accord energy corporation india pvt....

Accord Energy Corporation India Pvt. Ltd.

PRE-FEASIBILITY REPORT

ON

ENVIRONMENTAL ASPECTS

OF

PROPOSED

INCREASE IN CAPACITY

2 x 150 MW to 2 x 180 MW

OF

EXISTING ENVIRONMENTAL CLEARANCE

( J-13012/107/ 2009-IA-II (T) dated 18/05/2011 )

at

Sirupuzhalpettai Village,

Gummidipoondi Taluk, Thiruvallur District, Tamil Nadu.

October 2014

i

CONTENTS

1.0 EXECUTIVE SUMMARY ................................................................................ 1

2.0 INTRODUCTION ............................................................................................ 3

3.0 THE PROPOSED PROJECT ............................................................................ 3

4.0 PROJECT LOCATION .................................................................................... 3

5.0 LAND USE ........................................................................................................ 6

6.0 RAW MATERIALS CONSUMPTION .......................................................... 6

7.0 FUEL TRANSPORTATION ............................................................................ 6

8.0 PROCESS DESCRIPTION ............................................................................... 8

9.0 RAW WATER REQUIREMENT .................................................................... 9

10.0 ENERGY CONSUMPTION .......................................................................... 11

11.0 WORK FORCE ............................................................................................... 11

12.0 WASTE & WASTE MANAGEMENT ......................................................... 11

12.1 Air Pollution ............................................................................................ 11

12.2 Waste Water Management .................................................................... 14

12.3 Solid Waste Management ...................................................................... 14

13.0 SITE ANALYSIS, PLANNING & REHABILITATION AND

RESETTLEMENT ...................................................................................................... 15

14.0 PROJECT SCHEDULE & COST ESTIMATION ........................................ 15

15.0 CONCLUSION ............................................................................................... 15

Fig 1.0 Project Location .……………………………………………………………4

Fig 2.0 Plant Layout ………………………………………………………………...5

Fig 3.0 Route Map ………….. ………….……………………………………..……7

Pre-feasibility Report 1 Accord Energy - Gummidipoondi

1.0 EXECUTIVE SUMMARY

It is proposed to increase the capacity of 2 x 150 MW to 2 x 180 MW. The 2 x 150 MW

coal based thermal power plant was issued Environmental Clearance vide letter #

J-13012/107/ 2009-IA-II (T) dated 18/05/2011.

Present Status

The entire Land Acquisition is complete, and is awaiting issue of Consent to

Establish from TNPCB, which is in the final stages of issue.

Financial closure is also in the final stages, and is expected by December 2014.

Construction will commence after obtaining Consent to Establish from

TNPCB.

Project Location

The location of the project is at Sirupuzhalpettai Village, Gummidipoondi Taluk,

Thiruvallur District, Tamil Nadu. The plant site is devoid of any forest land. There

are no areas of ecological sensitivity or notified bio diversity area or wildlife

sanctuary etc. within 10 kms radius of the plant site.


Products & Capacity

Increase in capacity of Thermal Power generation using imported coal from 2 x 150

MW to 2 x 180 MW. The 2 x 150 MW Thermal Power Plant was already issued

Environmental Clearance.

Raw Material Requirement

The raw material used will be 100% Imported Coal.

Raw Water Requirement & Source

Main Condensate is based on Air Condensate Cooling. The daily make water

required for 2 x 180 MW will be 150 KLD, whereas the daily water make-up as per

Environmental Clearance issued for 2 x 150 MW was 802 KLD. This conservation of

water is possible due to use of fin fan coolers for Turbine Generation Cooling.

About 150 KLD will be the daily make-up after recycling 192 KLD of treated waste

water in the 2 x 180 MW unit.

Water will be sourced from Ground / Harvested Rain Water.

Solid Waste Generation & Method of Disposal

The total Ash generation will increase by 19.35 TPD by augmentation to 2 x 180 MW

compared to 2 x 150 MW.

Fly ash will be completely disposed & Bottom ash will be stored in ash dyke.

Man Power

There will be no increase in manpower owing to augmentation of capacity from 2 x

150 MW to 2 x 180 MW ie it will be 50 Employees as was originally proposed.

Project Cost

Project cost will remain the same at Rs.1950 Crores as was originally proposed.


2.0 INTRODUCTION

India's Electricity Act 2003 introduced structural changes to the power industry,

permitting private investment for the first time since 1948. This allowed power

producers to sell power directly to industrial consumers under the Group Captive

model.

Key features of the Group Captive and Merchant model are

Group Captive Merchant

Bilateral arrangements with consumers / traders / utilities

Offering reliable, consistent power supply, even during peak periods

Attractive prices relative to alternative tariffs

Sales with traders directly

Flexibility and risks of spot pricing

Returns dependent on available pricing

Limited to one day future trading

3.0 THE PROPOSED PROJECT

The present proposal is for increase in capacity to 2 x 180 MW of the originally

proposed 2 x 150 MW, the environmental clearance for which was obtained vide

letter # J-13012/107/ 2009-IA-II (T) dated 18/05/2011.

4.0 PROJECT LOCATION

The proposed augmentation from 2 x 150 MW to 2 x 180 MW is located at

Sirupuzhalpettai Village, Gummidipoondi Taluk, Thiruvallur District, Tamil Nadu,

wherein the Environmental Clearance for 2 x 150 MW has already been obtained.

The project location is as shown in Fig.1.0 and the Plant Layout of the project is as

shown in Fig 2.0.


Fig 1.0 Location Map


Fig 2.0 Plant Layout


5.0 LAND USE

The Augmentation of Capacity ie from 2 x 150 MW to 2 x 180 MW is within

the same site, wherein the Environmental Clearance for 2 x 150 MW has

already been obtained. Hence there is no change in land use.

The land however was a dry rainfed, and moreover was vacant, barren, with

no activity. There were also no Rehabilitation or Resettlement Issues.

6.0 RAW MATERIALS CONSUMPTION

The Marginal increase in coal consumption will be as follows.

for 2 x 150 MW for 2 x 180MW Additional Coal requirement (ie from 300 MW to 360 MW)

3600 TPD 3815 TPD* 215 TPD

*Heat Rate : 2341 Kcal/KWh.

Characteristics of Coal

S. No. Particulars Imported Coal 1 Gross Calorific Value 5300 k cal/kg 2 Moisture 9 % 3 Ash 9 % 4 Fixed Carbon 19 % 5 Sulphur 1.2 % 6 Volatile Matter 35.8 % 7.0 FUEL TRANSPORTATION

The existing road, viz. NH-5, SH-52 will be used for coal transportation.

Imported Coal will be shipped by sea and unloaded at Ennore Port and then

will be transported by road by 40T capacity container. The route map from

Ennore Port to Plant Site is as shown in Fig 3.0.

As per latest amendment of MoEF Minutes of Meeting of the 34th meeting of

re-constituted Expert Appraisal Committee (Thermal) held on 10th & 11th

October, 2011, Coal will be transported by road only for a period upto 4 years

of date of Commissioning, after which the rail transportation will be

implemented.


Fig 3.0 Route Map


8.0 PROCESS DESCRIPTION

Upgradation of capacity of the power plant from 2 X 150MW (MCR) to 2 X 180MW (MCR)

Accord Energy Corporation India Pvt. Ltd at Sirupulalpettai Village, Gummidipoondi Taluk, Thiruvallur District, Tamil Nadu was originally finalised as 2 x 150MW – Maximum Continuous Rating (MCR) with a capacity to produce 2 x 180MW at Valve Wide Open condition (VWO). Accordingly the equipments were sized as given below: Sl.No. Description Parameters

1 Boiler and its auxiliaries 535tph with a reheater capacity of 477.4tph.

2 Steam turbine generator 150MW (MCR);180MW (VWO) Heat rate: 2125 Kcal/kWh (MCR) 2135 Kcal/kWh (VWO) Generator sized for 150MW.

3 Air cooled condenser 370tph of steam flow

4 Generator transformer 176MVA

5 MS, CRH and HRH piping Designed to carry steam equivalent to 150MW

6 Boiler feed pumps Sized for a steam generation of 580tph.

During the technical meetings with the turbine suppliers,BHEL/Skoda/Siemens, it was understood that the turbine could be modified to generate 2 x 180MW on a continuous basis with a heat rate of 2015Kcal/kwh, by redesigning the turbine and upgrading the generator equivalent to 180MW. This has the following advantages:

a. Keeping the majority of the systems same, there is a possibility of generating 30MW more in each.

b. Much lower heat rate to generate higher capacity with less coal consumption

c. Time required is the same d. Better utilisation of the investment made on the transmission line e. The clearances already obtained, will remain the same except an

amendment for augmentation capacity at 2 x 180 MW

Hence, it was decided to go ahead with this proposal.


The increase in capacity necessitated the following changes: Sl.No. Description Parameters for 2 x 150MW

MCR Revised parameters for 2 x 180MW MCR

1 Boiler and its auxiliaries

535tph with a reheater capacity of 477.4tph each

580 tph with a reheater capacity of 510tph each

2 Steam turbine generator

2 x 150MW (MCR);180MW (VWO) Heat rate: 2125 Kcal/kWh (MCR) 2135Kcal/kWh (VWO) Generator sized for 2 x 150MW.

2 x 180MW (MCR): Heat rate: 2015Kcal/kwh Generator sized for 2 x180MW

3 Air cooled condenser 370tph of steam flow each 400 tph of steam flow each

4 Generator transformer 176MVA each 220MVA each

5 MS, CRH and HRH piping

Designed to carry steam equivalent to 2 x 150MW

Designed to carry steam equivalent to 2 x 180MW

6 Boiler feed pumps Sized for a steam generation of 535 tph each

Sized for a steam generation of 580 tph each

9.0 RAW WATER REQUIREMENT

Source of water will be Harvested Rain Water / Ground Water. Sufficient

draft is available, the total water requirement for 2 x 180 MW on daily make-

up will be 150 KLD. Clearance from Central Ground Water Authority has

already been obtained for drawl of 1300 KLD of Ground Water.

Water Consumption for 2x150 MW (As per Environmental Clearance)

Water Consumption for 2x180 MW (Daily Make-up)

802 KLD 150 KLD

Main Condensate is based on Air Condensate Cooling. There will be

reduction of water consumption by 652 KLD for 2 x 180 MW compared to 2 x

150 MW due to use of fin fan coolers for Turbine Generator.

About 150 KLD will be the daily make-up after recycling 192 KLD of treated

waste water.


Water Balance Diagram

All Values are in KLD

Total Raw 342

Boiler Feed

D M Plant

Coal Dust Suppression/

Ash Quenching

Blowdown 285

Neutralization Pit

From Bore well / Rain Water Harvesting Reservoir

Reject Tank

48

ETP/RO 340

Septic Tank

Dispersion Trench

192

192 Domestic

150

285

55

2 1.6 1.6

55

340


10.0 ENERGY CONSUMPTION

It is a proposed augmentation of power generation facility and hence the

auxiliary power requirement will be met internally.

11.0 WORK FORCE

There is no increase in work force required for increase in capacity from 2 x

150 MW to 2 x 180 MW, and will remain the same as was originally proposed

for 2 x 150 MW.

12.0 WASTE & WASTE MANAGEMENT

12.1 Air Pollution

The Stack height will remain the same at 220 Metres, the calculation of

which is as follows.

The daily consumption of coal for 2 x 180 MW is around 3815 Tonnes imported coal

The rate of SO2 emission due to usage of coal is calculated as given below

Sulphur content = 1.2 %

S = (3815 x 1.2 /100) = 45.78 T/D

SO2 = 45.78 x 2 T/D

= 91.56 T/D =3815 kg/hr

SO2 emission = 3815 kg/hr = 1059.72 g/s

Stack height calculation:

H = 14 Q0.3

Where,

H = height of the Stack

Q = SO2 Concentration in Kg/hr.

Hence

H = 14 x (3815)0.3 = 14 x 11.87 = 166.18 m


The stack height proposed to be constructed is however 220 metres, after considering

stack lossess, available draft etc at chimney bottom with reference to minimum gas

velocity of 21 m/sec at the top of chimney to design the height of the chimney.

Stack Emission Characteristics

2 x 150 MW 2 x 180 MW

Single Chimney

Twin Flue

Single Chimney

Twin Flue

Material of Construction RCC RCC

Stack attached to Boiler 1 Boiler 2 Boiler 1 Boiler 2

Stack height (m) 220 220

Flue diameter (m) 3.8 3.8 4.1 4.1

Volume Flow Rate (m3/s) 234.0 234.0 280.0 280.0

Velocity of flue gas (m/s) 21.0 21.0 21.21 21.21

Temperature of flue gas (oC) 140 140 150 150

Flue gas specific volume ( kg / m³) 1.3 1.3 1.2 1.2

Fuel Consumption (Kg/s) 20.84 20.84 22.08 22.08

Sulphur content (% w/w) 1.2 1.2 1.2 1.2

Emission rate – NOx (g/s) 187.5 187.5 198.7 198.7

Emission rate – SO2 (g/s) 500.00 500.00 529.85 529.85

Emission rate – SPM (g/s) 11.7 11.7 14.0 14.0

The following environmental protection or pollution control systems have

already been considered for mitigation of impacts on Air Environment.

220 m tall stack to emit flue gas.

Space provision for retrofitting FGD (Flue Gas Desulfurisation)

systems.

High efficiency ESPs to reduce SPM level in the exhaust gas to

<50mg/Nm³.

Dust suppression and extraction system at Handling Plant area to

Control Fugitive Emission.

Green belt development and afforestation in the plant and ash disposal

areas.


A minimum water depth will be maintained in the ash pond to prevent

fugitive dust emission.

Use of bagfilters at all transfer points.

Use of limestone to limit SO2 emission.

High efficiency Electrostatic Precipitator of 99.9% are provided for limiting

SPM concentration in the flue gas to less than 50 mg/Nm³. The tall stack of

220 m height based on maximum SO2 concentration in the flue gas is

provided for natural dispersion at high elevation so that ground level

concentration are within acceptable limits.

The emission of NOX, is reduced by burning fuel at a lower temperature and

shortening the throughput time of the fuel. NOX is also controlled by

operating at low excess air.

Fugitive Emissions

To control fugitive emissions from process units in the plant, the following

measures will be carried out.

Tarring of roads inside the factory.

Preventive maintenance of valves and other equipments.

Green belt on all sides within the project boundary, and community

plantation around the unit with help of local area development authorities

have already been done.

Ambient air quality and stack/fugitive emissions monitored regularly.

In-plant training provided to the plant personnel on operation and

maintenance of dust collectors, techniques of dust emission

measurements, particle size analysis etc.

Effective operation and maintenance of pollution control system is

ensured to contain the emissions/keep them within the CPCB limits


A good house keeping consisting of simple, obvious task of cleaning up

spills, removing accumulations around processing equipment and in

general keeping things neat and clean form a part of normal operation and

maintenance procedure

Measures for arresting fugitive dust emissions along with the envisaged

pollution control equipments are adequate and will help to have a healthy

and cleaner environment inside the plant thereby improve the productivity

and the efficiency of the workers as well as that of plant machinery.

12.2 Waste Water Management

Waste Water Generation in KLD

For 2 x 150 MW For 2 x 180 MW

Boiler Blow Down 675 285*

D.M. Plant Regeneration Waste

50 55

Domestic Sewage 1.6 1.6

* Reduction in blowdown due to reduced water consumption by use of Fin

Fan Coolers for Turbine Generator. The entire waste water is reused and recycled thus ensuring zero discharge.

12.3 Solid Waste Management

The Ash generation will increase by 19.35 TPD upon augmentation of

capacity from 2 x 150 MW to 2 x 180 MW.

Solid Waste For 2 x 150 MW (TPD)

For 2 x 180 MW (TPD)

Additional Quantity of Solid Waste

Generation (TPD)

Fly Ash 259.20 274.68 15.48

Bottom Ash 64.80 68.67 3.87

Total 324.00 343.35 19.35


13.0 SITE ANALYSIS, PLANNING & REHABILITATION AND RESETTLEMENT

The augmentation of the capacity from 2 x 150 MW to 2 x 180 MW is within

the same site, wherein the Environmental Clearance for 2 x 150 MW has

already been obtained.

There is no Rehabilitation and Resettlement issue.

14.0 PROJECT SCHEDULE & COST ESTIMATION

The construction of 2 x 180 MW Power plant will be started upon obtaining

Amendment in Environmental Clearance from MoEF and Consent to

Establish from TNPCB.

The scheduled to be commissioned in 24 months from the date of receipt of

Consent to Establish from TNPCB.

The project cost will be Rs.1950 Crores as was originally envisaged for 2 x 150

MW.

15.0 CONCLUSION

The proposed augmentation will result in better utilization without any

modification to the majority of existing systems.

The impact will be marginal, however, adequate measures already proposed

to mitigate negative impacts, and thus aid positive impacts.

accord energy corporation india pvt....

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