Presentation Of Thermal Power Plant

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

1

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.: Bellary District: Karnataka EXISTING PROJECT DESCRIPTION

Plot Area

95 Acre

Project

Ferro alloy plant

Location

Vyasankere, Ta: Hospet, Dist.: Bellary District: Karnataka

Activity status

The existing Ferro alloy plant is not operational since last 10 years due to unavailability of feasible power source. Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd.

2

PROJECT HIGHLIGHTS

Contd…….

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.

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

3

PROJECT HIGHLIGHTS

Contd…….

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)

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

4

PROJECT HIGHLIGHTS

Contd…….

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

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

5

Cont. 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

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

6

LOCATION OF PROJECT STAR METALLICS AND POWER PVT. LTD.

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

7

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

8

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

9

MAJOR REQUIREMENT RAW MATERIAL: Raw Materials /Consumables

Unit

Qty/year

Manganese ore

T

1,07,000

Lime stone

T

9,120

Coke

T

30,000

Quartz

T

Electrode paste

T

11,000 1,150

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

10

WATER CONSUMPTION AND EFFLUENT GENERATION Usage (1) Domestic

Quantity (m3/ day) Water Consumption

Effluent Generation

36

31

(2) Industrial - Cooling tower -Process

-

-

Nil

Nil

- Washing

Nil

Nil

- Boiler

Nil

Nil

100

15

- DM back wash

Nil

Nil

-Gardening

12

Nil

TOTAL

148

46

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

11

PRODUCTION PROCESS 

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

12

Cont. 

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.

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

13

MATERIAL FLOW CHART FOR SILICOMANGANESE T/T

TPM

TPY

2.25

8300

100000

MANGANESE ORE

0.588

2200

26300

COKE

0.23

850

10300

QUARTZ

00.2

740

8900

LIME STONE

0.025

92

1100

ELECTRODE PASTE

Kwh/T

GWH/M

3750

14.0

GWH/Y WH/Y 168

RAW MATERIAL STOCK PILE

DAY BINS

PROCESS

T/T

TPM

TPY

0.7

2600

31300

BACTH 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

SLAG

WATER TPM

TPY

1

3725

44700

3725

0.7

2600

31300

SUBMERGED ARC ELECTRIC FURNACE - SMELTING

FURNACE GAS

T/T

1

REPROCESS

44700

BAG HOUSE

0.04

150

1700

FINES

0.04

150

1800

LIQUID SILICO MANGANESE LADLES

CASTING

CRUSHING & SCREENING

0.95

3540

42460

SILICO MANGANESE

0.05

186

2240

SILICO MANGANESE

REPROCESS

0.04

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

150

1180

14

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.

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

15

AIR POLLUTANT : GASEOUS EMISSION :  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 DUST EMISSION :  Dust will be produced during product sizing ,finishing and packing will be managed by dust extraction system

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

16

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

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

17

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

18

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.

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

19

PROPOSED PROCESS 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.

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

20

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

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

21

GENERAL LAYOUT OF PROPOSED POWER PLANT

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

22

WATER CONSUMPTION AND EFFLUENT GENERATION Usage

Water requirement

Effluent generation

(1) Domestic

24

20

(2) Industrial

Nil

- Process

Nil

- Cooling tower - Washing

Nil

- Boiler

120

114

188

25

86.4

86

-

-

418.4

245

- Dm plant back wash - Gardening TOTAL

Nil

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

23

SCHEMATIC DIAGRAM FOR WATER SYSTEM

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

24

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

25

AIR POLLUTENT : GASEOUS 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.  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. Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd.

26

DUST 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. FLY ASH :  Fly ash generated from the boiler will be collected in dry form and disposed for commercial utilisation.

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

27

NOISE POLLUTION: 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 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. Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd.

28

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

29

WASTE WATER EFFLUENT GENERATION FROM EXISTING AND PROPOSED UNIT Effluent Generation (m3/ day)

Usage 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

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

30

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.

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

31

WATER BALANCE CHART FOR BOTH EXISTING AND PROPOSED UNIT

TOTAL WATER CONSUMPTION

Soak pit

TOTAL EFFLUENT GENERATION

Domestic water 36 m3/ day

31 m3/ day

Cooling tower 100 m3/ day

15 m3/ day

Gardening 12 m3/ day

Septic tank (51 m3/ day)

240 m3/ day

Ferro alloy unit 148 m3/ day

Gardening 12 m3/ day

Total Water Requirement 566.4 m3/ day

Dust supression12 m3/ day Ash handling 216 m3/ day

CPP 32 MW 418.4 m3/ day Domestic water 24 m3/ day

20 m3/ day

Boiler 120 m3/ day

114 m3/ day

DM Backwash 86.4 m3/ day

86.0 m3/ day

Cooling tower 188 m3/ day

ZERO DISCHARGE

25 m3/ day

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

32

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

33

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

34

Cont. For open yard operation, provision will be made to spray water to reduce the dust generation during handling operation. 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. Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd.

35

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

12.75

20.32

1177

35.4768.5 3 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

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

36

GAUSSIAN PLUME DISPERSION MODEL 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

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

37

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.

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

38

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.

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

39

THERMAL POLLUTION MANAGEMENT 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.

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

40

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

41

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 living Establishment of small and medium scale engineering ancillaries, agro based industries with cascading employment opportunities Superior communication and transport facilities etc. Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd.

42

WORK ZONE POLLUTION MANAGEMENT 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. 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. Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd.

43

PLANT SAFETY MANAGEMENT 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. GREEN BELT DEVELOPMENT 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. Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd.

44

POST PROJECT MONITORING 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.

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

45

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

46