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Presentation of Thermal Power Plant
Presentation of Thermal Power Plant
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
Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd. 3
PROJECT HIGHLIGHTS Contd…….
Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd. 4
PROJECT HIGHLIGHTS Contd…….
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 418.4 m3/ day (Tungabhadra Dam)
(Source)
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
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
Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd. 9
MAJOR REQUIREMENT
RAW MATERIAL:
Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd. 10
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
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
REPROCESS
0.588 2200 26300 COKE
0.23 850 10300 QUARTZ RAW
RAW MATERIAL
MATERIAL STOCK
STOCK PILE
PILE
00.2 740 8900 LIME STONE T/T TPM TPY
0.025 92 1100 ELECTRODE PASTE DAY
DAY BINS
BINS
PROCESS 0.7 2600 31300
CASTING
CASTING
1 3725 44700
Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd.
CONSUMER 14
SOURCE OF POLLUTION IN EXISTING PROCESS
EFFLUENT:
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.
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
Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd. 20
POWER PLANT PERFORMANCE INDICES
Sr. Description Index
No.
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 28.38
Plant, Million Units
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
Nil
- Washing Nil
188 25
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 :
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:
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
Usage (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
15 25 40
down
- 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
Soak pit
TOTAL WATER CONSUMPTION TOTAL EFFLUENT
GENERATION
Gardening 12
m3/ day
Total Water Requirement
566.4 m3/ day
Dust supression12
m3/ day
Ash handling
CPP 32 MW 418.4 m3/ day 216 m3/ day
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.
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
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.
Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd. 37
OTHER MEASURES
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
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
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
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