasein dust emissionload.

S.No.



Remarks

8. Max. SO2 in stack flue gasesa) Kg/Hr Coal – 855.72 Pet coke –

855.72orCoal -855.72

-

b) Mg/Nm3 750 750(Permitted1000)

Complying withnew emissionstandard whileusage ofPetcoke, Coal.

9. Max. NOx in stack flue gases

a) Kg/Hr Coal – 938.88 Pet coke -912.6orCoal -912.6

-

b) Mg/Nm3 823 800 Complying withnew emissionstandard whileusage ofPetcoke, Coal.

CAPTIVE POWER PLANT – 15 MW AFBC1 Capacity of

Power plant15 MW 15 MW No Change

2 Number ofBoilers

2 2 No Change

3 Type ofboiler

AtmosphericFluidised BedCombustion(AFBC)

AFBC No Change

4 Number ofSteamTurbines

1 1 No Change

5 Heat Input 100 % by coal Fuel Mix(53% by Coal+ 47 % bypetcoke)

Or100 % by coal

Use of Petcoke

6 Fuelrequirement(tones perday)*

Coal –304 (max) Fuel Mix(156 - Coal +60 Petcoke)Or

Use of Petcokeand there will bereduction in theoverall fuel mix

S.No.



Remarks

304 - Coal quantity due tousage of highcalorific valuepetcoke.



-


0.40 % max.(Coal)

0.40 %max.(Coal)or6.0 % max.(Pet Coke)

-

9. Max. PM in stack flue gasesa) Kg/Hr Coal – 6.05 Fuel Mix –

6.05orCoal -6.05

No Change

b) Mg/Nm3 50 50 No Change10. Max. SO2 in stack flue gases

a) Kg/Hr Coal – 101.2 Fuel Mix –72.58 after75 % SO2capture bylimestoneinjectionor72.58 - Coalafter 28.0%SO2 captureby limestoneinjection

-

b) Mg/Nm3 835 <600 Complying withnew emissionstandard whileusage ofPetcoke, Coal.

c) LimestoneInjection,TPD

- @ fuel mixfiring –26.54or@ Coal firing– 1.88

Limestoneinjection forcontrol of SO2emissionscomplying withnew emissionnorms

11. Max. NOx in stack flue gases

S.No.



Remarks

Kg/Hr Coal – 60.5 Fuel Mix -36.36orCoal -36.36

Reduction in theemission level

Mg/Nm3 500 300 Complying withnew standard

12. Ash GenerationTotal Ash 121.6 26.22 with fuel

mixOr123.2 with coal

Includes ashgenerated fromlime injection

Fly Ashgeneration(tpd)

97.28 2.10 with fuelmix (29 % ashin fuel mix)Or97.28 withCoal

100% fly ashwill be used incementmanufacturingprocess

Bottom Ashgeneration(tpd)

24.32 24.12 (0.50from fuel mixfiring and23.62bottom ashdue tolimestoneinjection)or25.98(24.32 fromcoal firingand 1.66bottom ashdue tolimestoneinjection)

100% bottomash will bereused as rawmix ingredientin cementmanufacturingprocess

13. Boiler stackheight (M)

80 M 80 M No Change.Stack heightrequirement is50.62 m as perCPCB norm.However thesame stackheights of 80mwill bemaintained

S.No.



Remarks

14. ParticulateMatteremission(mg/Nm3)

<50 <50 No Change

High efficiencyESP (2nos)provided

CAPTIVE POWER PLANT – 25 MW CFBC1 Capacity of

Power plant25 MW 25 MW No Change

2 Number ofBoilers

1 1 No Change

3 Type ofboiler

CirculatingFluidised BedCombustion(CFBC)

CFBC No Change

4 Number ofSteamTurbines

1 1 No Change

5 Heat Input 100 % by coal 100 % bypetcokeOr100 % by coalorCombinationof petcoke &coal

Use of Petcoke

6 Fuelrequirement(tones perday)*

Coal – 504 (max) 221.28PetcokeOr504 - Coal

Use of Petcokeand there will bereduction in theoverall fuel mixquantity due tousage of highcalorific valuepetcoke.



-


0.40 % max.(Coal)

0.40 % max.(Coal)or6.0 % max.(Pet Coke)

-

9. Max. PM in stack flue gasesa) Kg/Hr Coal – 6.55 Fuel Mix –

6.55No Change

S.No.



Remarks

orCoal -6.55

b) Mg/Nm3 50 50 No Change10. Max. SO2 in stack flue gasesa) Kg/Hr Coal – 167.94 Fuel Mix –

78.62 after95 % SO2

capture bylimestoneinjectionor78.62 kg/hr% - Coal after53.2 % SO2capture bylimestoneinjection

-

b) Mg/Nm3 762 <600 Complying withnew emissionstandard whileusage ofPetcoke, Coal.

c) LimestoneInjection,TPD

- @ 100 %Petcoke firing– 98.36or@ Coal firing– 8.27

Limestoneinjection forcontrol of SO2emissionscomplying withnew emissionnorms

11. Max. NOx in stack flue gasesKg/Hr Coal – 39.38 100 %

petcoke firing- 39.38orCoal -39.38

Mg/Nm3 500 300 Complying withnew standard

12. AshGeneration

202 89.75– withpet cokefiringor209.36 – withcoal firing

Fly Ash 131.3 58.66– with 100% fly ash

S.No.



Remarks

generation(tpd)

pet coke firing(1.76 frompetcoke firingand 56.90 dueto limestoneinjection

or136.08 – withcoal firing(131.30 fromcoal firingand 4.78 dueto limestoneinjection

will be used incementmanufacturingprocess

Bottom Ashgeneration(tpd)

70.7 31.08(0.442frompetcoke firingand 30.63bottom ashdue tolimestoneinjectionOr73.28(70.70 fromcoal firingand 2.58bottom ashdue tolimestoneinjection)

100% bottomash will bereused as rawmix ingredientin cementmanufacturingprocess

13. Boiler stackheight (M)

115 115 No Change.Stack heightrequirement is51.85 m as perCPCB norm.However thesame stackheight of 115mwill bemaintained

14. ParticulateMatteremission

<50 <50 No Change

High efficiency

S.No.



Remarks

(mg/Nm3) ESP (2 nos)provided

* Fuel quantity may vary depending upon the calorific value of fuel.

Overall Emissions Due To Use Of 100% Pet coke, biomass in addition to Coal In Kiln OfCement Plant And Boiler Of Captive Power PlantsS.No

Parameter

Existing EnvironmentalClearance (EC)

Proposed EC Amendment Remark

Kiln 15MW(AFBC)

25MW(CFBC

Total Kiln 15MW(AFBC)

25MW(CFBC

Total

1 AirEmissions, Kg/hr

ParticulateMatter

34.20

6.05

6.55

46.8

20.52

6.05

6.55

33.12

decreaseInoverallemissions

SulphurDioxide

855.72

101.20

167.94 1124.8

6

855.72

72.58

78.62 1006.9

2Oxides ofNitrogen

938.88

60.59

39.38 1038.8

5

912.60

36.36

39.38

988.34Kiln 15

MW(AFBC)

25MW(CFBC

Cumulative

Kiln 15MW(AFBC)

25MW(CFBC

Cumulative

2 GroundLevelConcentrations(µg/m3)

ParticulateMatter

0.74

0.61

0.42

1.50 0.44

0.61

0.42

1.27 decreaseingroundlevelconcentrations

SulphurDioxide

18.5

10.3

10.8

34.018.

57.3

65.0

6

27.6

Oxides ofNitrogen

20.3

6.14

2.53

26.619.

73.6

92.5

3

24.3

Note : decrease increase*Sulphur Dioxide Control By limestone stone injection in boiler

3.0 NEED FOR USE OF PET COKE

Due to uncertainty in the availability of coal linkage and rising pricesof imported coal, it is proposed to use petcoke as much as possible inaddition to coal depending upon its availability for which approvalfrom MoEF&CC is being sought. The proposed fuel, i.e. Pet Coke iswaste from the refinery, readily available in Indian market. For the

above Kiln/CPP, the conversion to pet coke as an alternative fuel isenvisaged due to the following reasons:

1) Petroleum coke (Pet coke) is a carbonaceous solid derived from oilrefinery coke units or other cracking processes. The chemicalcomposition of petroleum coke is mostly elementary Carbon (usuallyover the 85% C dry with sulphur content of about 8.5 % (max)) withhigh heating value and very little ash content (usually less than 1-2%).

2) Compared to other low ash coals, pet coke has advantage in terms ofbed material inventory. In spite of having low ash content, the bedmaterial requirement is minimum, since limestone and its reactedproducts (gypsum) act as the bed material.

3) Use of Pet Coke in cement Kiln will facilitate use of sub-gradelimestone to the optimum extent resulting in production of highquality clinker .

4.0 ENVIRONMENTAL BENEFITS OF USAGE OF PETCOKE

CEMENT PLANT

Use of Petcoke in the cement industry results in variousenvironmental benefits listed below

Petcoke is a refinery waste which is having a high calorific value.Usage of Petcoke at CCW provides waste disposal solution to therefinery thereby helps conserving virgin natural resources.

In case of 100 % availability & usage of Petcoke there will bereduction of approx. 0.1 to 0.5 % of gypsum usage which willresults in resources conservation.

Low particulate matter and fugitive emission as the ash content inPetcoke is negligible.

There will not be any change in Sulphur-di-oxide (SO2) emissionsfrom kiln as limestone is the main component of the kiln feed andsulphur in the fuel (Petcoke) gets absorbed in the process.

CAPTIVE POWER PLANT

The pet coke based captive power plant will ensure supply of power ata competitive cost, providing greater flexibility and viability to the ACCManufacturing operations in an environmentally responsive manner.

The project will result in following environmental and economicbenefits:

1) Generation of power at a competitive cost compared to power generatedby using imported coal.

2) Utilization of industrial waste thus resulting in fossil fuel conservation.3) Limestone injection in Boiler will greatly minimize SO2 emission from the

stack (>95 % reduction and to meet new environmental norms of <600mg/Nm3).

4) Solid wastes viz. Fly Ash and Bottom Ash generated from the CPP will bereused/ recycled in the cement plant located within the premises.

5.0 PROJECT COST

No additional project cost is involved.

6.0 PROJECT DESCRIPTION:

Cement Manufacturing unit of Chanda Cement Works is a fullyintegrated cement plant supported with captive power plant andcaptive mining of limestone.

Fuel is used in the following areas of cement plant complex

a. Kiln of Cement Plantb. Boilers of Captive Power plant

Presently fuel used is coal for which all clearances were obtained. Dueto non availability of coal, it is now proposed to use pet coke as a fuelfor Kiln and CPP. The pet coke is proposed to be brought to site byrail/ road. In case of road transport, pet coke will be brought in highcapacity covered trucks to avoid spillage.

Pet coke requirement for the project (Kiln and CPP) will be about0.345 million TPA. It is proposed to inject limestone into the boiler to

control SO2 emission. The limestone requirement is about 0.06 millionTPA.

6.1 CEMENT PLANT

CCW proposes to use pet coke due to uncertainty in the availability aswell as rising prices of coal/imported coal. Use of pet coke inInLinecalciners (ILC) is viable as the kiln is already equipped withInLineCalciner (ILC). In-line calciners generally have lower NOxemissions than separate-line calciners (SLC), since all of the kilnexhaust gases must pass through the calciner. In an ILC, the fuel isinjected into the kiln riser below where the tertiary air enters at thebase of the calciner. This so-called reduction zone, designed for aparticular gas retention time, has an oxygen deficient atmosphere thatpromotes NOx reduction.

The process of clinker production in kiln systems creates favourableconditions for use of pet coke due to high temperatures, longresidence times, an oxidising atmosphere, alkaline environment, ashretention in clinker, and high thermal inertia which ensure that thefuel’s organic part is destroyed and the inorganic part, includingheavy metals is trapped and combined in the product.

No additional machinery is required for firing of Petcoke in kiln. Noadditional pollution control equipment will be required for control ofParticulate matter, SO2 and NOx.

6.2 CAPTIVE POWER PLANT

To increase the thermal efficiency, a pre-heater for the fluidizing airand combustion air, and a boiler feed water heater, are installed SO2

emission is reduced by injection of limestone in the combustionchamber.

Limestone Feed and Control Mechanism

Sulphur capture in boiler happens by injecting Limestone along withfuel. The fuel and Lime mixture enters into combustion chamberthrough multiple feed points located in furnace front close to thebottom primary zone. Limestone undergoes decomposition by takingheat from the hot bed material (endothermic) and converts into

Calcium Oxide (CaO).This process is called Calcination. The calcinedLimestone being porous in nature gets entrained in flue gas andenters the top section of furnace where the mixture of Oxygen andSulphur Dioxide reacts with Calcium Oxide and converts into CalciumSulfate (CaSO4).This Process is called Sulfation. This process is anexothermic reaction. Thus, the Limestone converts gaseous SO2

emission to solid Calcium Sulfate and gets removed from the system.Attributing higher particle residence time and recirculation, theSulphur capture efficiency in boilers can be achieved to almost 80 %in AFBC boiler and 95 % in CFBC boiler. The amount of limestonethat is required for a given amount of fuel depends on the sulphurcontent of fuel mix i.e coal/petcoke/coal+petcoke. An increase insulphur dioxide emissions will necessitate an increase in the amountof limestone that is required for a given fuel flow to the furnace. Thelimestone demand is a function of the main fuel flow. An increase infuel flow demand will result in a corresponding increase in thelimestone demand to provide the demand signal to the LimestoneVariable Rotary Feeder.

7.0 FUEL-REQUIREMENT, QUALITY AVAILABILITY &TRANSPORTATION:

It is envisaged that pet coke required for the project will betransported through rail/ road. During road transport pet coke will bebrought in closed trucks. Limestone available inside the plant will beused.

PET COKE QUANTITY:

Considering pet coke with gross calorific value (GCV) of 8000 kCal/kgand plant load factor of 100%, the annual pet coke requirement forCPP works out to be about 0.137 Million Tonnes and 0.207 millionTonnes for Cement Plant.

FUEL QUALITY (PET COKE):

Pet coke for the project will be available either from Indianrefineries/imported. During road transport, pet coke will be broughtin high capacity covered trucks. The proximate and ultimate analysisof pet coke to be used for the captive power plant& Kiln, are asfollows:

Heating ValuesCalorific Value 8000 kcal/kgUltimate Analysis (weight %)Moisture 4.50Ash 0.84Carbon 79.00Hydrogen 3.21Nitrogen 1.37Sulphur 6.00Oxygen 1.69Proximate Analysis (weight %)Moisture 4.5Ash 0.84Volatile Matter 10.60Fixed Carbon 80.30Source :ACC Ltd

Because of the extremely low ash (<1%) and high sulphur content ofpet coke (6.0%), limestone is used in the majority of bed materials ofthe fluidized boilers using pet coke. Limestone sizing is critical notonly for efficient sulphurcapture but also for effective fluidization andfuel mixing thereby uniform temperatures and heat transfer isattained. Limestone will be sourced from the captive mine situatedadjacent to the cement plant. Limestone of approx. 45% CaO contentwill be used for CPP for desulphurization.

PET COKE HANDLING PLANT:

The pet coke handling will be done in the same system designed forcoal.

8.0 ENVIRONMENTAL IMPACTS

Environmental impacts due to use of pet coke in the Cement plantand power plant has been worked out and presented below undereach environmental component.

There will be no change in water and wastewater components of theplant due to use of Pet coke

8.1AIR ENVIRONMENT

The emission details along with emission parameters for Coal andPetcokeare given below.

EMISSION DETAILS (EC OBTAINED)Location Height Temp- Dia- Velocity

of fluegas

Flow ratem3/hr

Emissions fromstacks (gm/sec)

(Max.)

M OC M M/sec PM SO2 NOxCEMENT PLANT

*RawMill/Kiln-

1

114 140 4.75 24 15813009.50 237.70 260.80

CAPTIVE POWER PLANT+CPPBoilerstack-1 –15 MW 80

140 2.6 9.0 168000

1.68 #28.11 #16.83

+CPPBoilerstack-2 -25 MW 115

140 2.5 10.0 182000

1.82 $46.65 $10.94

*emissions are based on operating values PM = 50 mg/Nm3, SO2 = 750 mg/Nm3 andNOx - 823 mg/Nm3 in case of kiln+ emissions are based on PM=50 mg/Nm3 , #SO2 = 835 mg/Nm3and $SO2 = 1279mg/Nm3, and #NOx = 500 mg/Nm3 and $NOx = 300 mg/Nm3 in case of power plant

EMISSION DETAILS (EC REQUESTED)

Location Height Temp- Dia- Velocityof flue

gas

Flow ratem3/hr

Emissions fromstacks (gm/sec)

(Max.)

M OC M M/sec PM SO2 NOxCEMENT PLANT

*RawMill/Kiln-

1

114 140 4.75 24 15813005.70 237.70 253.5

CAPTIVE POWER PLANT+CPPBoilerstack-1 –15 MW 80

140 2.6 9.0 168000

1.68 20.16 10.10

+CPPBoilerstack-2 -25 MW 115

140 2.5 10.0 182000

1.82 21.84 10.94

*emissions are based on operating values PM = 30 mg/Nm3, SO2 = 750 mg/Nm3

(permitted 1000 mg/Nm3) and NOx - 800 mg/Nm3 in case of kiln+ emissions are based on PM=50 mg/Nm3, SO2 = 600 mg/Nm3 and NOx 300 mg/Nm3

in case of power plant

The emission load in terms of Kg/hr (both from cement plant kiln andpower plant is given below :

Kg/Hr EC granted EC requestedCoal Fuel mix/

Petcoke/Coal

Particulate Matter 46.80 33.12

Sulphur Dioxide 1124.86 1006.92

Oxides of Nitrogen 1038.85 988.34

GROUNDLEVEL CONCENTRATION

The ground level concentration due use of petcoke in kiln of cementplant and CPP computed using AERMOD model (EPA recommendedmodel) is given below :

EC granted EC requestedCoal Fuel mix/

Petcoke/Coal

Ground LevelConcentrations(ug/m3)

Particulate Matter 1.50 1.27Sulphur Dioxide 34.0 27.6Oxides of Nitrogen 26.6 24.3

Predicted ground level concentration of PM10, SO2 and NOx due to useof petcoke in kiln of cement plant and boiler of power plant are shownin Fig - 1to Fig – 3. 50 High 24-hourly average ground levelconcentrations of PM10, SO2 and NOx are given in Table – 1to Table –3.

AIR POLLUTION CONTROL MEASURES

The change in pollution control equipment due to use of pet coke inkiln and power plant are given below :

POLLUTION CONTROL EQUIPMENTEC Granted EC Requested Remarks

Sl.No.

Location / Unit Type ofEquipment

Type of Equipment

Control of Particulate Emissions1 Kiln/Rawmill Bag house –

1 noBag house – 1 no No change

2 Boiler – CPP ESP – 3 nos ESP – 3 nos No change

Control of SO2

1 Kiln/Raw mill Absorption inKiln

Absorption in kiln Optimizationof raw mix

and processparameterswill be donefor efficient

absorption ofSO2 in kiln

atmosphere.2 Boiler – CPP - Limestone injection at

boiler

Control of NOx emissions

EC Granted EC Requested RemarksSl.No.

Location / Unit Type ofEquipment

Type of Equipment

1 Kiln/raw mill Low NOxburner andLow NOxCalciner

Low NOx burner andLow NOx Calciner

No Change

2 Boilers – CPPAFBC/CFBC

Boilers

AFBC/CFBC Boilers,Biomass will be used

Biomass willbe used

Note: Results of Pet Coke Trial Run conducted by NCCBM at 33 Kilnsshowed that there is no increase in SO2, NOx and PM in kiln while the PetCoke was used.

CONTROL OF PARTICULATE MATTER

Cement plant:Pollution control equipment for control of particulateemission specified above are designed for meeting outlet emissionsbelow 30 mg/Nm3.

Captive Power plant:Due to the very low ash content in Petcoke, therewill be low particulate matter emission in power plant and the outletemissions will be well below 50 mg/Nm3

CONTROL OF SULPHUR DIOXIDE

Cement Plant

The combustion zone of the kiln with the presence of high lime dustacts as a scrubber combining to form calcium sulfate preventingmuch of the potential SO2 from the emission gas stream.

The combustion of Sulfur: S + O2 → SO2

The formation of Calcium Sulfate: CaO + SO2 + ½ O2 → CaSO4

Captive Power Plant

Fluidised Bed Combustion (FBC) Technology is ideal for pet coke firingbecause its long burning process ensures complete combustion of thelow volatile pet coke. The technology also captures a large amount ofPet Coke's sulphur during the combustion process. The vigorous

mixing of the fuel, limestone and ash particles during the low-temperature fluidized process allows the FBC to cleanly and efficientlyburn almost any combustible material, while minimizing the formationof NOx and optimizing the capture of SO2 as the fuel burns. Thecombustion temperature is well below the melting point of the fuel'sash, which allows tominimize the corrosion and fouling issuesexperienced in conventional boilers.

CONTROL OF OXIDES OF NITROGEN

Cement Plant: The kiln is equipped with InLineCalciner (ILC). In-linecalciners generally have lower NOx emissions than separate-linecalciners, since all of the kiln exhaust gases must pass through thecalciner. In an ILC, the fuel is injected into the kiln riser below wherethe tertiary air enters at the base of the calciner. This so-calledreduction zone, designed for a particular gas retention time, has anoxygen deficient atmosphere that promotes NOx reduction.

The kiln at Chanda is equipped with 6 stage preheater along with ILCcalciner. Already Low Nox burner and Low Calciner are in place andNOX emissions will be within the emission limit.

Captive Power Plant:NOx emissions are low in FBC boilers andAdditionally, to reduce NOx to an extent of 20 %, process optimizationand use of Biomass will be done.

8.2SOLID WASTE GENERATION

The solid waste generation is mainly ash from the power plant. Theash generation from the plant with use of coal and petcoke is givenbelow.

Maximum ash generation from the power plant is 323.6tpd (from fuelash and limestone injection)with coal firing. With use of fuel mix in 15MW power plant and 100 % petcoke in 25 MW power plant, the ashgeneration will reduce to 116 tpd(from fuel ash and limestoneinjection). Only dry ash handling system is adoptedand the ash isstored in silos. Transportation of Ash in dry form from the hoppers tostorage silos is done through pneumatic conveying. 100% ash will beutilized for manufacturing of Portland Pozzolana Cement (PPC). The

bottom ash of FBC boilers will have minimum unburnt carbon andthus will be used in cement raw mix.

SOLID WASTE GENERATION (T/DAY)EC

GrantedEC Requested utilization

15 MW Captive Power PlantFuel Coal Fuel mix

OrCoal

Total Ash 121.6 26.22 with fuel mixOr123.2 with coal

Total ash will be utilized incement manufacturingprocess

Fly Ashgeneration (tpd)

97.28 2.10 with fuel mix (29 % ashin fuel mix)Or97.28 with Coal

Bottom Ashgeneration (tpd)

24.32 24.12 (0.50 from fuel mixfiring and 23.62bottom ash due to limestoneinjection)or25.98(24.32 from coal firing and1.66bottom ash due to limestoneinjection)

25 MW Captive Power PlantFuel Coal Pet Coke

OrCoal

Total ash will be utilized incement manufacturingprocess

Ash Generation 202 89.75– with pet coke firingor209.36 – with coal firing

Fly Ashgeneration (tpd)

131.3 58.66 – with pet coke firing(1.76 from petcoke firingand 56.90 due to limestoneinjection

or136.08 – with coal firing(131.30 from coal firingand 4.78 due to limestoneinjection

Bottom Ashgeneration (tpd)

70.7 31.08 (0.442 from petcokefiring and 30.63bottom ash due to limestoneinjectionOr73.28(70.70 from coal firing and2.58bottom ash due to limestoneinjection)

9.0 CONCLUSION

ACC – CCW proposes to obtain Amendment in EC for use of petcokein addition to coal as alternative fuel in Kiln of cement plant andBoilers of power plant.

Use of Pet coke will not result in increase of SO2 and due to completeabsorption by the limestone in Kiln.

Use of Petcoke in the cement industry results in variousenvironmental benefits listed below

1) Generation of power at a competitive cost compared to powergenerated by using imported coal.

2) Utilization of industrial waste thus resulting in fossil fuelconservation.

3) Limestone injection in Boiler will greatly minimize SO2 emission fromthe stack (>95 % reduction and to meet new environmental norms of<600 mg/Nm3).

4) Solid wastes viz. Fly Ash and Bottom Ash generated from the CPP willbe reused/ recycled in the cement plant located within the premises.

5) Lowering CO2 emissions

FBC technology adopted enables use of pet coke in the boiler andinjection of limestone which controls the sulphur dioxide emission by80 % in AFBC and 95 % in CFBC boilers meeting outletconcentration of 600 mg/Nm3.

AFBC boiler use less excess air (3 to 5%) and use staged combustion(fuel and air are combusted in multiple stages) thus low NOx in eachstage of combustion. NOx emissions are low in CFBC boilers due tolow temperatures.

There will be decrease in pollution load with pet coke usage as limeinjection in boiler is proposed for capturing the sulphur dioxide. Thecomparison statement of pollution load and correspondingGroundlevel concentrations are shown below:

Overall Emissions Due To Use Of 100% Pet coke, biomass in addition toCoal In Kiln Of Cement Plant And Boiler Of Captive Power Plants

Parameter Existing EnvironmentalClearance (EC)

Proposed EC Amendment Remark

Kiln 15MW

(AFBC)

25MW

(CFBC

Total Kiln 15MW

(AFBC)

25MW

(CFBC

Total

AirEmissions,Kg/hr

ParticulateMatter

34.20

6.05 6.55

46.8

20.52

6.05 6.55

33.12

decreaseInoverallemissions

SulphurDioxide

855.72

101.20

167.94

1124.86

855.72

72.58

78.62

1006.92

OxidesofNitrogen

938.88

60.59

39.38 1038.

85

912.60

36.36

39.38 988.3

4

Ground Level Concentrations (µg/m3)Kil

n15

MW(AFB

C)

25MW

(CFBC

Cumulative

Kiln

15MW

(AFBC)

25MW

(CFBC

Cumulative

Particulate Matter

0.74 0.61 0.42 1.50 0.4

4 0.61 0.42 1.27 decreasein groundlevelconcentrations

SulphurDioxide

18.5 10.3 10.8 34.0 18.

5 7.36 5.06 27.6

Oxides ofNitrogen

20.3 6.14 2.53 26.6 19.

7 3.69 2.53 24.3

Note : decrease increase*Sulphur Dioxide Control By limestone stone injection in boiler

There will be no change in water and wastewater components of theplant due to use of Pet coke.

Solid waste generated from limestone injection will be totally used inthe cement plant

Amendment in EC proposal facilitates use of petcoke in Kiln andBoiler. Use of Pet Coke in cement Kiln facilitates use of sub-gradelimestone to the optimum extent resulting in production of highquality clinker

In view of the above, ACC-CCW requests MOEF&CC to considerthe above aspects and issue the amendment in Environmentalclearance for use of Pet coke in addition to coal in kiln of cementplant and boiler of captive power plant

* * *

Table – 1Predicted 50 high 24-hourly Average Ground Level Concentration

Of Particulate Matter Due To Use Of Pet CokeIn Kiln Of Cement Plant And Boiler Of Captive Power PlantsRANK CONC (YYMMDDHH) AT RECEPTOR (XR,YR) OF

(UTM COORDINATES)TYPE RANK CONC (YYMMDDHH) AT RECEPTOR (XR,YR) OF

(UTM COORDINATES)TYPE

1 1.27380c 16050224 AT ( 304259.84, 2205099.30) GP 26 0.94054 16050124 AT ( 304025.88, 2204456.51) GP2 1.19920c 16050224 AT ( 304244.65, 2205272.95) GP 27 0.93740c 16051224 AT ( 302826.83, 2204849.30) GP3 1.18628c 16052724 AT ( 304199.53, 2205441.32) GP 28 0.92615c 16051424 AT ( 303759.84, 2205099.30) GP4 1.08115b 16052224 AT ( 302826.83, 2204849.30) GP 29 0.92586c 16050224 AT ( 304737.05, 2205359.77) GP5 1.07894b 16052224 AT ( 302876.82, 2204777.91) GP 30 0.92310b 16050324 AT ( 303729.69, 2205270.31) GP6 1.06337c 16050224 AT ( 303752.24, 2205012.48) GP 31 0.92291c 16052624 AT ( 304259.84, 2205099.30) GP7 1.05792c 16052824 AT ( 304244.65, 2205272.95) GP 32 0.92013c 16051024 AT ( 303759.84, 2205099.30) GP8 1.04817c 16052824 AT ( 304259.84, 2205099.30) GP 33 0.90699c 16051424 AT ( 304259.84, 2205099.30) GP9 1.03477c 16051224 AT ( 302767.44, 2205012.48) GP 34 0.90699c 16052824 AT ( 303752.24, 2205012.48) GP

10 1.02756c 16051024 AT ( 303729.69, 2204928.29) GP 35 0.90671c 16052724 AT ( 303752.24, 2205186.12) GP11 1.02490c 16051224 AT ( 302789.99, 2204928.29) GP 36 0.89754c 16051424 AT ( 303729.69, 2204928.29) GP12 1.02010c 16050224 AT ( 303759.84, 2205099.30) GP 37 0.89657c 16051224 AT ( 302789.99, 2205270.31) GP13 1.01556c 16052724 AT ( 304244.65, 2205272.95) GP 38 0.89463b 16050324 AT ( 303752.24, 2205186.12) GP14 1.01059b 16052224 AT ( 302789.99, 2204928.29) GP 39 0.89132b 16052224 AT ( 302767.44, 2205012.48) GP15 1.00820c 16051224 AT ( 302759.84, 2205099.30) GP 40 0.88569c 16052824 AT ( 304244.65, 2204925.65) GP16 1.00285c 16051024 AT ( 303752.24, 2205012.48) GP 41 0.88471c 16052824 AT ( 303729.69, 2205270.31) GP17 0.99845b 16052224 AT ( 302938.45, 2204716.28) GP 42 0.88120c 16052724 AT ( 304669.38, 2205612.33) GP18 0.98324c 16051024 AT ( 303692.85, 2204849.30) GP 43 0.87741c 16052624 AT ( 304244.65, 2204925.65) GP19 0.97857c 16052724 AT ( 304125.87, 2205599.30) GP 44 0.87393c 16051424 AT ( 304244.65, 2205272.95) GP20 0.97327c 16052824 AT ( 303759.84, 2205099.30) GP 45 0.86841b 16050324 AT ( 303692.85, 2205349.30) GP21 0.97318c 16051424 AT ( 303752.24, 2205012.48) GP 46 0.86659c 16050224 AT ( 303729.69, 2204928.29) GP22 0.97268c 16050224 AT ( 304244.65, 2204925.65) GP 47 0.86639c 16052624 AT ( 304244.65, 2205272.95) GP23 0.96924c 16052824 AT ( 304199.53, 2205441.32) GP 48 0.86352c 16051024 AT ( 303642.86, 2204777.91) GP24 0.96159c 16051224 AT ( 302767.44, 2205186.12) GP 49 0.85507c 16050224 AT ( 304759.84, 2205099.30) GP25 0.95792c 16052824 AT ( 303752.24, 2205186.12) GP 50 0.85413b 16052124 AT ( 303581.23, 2204716.28) GP


Of Sulphur Dioxide Due To Use Of Pet CokeIn Kiln Of Cement Plant And Boiler Of Captive Power PlantsRANK CONC (YYMMDDHH) AT RECEPTOR (XR,YR) OF



1 27.57139c 16050224 AT ( 304244.65, 2205272.95) GP 26 19.28878c 16052824 AT ( 304737.05, 2205359.77) GP2 25.38493c 16050224 AT ( 304259.84, 2205099.30) GP 27 19.13095c 16051024 AT ( 303759.84, 2205099.30) GP3 24.97375c 16052724 AT ( 304199.53, 2205441.32) GP 28 19.02460b 16052324 AT ( 302275.03, 2205272.95) GP4 24.44569c 16052824 AT ( 304244.65, 2205272.95) GP 29 19.02230c 16051424 AT ( 304259.84, 2205099.30) GP5 23.67089c 16052724 AT ( 304125.87, 2205599.30) GP 30 18.95496c 16052624 AT ( 304244.65, 2204925.65) GP6 23.36458c 16052824 AT ( 304199.53, 2205441.32) GP 31 18.81304c 16050224 AT ( 303759.84, 2205099.30) GP7 22.63546c 16050224 AT ( 304737.05, 2205359.77) GP 32 18.80428c 16050224 AT ( 304759.84, 2205099.30) GP8 22.32496c 16052824 AT ( 304259.84, 2205099.30) GP 33 18.55208c 16051224 AT ( 302789.99, 2204928.29) GP9 21.70486c 16050224 AT ( 304199.53, 2205441.32) GP 34 18.54999 16052924 AT ( 304125.87, 2204599.30) GP

10 21.58014b 16052224 AT ( 302826.83, 2204849.30) GP 35 18.50986c 16051024 AT ( 303729.69, 2204928.29) GP11 21.39305b 16052224 AT ( 302789.99, 2204928.29) GP 36 18.49458c 16051224 AT ( 302826.83, 2205349.30) GP12 21.00718c 16052724 AT ( 304558.88, 2205849.30) GP 37 18.45488c 16052724 AT ( 304244.65, 2205272.95) GP13 20.78042c 16052624 AT ( 304259.84, 2205099.30) GP 38 18.38112c 16052824 AT ( 304669.38, 2205612.33) GP14 20.55683c 16051224 AT ( 302759.84, 2205099.30) GP 39 18.23441 16050124 AT ( 304025.88, 2204456.51) GP15 20.49223c 16051224 AT ( 302767.44, 2205186.12) GP 40 18.17505c 16050224 AT ( 304669.38, 2205612.33) GP16 20.37763c 16052724 AT ( 304669.38, 2205612.33) GP 41 18.13512c 16050224 AT ( 303752.24, 2205186.12) GP17 20.36273c 16052624 AT ( 304244.65, 2205272.95) GP 42 17.84211c 16051024 AT ( 303752.24, 2205186.12) GP18 20.25330b 16052224 AT ( 302876.82, 2204777.91) GP 43 17.80992c 16052624 AT ( 304199.53, 2205441.32) GP19 20.20970c 16052824 AT ( 304125.87, 2205599.30) GP 44 17.76861c 16052824 AT ( 303752.24, 2205186.12) GP20 19.99334c 16051424 AT ( 304244.65, 2205272.95) GP 45 17.74818c 16052624 AT ( 304759.84, 2205099.30) GP21 19.96814b 16052224 AT ( 302767.44, 2205012.48) GP 46 17.74598b 16052324 AT ( 302259.84, 2205099.30) GP22 19.87190c 16051224 AT ( 302767.44, 2205012.48) GP 47 17.68404b 16052224 AT ( 302759.84, 2205099.30) GP23 19.7395 16050124 AT ( 304125.87, 2204599.30) GP 48 17.60208c 16051424 AT ( 304199.53, 2205441.32) GP24 19.68997c 16051224 AT ( 302789.99, 2205270.31) GP 49 17.60014b 16052224 AT ( 302938.45, 2204716.28) GP25 19.40411c 16051024 AT ( 303752.24, 2205012.48) GP 50 17.59691c 16050224 AT ( 305229.46, 2205446.60) GP


Of Oxides of Nitrogen Due To Use Of Pet CokeIn Kiln Of Cement Plant And Boiler Of Captive Power PlantsRANK CONC (YYMMDDHH) AT RECEPTOR (XR,YR) OF



1 24.27769c 16050224 AT ( 304244.65, 2205272.95) GP 26 16.95504c 16051224 AT ( 302789.99, 2205270.31) GP2 21.57610c 16052824 AT ( 304244.65, 2205272.95) GP 27 16.27013c 16052624 AT ( 304199.53, 2205441.32) GP3 21.32883c 16052724 AT ( 304125.87, 2205599.30) GP 28 16.21286c 16050224 AT ( 305229.46, 2205446.60) GP4 21.03694c 16052724 AT ( 304199.53, 2205441.32) GP 29 16.20354c 16050224 AT ( 304759.84, 2205099.30) GP5 21.02112c 16052824 AT ( 304199.53, 2205441.32) GP 30 16.18582c 16052624 AT ( 304244.65, 2204925.65) GP6 20.73553c 16050224 AT ( 304259.84, 2205099.30) GP 31 16.09900c 16051224 AT ( 302826.83, 2205349.30) GP7 20.49022c 16050224 AT ( 304737.05, 2205359.77) GP 32 16.08479c 16052624 AT ( 304737.05, 2205359.77) GP8 20.03131c 16050224 AT ( 304199.53, 2205441.32) GP 33 16.07054 16052924 AT ( 304125.87, 2204599.30) GP9 19.47477c 16052724 AT ( 304558.88, 2205849.30) GP 34 16.01497c 16052624 AT ( 304759.84, 2205099.30) GP

10 18.92284c 16052824 AT ( 304259.84, 2205099.30) GP 35 16.00671c 16051024 AT ( 303759.84, 2205099.30) GP11 18.11614c 16052624 AT ( 304259.84, 2205099.30) GP 36 15.99113c 16051424 AT ( 304259.84, 2205099.30) GP12 18.11384c 16052624 AT ( 304244.65, 2205272.95) GP 37 15.96856 16050124 AT ( 304558.88, 2204349.30) GP13 18.11174c 16052824 AT ( 304125.87, 2205599.30) GP 38 15.94700b 16052224 AT ( 302876.82, 2204777.91) GP14 18.07413b 16052224 AT ( 302789.99, 2204928.29) GP 39 15.87390c 16051224 AT ( 302767.44, 2205012.48) GP15 17.99200c 16052724 AT ( 304669.38, 2205612.33) GP 40 15.76514c 16051424 AT ( 304199.53, 2205441.32) GP16 17.70221c 16052824 AT ( 304737.05, 2205359.77) GP 41 15.72995b 16052224 AT ( 302759.84, 2205099.30) GP17 17.69982b 16052324 AT ( 302275.03, 2205272.95) GP 42 15.69947c 16052824 AT ( 304759.84, 2205099.30) GP18 17.64409b 16052224 AT ( 302826.83, 2204849.30) GP 43 15.57226c 16051024 AT ( 303752.24, 2205012.48) GP19 17.61865 16050124 AT ( 304125.87, 2204599.30) GP 44 15.56109c 16050224 AT ( 303752.24, 2205186.12) GP20 17.56359c 16051424 AT ( 304244.65, 2205272.95) GP 45 15.46809c 16052724 AT ( 304991.89, 2206099.30) GP21 17.37448c 16051224 AT ( 302767.44, 2205186.12) GP 46 15.41406c 16051024 AT ( 303752.24, 2205186.12) GP22 17.36528b 16052224 AT ( 302767.44, 2205012.48) GP 47 15.24359b 16052324 AT ( 302259.84, 2205099.30) GP23 17.08629c 16052824 AT ( 304669.38, 2205612.33) GP 48 15.21265c 16051224 AT ( 302275.03, 2205272.95) GP24 17.01397c 16051224 AT ( 302759.84, 2205099.30) GP 49 15.08797b 16052224 AT ( 302320.15, 2204757.28) GP25 16.99917c 16050224 AT ( 304669.38, 2205612.33) GP 50 15.07151c 16051224 AT ( 302876.82, 2205420.69) GP

Fig – 1Predicted Ground Level Concentration

Of Particulate Matter Due To Use Of Pet CokeIn Kiln Of Cement Plant And Boiler Of Captive Power Plant

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Of Sulphur Dioxide Due To Use Of Pet CokeIn Kiln Of Cement Plant And Boiler Of Captive Power Plant

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Of Oxides of Nitrogen Due To Use Of Pet CokeIn Kiln Of Cement Plant And Boiler Of Captive Power Plant

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note on due to use of pet coke in addition to...

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