Annexures of Form -1 ANNEXURES
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Annexures of Form -1
ANNEXURES
Annexures of Form -1
Annexure-1
Location Map
District Map: Bharuch
Annexures of Form -1
Annexure -2
Google Image Showing Location of the Project Site
Annexures of Form -1
Annexures of Form -1
Annexure - 3
Plan Layout
ONGC
Annexures of Form -1
Annexure–4
Break-up of Land Area Requirement
It may be noted that the total land area of the company is 567 acres, out of which
Existing power plant area is approx. 86.48 acres and 17.23 acres of land will be utilized for proposed expansion of 45 MW captive power plant.
Total 33 % of plot area will be utilized for the greenbelt development.
Description Area (m2)
Existing Plant
Proposed For Plant
Total after proposed expansion
Power Plant area 350000 69750 419750
Annexures of Form -1
Annexure–5
Details of Power Generation and Raw Material Consumption
DETAILS OF PRODUCTS
Name of Product Project Activity as per EIA
Notification -2006
Production Capacity (MW/Day)
Existing (a)
Proposed (b)
Total (a+b)
Captive Power Plant 1(d) 96MW 45 MW 141MW
DETAILS OF RAW MATERILAS
Name of Raw Material MT/Month
Existing
(a)
Proposed
(b) Total (a+b)
Imported Coal 72000 21000 93000
Lime for Desulphurization of Coal 1920 560 2480
Annexures of Form -1
Annexure–6
Captive Power Plant (Exiting 96 MW)
The power requirement for VSF plant is 25 MW and that of Chlor –Alkali plant is 52 MW (peak). High Pressure and Low Pressure steam is also required in the process. Considering the in-house consumption of 14%, the required generation capacity is 88 MW
The plant configuration is 3 x 32 MW Extraction cum Condensing Steam Turbo Generator (STG) with 4 x 175 TPH CFBC Boiler. Steam pressure and temperature has been selected as 110 ATA and 545º C.
Operation of power plant requires other auxiliary plants like
Fuel handling plant for crushing and screening of coal
DM plant for generating DM water
Ash handling plant for Evacuation
Silos capacity 2 x 350 MT
Cooling towers for circulating cooling water
Exhaustive control system are installed to control & regulate the plant operation including pollution control equipments
Two RCC chimney of 125 m height provided
Steam is generated in the CFBC boilers by the use heat from coal. Chemical energy of coal is converted into heat energy. Start up firing of boiler is done by Light Diesel Oil (LDO). High pressure steam from boiler is taken to STEAM TURBINE. The turbine is rotated by action of steam where heat and kinetic energy of steam is converted into mechanical energy. Process steam required at 17.5 kg/cm2 and 4.5 kg/cm2 is tapped off from steam turbine and balance steam is taken to condenser where exhaust steam is cooled and circulated back to boiler.
Process steam network will distribute the process steam to Viscose Staple Fiber plant and Chemical Division. Ash generated in boiler is collected pneumatically in ash silo and sealed bulker loading system.
Annexures of Form -1
Proposed 45 MW The turbine will be a double extraction-cum-condensing turbine. The turbine system is based
on modified rankine cycle which could be summarized as expansion of steam in the turbine
giving up heat energy, a high proportion of which is converted into work energy on the turbine
shaft. The turbine shaft turns an electrical generator, which produces electric power.
Since, it will be extraction turbine, some of the steam passing through the turbine cylinder will
be bled from two extraction belts located after moving blade stage and fed to high pressure feed
water heater, de-aerator and will be used for various processes.
Finally, the steam after doing work in various turbine stages and two extractions will be
exhausted to the condenser. In condenser, which is surface type heat exchanger, the steam is
condensed by transferring its latent heat of evaporation to the cooling tower. The steam having
been condensed will be pumped by condensate extraction pumps from condenser hot well to
de-aerator via steam jet air ejector and gland steam condenser to increase the temperature of
feed water and remove dissolved gases such as O2, CO2 etc. De-aerator is a direct contact heat
exchanger, where make-up water is taken.
Boiler feed pump feed water from de-aerator to boiler drum via high pressure feed water
heater. The temperature of feed water after HP heater is 196˚C. The boiler feed pump increases
the feed water pressure to a level in excess of the boiler drum, to provide for pressure loss in the
boiler and HP heater.
The power generated will be used for manufacturing process. Operation of power plant requires other auxiliary plants like
150 m3/hr DM water plant
Silo capacity 350 MT
One RCC chimney of 125 m height will be provided
Cooling towers for circulating cooling water
Existing fuel handling for coal crushing and screening will be used.
Annexures of Form -1
Process Flow Diagram
Annexures of Form -1
Circulating Fluidized Bed Combustion (CFBC) Boiler Technology: Steam requirement is fulfilled with the help of one Circulating Fluidized Bed Combustion (CFBC) boiler, which is designed for dual fuel and imported coal will be used for boiler. Major advantage of CFBC technology is as follows.
Fuel flexibility
Low SO2 emissions due to efficient sulfur capture with limestone in the furnace
Proper limestone feeding system to desulphurization of sulfur
Low NOx emission due to low combustion temperature
Stable operating conditions and good turn-down ratio
Electrostatic Precipitators (ESPs) for control of dust emissions
Desulfurization System:
Lime stone is used for desulphurization in boilers in existing plant and same will be used for proposed expansion (of 45 MW CPP) as imported coal contains sulphur.
Limestone is mixed with coal in conveyer.
Apprx. 90 % sulphur remove from this process
Fly-Ash Handling System
Fly ash /Bed Ash Pneumatic system
ESP
Convection cage
IInd pass
Fly Ash silo
Spray
Bed Ash silo (1No)
Dumper/Bulker
Bed Ash cooler
Furnace
Fly Ash
Fly Ash Fly Ash
Bed Ash
Conditioner
Cyclone
Boiler
Brick Mfg/Cement/
Brick Mfg/ Cement
Annexures of Form -1
Annexure–7
Details of Water Consumption and Wastewater Generation
Water Consumption
Wastewater Generation
Sr. No.
Description Water Consumption Quantity (kl/day)
Existing (96 MW)
PROPOSED (45 MW)
Total (141 MW)
a. Domestic 5.5 2.5 8 b. Industrial
D.M. Water
Boiler - makeup 6450 3100 9550 Cooling - makeup 4000 1875 5875 DM water regeneration 750 500 1250 Washing 50 25 75
Sub-total (b) 11250 5500 16750
c. Greenbelt Treated domestic wastewater will be used for gardening
TOTAL (a+b+c) 11255.5 5502.5 16758
Sr. No.
Description Wastewater Generation Quantity (kl/day)
Existing (96 MW)
PROPOSED (45 MW)
Total (141 MW)
a. Domestic 4.4 2 6.4 b. Industrial
D.M. Water
Boiler - blow down 2500 1180 3680 Cooling - purge 1500 710 2210 DM water regeneration 750 500 1250 Washing 50 25 75
Sub-total (b) 4800 2417 7215 TOTAL (a+b) 4804.4 2415 7221.4
Annexures of Form -1
5772 (5870) 1250 Steam condensate 2210 75 1250 2285
Note:*All units in Kl/day Recycle line
1- Dust suppression in coal handling area
2- Sprinkling on fly-ash 3- Road cleaning
TOTAL WATER BALANCE DIAGRAM (Existing + Proposed)
Total Water Consumption 16758 kl/day* (First Day)
10986 [16758-5772)] = form 2nd Day onwards
DM Water 10800
Cooling (make-up) 5875
Boiler (make-up) 9550
Domestic 8
From Washing 75
Water from GIDC
DM water regeneration
1250
Washing 75
9550
Boiler (blow down) 3680
Cooling purge 2210
7215 Industrial Effluent to primary treatment
3680
6.4 To STP
For Gardening within premises
From Domestic
6.4
To RO Plant
20% RO Reject
1443
5772
Annexures of Form -1
Mode of Disposal
Domestic effluent
Domestic effluent will be treated in Sewage Treatment Plant and treated wastewater will be used for gardening purposes within premises.
Industrial Effluent
Wastewater generation from power plant for proposed expansion is “Zero Discharge”. All plants have collection pits constructed in each of the sections. The wastewater generated is collected in the collection pits and after physico-chemical treatment the water will be passed to RO system. After passing through RO water will be reused for cooling make-up and RO reject water will be reused for dust suppression for coal handling, sprinkling on fly ash and road washing purposes.
Annexures of Form -1
Annexure–8
Details of Hazardous/Solid Wastes and its Mode of Disposal
Sr. No.
Name of Waste Sch/ Cat.
Quantity per Annum Mode of Storage & Disposal As per
Existing EC
Proposed
Total after Expansion
1. Spent Resin 35.2 0.33 MT 0.09MT 0.42 Collected, stored, transported & disposed at TSDF site of BEIL,
2. Used Oil 5.1 100 KL 28 kL 128 kL Collected, stored and sold to authorized recycler.
3. Discarded Containers/
33.1 1680 Nos. -- 1680 Nos. Collected, stored and reused/ sold to authorized recycler.
Bags/ Liners 25 MT 16.8 MT 41.8 MT
4. Fly Ash -- 86400 MT 25200 MT 111600 MT Will be sold fly ash to cement, manufacturing unit.
Annexures of Form -1
Annexure–9
Details of Stack/Vent, Fuel and Air Pollution Control Measures
Sr. No.
Stack / Vent attached to
Type & Quantity of Fuel
Diameter of the Stack/
Vent (m)
Height of the Stack/
Vent (m)
Expected Emission
Air Pollution Control Measures
(A). EXISTING Flue Gas Emission 1. Boiler 1 & 2 Coal
[100 MT/hr]
2.5 125 PM < 100 mg/Nm3 SO2 < 600 mg/Nm3 NOx< 600 mg/Nm3
ESP and Low NOx Burners
2. Boiler 3 & 4 2.5 125 PM < 100 mg/Nm3 SO2 < 600 mg/Nm3 NOx< 600 mg/Nm3
ESP and Low NOx Burners
(B). PROPOSED Flue Gas Emission
1. Boiler -5 (175 TPH)
Coal [29.16
MT/hr]
2.5 125 PM < 30 mg/Nm3 SO2 < 100 mg/Nm3 NO2< 100 mg/Nm3
ESP and Low NOx Burners
Fuel Consumption:
Type of fuel Consumption Per Month Source
Existing Proposed Total [Existing +Proposed ]
Coal 72000 MT 21000 MT 93000 MT Adani Enterprises Limited
Surya Exim Limited
LDO for cold start -up 17 kl 8 kl 25 kl Local supplier
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