presentation of thermal power plant

Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd. 1

Presentation for Environmental Clearance before the esteemed members of Karnataka

State Level Expert Appraisal Committee

Proposed Project

32 MW Captive Power Plant in Existing Ferro

Alloy Unit

Proponent

M/s. Star Metallics & Power Pvt. Ltd.

Hospet, Karnataka.


PROJECT HIGHLIGHTS

Name of company M/s. Star Metallics & Power Pvt. Ltd

Promoter of company

EIEL, India & ETA group, Dubai.

Location Vyasankere, Ta: Hospet, Dist.: BellaryDistrict: Karnataka

EXISTING PROJECT DESCRIPTION

Plot Area 95 Acre

Project Ferro alloy plant

Location Vyasankere, Ta: Hospet, Dist.: BellaryDistrict: Karnataka

Activity status The existing Ferro alloy plant is not operational since last 10 years due to unavailability of feasible power source.


Product Silicomanganese (SiMn )

Capacity of plant 44,700 MTPA (SiMn )

No. of Furnace (Type) Two ( Submerged Arc Furnace)

Rating of furnace 1 x 15000 KVA, 1 x 20000 KVA

Projected operating load of ferroalloy plant

24000 KW

Total Connected Load 33 MVA

Raw Materials Manganese ore, Metallurgical coke, Limestone & Quartz.

Contd…….PROJECT HIGHLIGHTS


Water requirement and Source 148 m3/ day, Tungbhadra dam reservoirs

Effluent Generation & Disposal 46 m3/ day

Gardening & dust suppression

Source of power GESCOM Grid (It is used to run 15,000 MVA furnace only, untill the proposed CPP will not be operational)



PROPOSED PROJECT DESCRIPTION

Project Installation of new 32 MW Captive Power Plant in existing ferro alloy unit.

Location Within existing ferro alloy unit.

Power generation 32 MW

Area for proposed plant 25 Acre ( Within existing plant)

No of Boilers One

Type of Boilers Fluidized Bed Combustion type

Capacity of boiler 140 TPH

Fuel Low sulphur containg Indonesian Coal

Fuel Consumption Rate 1,30,000 MTPA



No of Turbogenerator One

Type of Turbogenerator Straight Condensing With Air Cooled Condenser

Water Requirement for CPP (Source)

418.4 m3/ day (Tungabhadra Dam)

Effluent Generation 245 m3/ day

Cost Of Project 102.78 crore

Cont.


LOCATION OF PROJECT

STAR METALLICS AND POWER PVT. LTD.


EXISTING UNIT

Product Silicomanganese

Production Capacity 44,700 MTPA

Raw Material Manganese ore, Metallurgical coke, Limestone & Quartz. All these material are locally available

Power Power requirement of ferroalloy industry i.e. 181 million KW will be provided by GESCOM Grid ( It is only for 15,000 MVA furnace and untill proposed CPP will not be operational)

WATER Water requirement of the existing unit is 148 m3/ day and it will be fulfilled by Tungabhadra dam reservoir.


MAJOR REQUIREMENTRAW MATERIAL:

Raw Materials /Consumables Unit Qty/year

Manganese ore T 1,07,000

Lime stone T 9,120

Coke T 30,000

Quartz T 11,000

Electrode paste T 1,150


WATER CONSUMPTION AND EFFLUENT GENERATION

Usage Quantity (m3/ day)

Water Consumption Effluent Generation

(1) Domestic 36 31

(2) Industrial - -

-Process Nil Nil

- Washing Nil Nil

- Boiler Nil Nil

- Cooling tower

100 15

- DM back wash Nil Nil

-Gardening 12 Nil

TOTAL 148 46


The raw materials will be taken to a set of day bins by a set of belt

conveyors.

The raw materials will be fed into the furnace through chutes.

The manganese ore added in the form of lumps will be smelted in the

smelting furnace.

Coke will be used as reductant, quartzite as silicon additive and

lime stone as flux.

The energy required for this reduction will be supplied by means of

submerged arc through three self-baking electrodes.

Liquid Silico Manganese along with slag will be tapped out at suitable

intervals.

PRODUCTION PROCESS


The metal will be tapped into on to refractory lined beds dressed with

Silico Manganese powder to form cakes.

The cakes after cooling will be sent to a product sizing yard. The sized

Silico Manganese will then be weighed and bagged. Thereafter, it will

be ready for despatch by road transport.

Slag produced during the operation is granulated. This slag is poured

into a stream of high pressure water, which converts the liquid slag into

granules and this slag will go for reprocessing.

Cont.


MATERIAL FLOW CHART FOR SILICOMANGANESE

1 3725 44700

0.95 3540 42460

0.05 186 2240

MANGANESE ORE

T/T TPM TPY

0.588 2200 26300 COKE

0.025 92 1100 ELECTRODE PASTE

00.2 740 8900 LIME STONE

Kwh/T GWH/M GWH/YWH/Y16814.03750 ELECTRIC POWER

SMELTING

300 1.1 13 ELECTRIC POWER AUXILLIARY

4050 15.1 181 TOTAL

CUM/T CUM/M

CUM/Y

13.06 48649 583782 WATER

T/T TPM TPY

1 3725 44700

FURNACE GAS

DAY BINSDAY BINS

RAW MATERIAL STOCK PILERAW MATERIAL STOCK PILE

LIQUID SILICO MANGANESE LADLESLIQUID SILICO MANGANESE LADLES

SUBMERGED ARC ELECTRIC FURNACE - SMELTINGSUBMERGED ARC ELECTRIC FURNACE - SMELTING

CONSUMER

SILICO MANGANESE SILICO MANGANESE

SILICO MANGANESE SILICO MANGANESE

CRUSHING & SCREENINGCRUSHING & SCREENING

CASTINGCASTING

PROCESS

TPYTPMT/T

3130026000.7

SLAG 3130026000.7

BAG HOUSE 17001500.04

FINES 18001500.04

REPROCESS 11801500.04

2.25 8300 100000

0.23 850 10300 QUARTZ

BACTHBACTH

REPROCESS


SOURCE OF POLLUTION IN EXISTING PROCESS

EFFLUENT:

There is no process effluent generation.

Only domestic effluent i.e. 31 m3 /day and cooling tower blow down i.e. 15 m3 /day will be generated.

The quality of cooling tower blow down will be as per the standards prescribed by Pollution Control Board for discharging into inland for irrigation.

Sewage (31 m3 /day) from various buildings of the unit will be conveyed through separate drains to septic tank connected to soak pit.


AIR POLLUTANT :

The gas emissions from furnace will contain dust particulates, Sulphur dioxide, oxides of nitrogen, carbon monoxide.

The exit gases would be cleaned by dry gas de-dusting system.

In the bag house fine particulate matter will settle in the settling chamber. Resultant clean gas will be vented out to atmosphere at appropriate height

GASEOUS EMISSION :

DUST EMISSION :

Dust will be produced during product sizing ,finishing and packing will be managed by dust extraction system


SOLID WASTE

Raw material handling fine( 7800 TPA) , product fine(2240 TPA) and furnace slag (31300 TPA) will be the main solid waste in the existing process

The dust and ash generated during operation will be collected, packed in bags and finally disposed off for commercial usage.

The slag will be reprocessed and finally reused for commercial purposes


NEED OF PROJECT

The existing Ferro alloy plant had been stopped since last ten years due to

unavailability of power. Since the state grid power supply is economically

unviable in long run and every effort to restart the ferro alloy plant using

power from other sources were unsuccessful, it has decided to install a 32

MW Captive Power Plant to augment the power requirement. The

proposed 32 MW captive power plant is coal based with fluidized bed

combustion technology. Power from the CPP will be used to run ferro

alloy plant and the surplus power will be exported to consumers.


Product Power

Production Capacity 32 MW

Raw Material Indonesian coal with vary little percentage of sulphur.( Calorific value 5250 kcal/kg)

Fuel Consumption Rate 1,30,000 TPA

Water Water requirement of the proposed unit is 418.4 m3/ day and it all will be provided by Tungabhadra dam.

Boiler Fluidized bed combustion type of 140 TPH capacity.

PROPOSED PROCESS


POWER PLANT PERFORMANCE INDICES

Sr.No.

Description Index

1. Plant Rated Capacity, MW 32

2. Rated Capacity, Million Units/Annum 262.8

3. Plant Load Factor, % 90

4. Annual Power Generation, Million Units 236.52

5. Auxiliary Power Consumption Of Power Plant, Million Units

28.38

6. Annual Send Out Power, Million Units 208.14

7. Annual Imported Coal Consumption, Tons 1,30,000

8. Grade Of Coal To Be Used Calorific value of 5250 kcal/kg

9. Annual Ash Generation (Total), Tons 1300

10. Annual Make-Up Water Requirement, m3 About 1,52,716


GENERAL LAYOUT OF PROPOSED POWER PLANT


Usage Water requirement Effluent generation

(1) Domestic 24 20

(2) Industrial -

- Process Nil Nil

- Washing Nil Nil

- Boiler 120 114

- Cooling tower

188 25

- Dm plant back wash 86.4 86

- Gardening - -

TOTAL 418.4 245

WATER CONSUMPTION AND EFFLUENT GENERATION


SCHEMATIC DIAGRAM FOR WATER SYSTEM


SOURCE OF POLLUTION IN PROPOSED PROCESS

EFFLUENT:

Effluents are generated during regeneration of ion exchangers. Alkalies effluents are generated during the rinsing of anion and mixed bed exchangers.

Blow down from the plant consists of cooling tower blow down and boiler blow down.

The effluents from the water treatment plant are led to a properly sized neutralisation pit having a holding capacity of two regenerations.

The quality of cooling tower blow down will be as per the standards prescribed by Pollution Control Board for discharging into inland. Residual chlorine in cooling tower blow down will be maintained within acceptable levels.

Sewage from various buildings in the power plant area will be conveyed through separate drains to a septic tank before being discharged into soak pit.


AIR POLLUTENT :

The flue gases from the boiler exhausted into the atmosphere carry with them considerable quantities of pollutants such as SPM, SO2, NOx, CO etc.

Boiler of Circulating Fluidised bed combustion type of firing to reap the inherent advantages of very low liberation of NOx in the furnace.

Electrostatic precipitator at boiler outlet for extracting the dust pollutant from flue gas for achieving the dust concentration at the outlet of chimney as low as 100 mg/Nm3.

The flue gas emission from DG sets contains significant proposition of SO2 since HSD will be used as fuel.

DG set are also provided and will be used in case power emergency. Stack of adequate height is provided for effective dispersion of pollutants.

GASEOUS EMISSION :


Raw material handling process is one of the main sources of dusting. Coal will be drawn from stockyard and ground in hoppers leads to dusting.

The dust would be captured by dust extraction (DE) system and taken to a bag filter to separate out the dusts and clean air finally vented through a stack.

For open yard operation, provision will be made to spray water to reduce the dust generation during handling operation.

DUST EMISSION :

Fly ash generated from the boiler will be collected in dry form and disposed for commercial utilisation.

FLY ASH :


The major noise producing equipment such as turbogenerator will be

provided with acoustic enclosures, pumps, fans, compressor etc. and will

be run at speeds less than 1500 rpm. Equipment will be statically and

dynamically balanced. Safety blow off valves, discharge pipes; relief

valves etc. will be equipped with silencers. Pipe lines will be liberally sized

for low velocities

NOISE POLLUTION:

SOLID WASTE:

Power plant ash, 1700 TPA will be the main solid waste in proposed

plant and will be collected, packed in bags and finally disposed off for

commercial usage.


WASTE WATER

Usage

Effluent Generation (m3/ day)

Existing Proposed TOTAL

(1) Domestic 31 20 51

(2) Industrial Nil Nil Nil

- Process Nil Nil Nil

- Washing Nil Nil Nil

- Boiler blow down Nil 114 114

- Cooling tower blow down

15 25 40

- DM plant discharge Nil 86 86

TOTAL 46 245 291

EFFLUENT GENERATION FROM EXISTING AND PROPOSED UNIT


WASTE WATER MANAGEMENT

The final quality of the wastewater will meet the GSR 422 (E) on land discharge

standards. The treated waste water (348 m3/day) will be reused for dust suppression

(12 m3/day), green belt development (12 m3/day) and remaining (324m3/day) will

be used for ash handling system. There will be no discharge of effluent outside the

plant site.


Soak pitTOTAL WATER CONSUMPTION TOTAL EFFLUENT

GENERATION

Domestic water 36 m3/ day

Total Water Requirement566.4 m3/ day

Cooling tower 100 m3/ day

Gardening 12 m3/ day

Ferro alloy unit 148 m3/ day

Domestic water 24 m3/ day

Boiler 120 m3/ day

DM Backwash 86.4 m3/ day

Cooling tower 188 m3/ day

15 m3/ day

31 m3/ day Septic tank(51 m3/ day)

20 m3/ day

114 m3/ day

86.0 m3/ day

25 m3/ day

CPP 32 MW 418.4 m3/ day

240 m3/ day

Gardening 12 m3/ day

Dust supression12 m3/ day

Ash handling 216 m3/ day

ZERO DISCHARGE

WATER BALANCE CHART FOR BOTH EXISTING AND PROPOSED UNIT


AIR POLLUTANTS

SMELTING FURNACE:

Hot SAF off gas emissions contain dust particulates, Sulphur dioxide, oxides of nitrogen, carbon monoxide and traces of oxides of silica

FINISHED PRODUCT SIZING & PREPARATION:

The cast product would be cooled, ground and screened for final bagging. Such operation would generate fugitive dust .

BOILER EMISSION :

The flue gases from the boiler exhausted into the atmosphere carry with them considerable quantities of pollutants such as SPM, SO2, NOx, CO etc. Following measures are provided to control flue gas emissions:

DG SET:

Two DG set will be used as power back up. The flue gas emission from DG sets contains significant proposition of SO2 since HSD will be used as fuel.


AIR POLLUTION MANAGEMENT

SMELTING FURNACE:

Hot off gases from submerged arc furnace (SAF) and tap hole secondary

emissions laden with fine product dust would be cooled to 150-250oC by air

dilution prior to passing it through fume extraction system. The exit gases

would be cleaned by dry gas de-dusting system. Bag filters are provided

to remove fine particulate matter will settle in the settling chamber.

Resultant clean gas will be vented out to atmosphere at appropriate height.

FINISHED PRODUCT SIZING & PREPARATION:

Significant amount of fugitive emission mainly in form of dust will be envisaged during coal and raw material handling. Dust extraction system will be provided at all material transfer points The dust would be captured by dust extraction (DE) system and taken to a bag filter to separate out the dusts and clean air finally vented through a stack


BOILER & DG SET EMISSION :

Electro Static Precipitator (ESP) will be provided to control dust emission

from the boiler. Further low sulphur content coal will be used to reduce SO2

generation. The flue gas will be dispersed into the atmosphere through a

stack of around 60 meter height for effective dispersion of pollutants.

DG set are also provided and will be used in case power emergency. Stack of

adequate height is provided for effective dispersion of pollutants.

For open yard operation, provision will be made to spray water to reduce the dust generation during handling operation.

Cont.


Max. Conc. Zone of Pollutants from Stack discharge at above height Simulation.

Distance w.r.t. stack discharge (m)

Pollutant concentration (microgram/m3)

SO2 NO2 SPM

817 32.18 11.57 18.44

877 34.06 12.24 19.52

937 35.19 12.65 20.16

997 35.71 12.83 20.47

1057 35.77 12.85 20.50

1117 35.4768.53

12.75 20.32

1177 34.90 12.54 20.00

1237 34.14 12.27 19.56

1297 33.25 11.95 19.05

1357 32.27 11.60 18.49


The dispersion of pollutants in the atmosphere is determined using Gaussian plume dispersion model. For the present study, this model is used for the prediction of maximum ground level concentration (GLC).

The different air emissions from the unit are PM, SO2, NOx and CO from boiler and process vent. Maximum ground level concentration is predicted using dispersion model. The maximum ground level concentration for different parameters is shown in Table 6.3 for proposed scenario. Equal concentration contour plots for the PM, NO2, and SO2 are shown in Figure 6.1 to 6.5 for the proposed scenario.

Based on KSPCB limit of pollutants, calculated ground level concentration is superimposed on existing ambient air quality to obtain proposed scenario for the purpose of prediction and evaluation of impact of stack and process emission on surrounding

GAUSSIAN PLUME DISPERSION MODEL


OTHER MEASURES

Regular ambient air quality monitoring should be carried out within premises and nearby area for PM, RSPM, SO2, NOX and CO.

Occasionally ambient air quality should also to be monitored for work area to check fugitive emissions, if any.

A greenbelt around the factory and near the possible source of fugitive emissions should be developed for reducing the air pollution and attenuation of noise.


FLY ASH MANAGEMENT

Ash generated during the operation of power plant will be suitably

collected and disposed off. A system for collection and commercial

disposal of this waste product to end users’ works will be planned. Ash

generated in the furnace bed will be periodically removed by means of

wet scraper chain conveyor and discharged on to the ash silo meant for

wet ash. The fly ash collected from the Economizer, Air Heater and

Electro-Static Precipitator will be conveyed to the fly ash silo through

mechanical ash handling system. Ash shall be disposed manually or by

means of truck from the silos.


All equipments and pipelines whose surface temperature is 50 0C and above will be provided with thermal insulation.

Further the plant building will be designed for adequate air circulation through natural ventilation. In addition, air conditioning systems will be provided for specific areas. Man coolers will be installed at hot work spots.

THERMAL POLLUTION MANAGEMENT


The plant and equipment will be specified and designed with a view to

minimise noise pollution. The major noise producing equipment such as

turbogenerator, pumps, fans, compressors etc will be provided with

acoustic enclosures and will run at speeds less than 1500 RPM.

Equipment will be statically and dynamically balanced. Safety blow off

valves, discharge pipes; relief valves etc. will be equipped with silencers.

Pipe lines will be liberally sized for low velocities. Wherever necessary

insulation will be provided for reducing heat loss and noise pollution. In

effect, the abatement measures will ensure that noise levels are kept

below 90 dB (A) at a distance of 1 m from the equipment.

NOISE MANAGEMENT


SOCIAL ENVIRONMENT MANAGEMENT:

The plant site is in the existing ferroalloy industry. The project did not involve

displacement of population as the project site is within the existing plant. Instead

of displacement project provides employment to about 45 persons in power plant.

SMPPL has also constructed a full-fledged colony consisting of houses for

the benefit of employees. Most of the employees shall be from the local area.

Hence, the influence of influx on environment is insignificant. It is anticipated

that the project would bring following benefits to the people of the surrounding

villages

Generation of employment and improved standard of livingEstablishment of small and medium scale engineering ancillaries, agro based industries with cascading employment opportunities Superior communication and transport facilities etc.


The work zone pollution would be mostly due to fugitive dusts, heat and noise. The fugitive dust emission in open area would be controlled by Dust Extraction and Dust Suppression systems as described earlier.

As far as possible, natural draft ventilation would be enabled in the shop. All the process vessels would be lined with adequately thick refractory bricks to contain the surface heat emission and in some cases they would be indirectly cooled by water. In addition to this, there would be provision for forced draft cooling and ventilation of closed environment in the work zone.

WORK ZONE POLLUTION MANAGEMENT

The work zone noise would be mostly emanating from the rotary equipment and machinery like fans, blowers, compressors and pumps. Proper equipment design for control of noise at source, adopting proper protective appliances and administrative control for rotation of manpower in noisy areas would prevent exposure of workmen to high noise levels.


Plant safety measures would form an integral part of the environmental management plan of the proposed plant. Workers’ safety would be given highest priority so as to avoid any form of personal injury or lost-time accident. In-built safety features of the plant and machinery would help avoid hazardous events causing damage to the life and property.

PLANT SAFETY MANAGEMENT

More than 100 trees are present all around existing industry including Fuel storage area, Ash handling system and Administration building etc. There is no tree cut and the area of 10 acre is proposed for tree plantation. The name of the trees will be decided after the discussion with the Local Agricultural Authority and Forest Department. The waste water from the plant after treatment will be used for green belt development (i.e. 12 m3/day) within the plant premises.

GREEN BELT DEVELOPMENT


As a part of the Environmental Management Plan (EMP) to be implemented

for the Ferro Alloy Plant and Captive Power Plant as a whole, monitoring of

air and water quality both at source and in the ambient at the plant site will

be done regularly as per Central Pollution Control Board (CPCB) guidelines

after the plant is commissioned. For this purpose, appropriate equipment and

instruments will be procured along with necessary chemicals, consumables

and glassware.

To Summarise, the pollution control measures planned for the entire plant

will ensure that it will have the least adverse impact on the environment.

The adverse impacts of the plant on environment are planned to be prevented

by provision of preventive and control systems.

POST PROJECT MONITORING

presentation of thermal power plant

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