m/s. nuvoco vistas corporation ltd. ( formerly …€¦ · 8 proposed capacity 1x27mw captive...

PRE-FEASIBILITY REPORT

On

Proposed Installation of 1 X 27 MW Coal Based CaptivePower Plant in the Existing 4.6 MTPA Cement Grinding Unit

at Jojobera, Dist-East Singhbhum, JharkhandOF

M/s. NUVOCO VISTAS CORPORATION LTD.( Formerly Lafarge India Limited)

At-Jojobera, Jamshedpur, Dist– East SinghbhumJharkhand

Prepared by:- APRIL 2017

VISIONTEK CONSULTANCY SERVICES PVT. LTD(An Enviro Engineering Consulting Cell)

Plot No.– M 22 & M23 , Chandaka Industrial Area, Patia, Bhubaneswar-24,Phone No. : 91-674-6451781

[email protected] , [email protected] us at - www.vcspl.org

M/s Nuvoco Vistas Corporation Limited (Formerly Lafarge India Limited)Pre-Feasibility Report on Proposed Installation of 1 X 27 MW Coal based Captive Power Plant in theExisting 4.6 MTPA Cement Grinding Unit at Jojobera, Dist- East Singhbhum. Jharkhand

Visiontek Consultancy Services Private Limited

TABLE OF CONTENTChapter No DESCRIPTION PAGE

NOChapter-1.0 Executive Summary 11.0 Introduction 22.0 Identification Of Project And Project Proponent 2

2.1 Need For The Project & Its Importance To The Country OrRegion

2

2.2 Employment Generation 33..0 Project Description 33..1 Location 33.2 Site Selection 43.3 Technology Selection 43.4 Raw Material Requirement 43.5 Water & Power Requirement 53.6 Waste Generation & Management 54.0 Site Analysis 54.1 Connectivity 54.2 Present Land Use 54.3 Topography 54.4 Existing Infrastructure 64.5 Climatic Data From Secondary Sources 65.0 Planning Brief 65.1 Planning Concept 65.2 Land Use Planning 76.0 Proposed Infrastructure 76.1 Green Belt 76.2 Others 77.0 Rehabilitation And Ressettlement (R & R) Plan 78.0 Project Schedule And Cost Estimates 78.1 Project Schedule 78.2 Project Cost 89.0 Analysis Of Proposal 8

Chapter-2.0 Introduction2.1 Identification Of Project And Project Proponent 92.2 Description Of Nature Of The Project 102.3 Need Of The Project And Its Importance To The Country And/Or

Region10

2.4 Employment Generation 13



Chapter-3.0 Project Description3.1 Type Of Project 153.2 Location 153.2.1 Plant Location 153.2.2 Land Requirement 163.2.3 Plant Layout 163.3 Site Selection 193.4 Technology Selection 193.4.1 Selection Recommendation 203.5 Process Description 213.5.1 Mechanical Equipment And System 213.5.2 Steam Turbine & Auxiliaries 233.5.3 Flue Gas De Sulfurization System (Fgd) 263.5.4 Utilities & Services 303.5.5 Electrical Equipment And System 343.5.6 Power Evacuation And Interconnection System 363.6 Heat & Mass Balance 413.7 Raw Material 413.7.1 Raw Material Analysis 423.8 Water & Power Requirewment 433.9 Waste Geneartion And Its Management Plan 433.9.1 Waste Water 433.9.2 Solid Waste 443.10 Noise Levels 453.11 Schematic Representations Of The Feasibility Drawing Which Give

Information Of Eia Purpose.46

Chapter-4.0 Site Analysis

4.1 General 474.2 Connectivity 474.3 Present Land Use 474.4 Topography 484.5 Existing Infrastructure 484.6 Climate Data From Secondary Sources 48

Chapter-5.0 Planning Brief5.1 Planning Concept 495.1.1 Technical Concept 495.1.2 Power To Be Produced 49



5.1.3 Human Resources 495.14 Organization Structure 495.2 Project Engineering 505.2.1 Project Conceptualization 505.2.2 Project Planning 505.2.3 Budgeting 505.2.4 Procurement 505.2.5 Design And Engineering 515.2.6 Project Execution 515.2.7 Coordination With Site Management 515.2.8 Overall Time And Cost Control 515.2.9 Project Site Management 515.2.10 Commercial And Financial Services 525.3 Organizational Structure For Operational Phase 525.3.1 Training 52

Chapter-6.0 Proposed Infrastructure6.1 Industrial Area 53

Chapter-7.0 Rehabilitation And Resettlement (R & R) Plan 55

Chaptre-8.0 Project Schedule & Cost Estimates8.1 Project Schedule 568.2 Project Cost 568.3 Environment Cost 57

Chapter-9.0 Analysis Of Proposal 58

LIST OF TABLESR. NO DESCRIPTION PAGE

NO1.1 Raw Materials Requirement & Source 42.1 Background of the Project 92.2 Project Profile 102.3 Peak Demand and Peak Met in India 122.4 Manpower Requirement-Existing 132.5 Manpower Requirement-Proposed Expansion 133.1 Land Use Breakup 163.2 Proposed Configuration 203.3 Steam Generator Design Parameter 21



3.4 Basic Technical Parameters 373.5 Raw Material Requirement & Source 423.6 Chemical Analysis 423.7 Water Requirement 433.8 Air Quality Environment & Management (Air Environment- Mitigation

Measures) Source of air pollution and control measures44

4.1 Environmental Setting of the Area 478.1 Project Cost 568.2 Expenditure on Pollution Control Measures 57

LIST OF FIGURESSR. NO DESCRIPTION PAGE

NO3.1 Index Map 153.2 Topo Map (10 Km Radius) 163.3(a) Plant Layout-Exisitng 173.3(b) Plant Layout- Proposed Expansion 183.4 Air Cooled Condenser 253.5 Process Flow Diagram-FGD 293.6 Process Flow Diagram 303.7 Heat & Mass Balance 41


Visiontek Consultancy Services Private Limited Page 1

CHAPTER – 01

EXECUTIVE SUMMARY

1 Name of the projectProposed 1 X 27 MW Coal based Captive PowerPlant within Existing 4.6 MTPA Cement GrindingUnit at Jojobera, Dist- East Singhbhum. Jharkhand

2 S.No in the schedule Activity 1(d)

3 Registered Office

M/s Nuvoco Vistas Corporation Limited(Formerly Lafarge India Limited)Jojobera Cement PlantP.O. Rahargora, Jamshedpur - 831016

4 Name of the promoters M/s Nuvoco Vistas Corporation Limited(Formerly Lafarge India Limited)

5 Area of plant3.00 Ha (7.41 Acre)within existing premises of .123 Acres (49.77 ha.)

6 Topo Sheet No 73 J/1

7LatitudeLongitude

Latitude: 22°44’55.64”NLongitude: 86°15’02.9”E

8 Proposed capacity 1x27MW Captive Thermal Power Plant

9 Cost of Project Rs. 163.28 Cr.

10 Man power Requirement

Proposed Manpower for CPP – 43

Existing Manpower-1347

Total Manpower after proposed expansion :1390

11 Water Requirement576 m3/day for CPPSource- JUSCO

12 Power Requirement 2000 KW-Startup power

13Nearest railwaystation/airport along withdistance in kms

Tatanagar Railway Station- 4.0 Km WNWSonari Airport, Jamshedpur – 12.5 Km NWRanchi Airport- 112 Km NW

14Nearest Town, City, DistrictHead quarters along withdistance in kms.

Jamshedpur (approx 6.5 km in NW direction from theplant site)

15

Village penchants, Parishad,Municipal corporation, localtelephone nos to be given)body (complete postaladdresses with telephone no.sto be given)

Jamshedpur Notified Area Committee(JNAC)Jamshedpur-831001



1.0 INTRODUCTION

M/s Nuvoco Vistas Corporation Limited (Formerly M/s Lafarge India Limited)

proposes for installing 1 X 27 MW Coal based Captive Power Plant in its existing 4.6 MTPA

Cement Grinding Unit within existing plant premises of 123 Acres(49.77 Ha.) and CPP over an

area of 3.0 Ha. at Village-Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand.

2.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

M/s Nuvoco Vistas Corporation Limited (Formerly M/s Lafarge India Limited) hereafter

refer as NVCL entered the Indian market in 1999. Lafarge has 3 integrated units , 2 grinding

units & 1 blending units in India: two plants in the state of Chattisgarh (Sonadih and Arasmeta)

and grinding units in Jharkhand (Jojobera & Mejia) and cement plant in Chittorgarh. NVCL have

cement grinding capacity of 4.6 MTPA at Jojobera & are planning to increase production

capacity to 6.6 MTPA. The power demand of the plant at present is met from JUSCO.

In view of the high power tariff & plan of JUSCO to increase same in future NVCL is

contemplating to have Self Power generation to meet bulk power requirement of the cement

grinding plant.

2.1 Need for the project & its importance to the country or Region

Indian cement industry is large, growing and with consumption of 185kg/capita/yr in

2011 (compared to global average of ~300 kg/capita/yr) the country itself has the capacity to

demand significantly more cement as it develops.

In India, Jharkhand has around 40 per cent of the country’s mineral wealth such as coal,

limestone etc. In addition to the large raw material deposits, the strategic location of Jharkhand,

proximity to large markets in southern and central India (providing an opportunity to cater to

these markets) and 1805 kms of national highway passing through the State, have made

Jharkhand an ideal destination for establishing cement units.

Now with the government of India giving push to various infrastructure projects, housing

facilities and road networks, the cement industry in India is currently growing at an enviable

pace and further growth in the Indian cement industry is expected in the coming years.

Therefore, there is an urgent need to increase the production capacity in the country.



Hence, the proposal for expansion of Grinding Unit by NVCL will cater the increasing

demand of cement in the country and region of Jharkhand.

NVCL have cement grinding capacity of 4.6 MTPA at Jojobera & are planning to

increase production capacity to 6.6 MTPA. The power demand of the plant at present is met from

JUSCO.



grinding plant by installing 1 X 27 MW Coal based CPP.

2.2 Employment Generation

Direct and indirect employment will be generated to the local population, the total man

power requirement during construction phase for the project will be 200-250, out of which 8 are

the permanent senior level persons and rest will be the casual workers for construction, erection

gardening, packing, cleaning etc.

Similarly, during operation expected additional employment to the existing plant will be

43 and total employment after expansion will be 1390.

3.0 PROJECT DESCRIPTION

The proposed installation of 1 X 27 MW Coal Based Captive Power Plant based on

Conventional Steam Cycle Operating in Rankine Cycle, consisting of 120 TPH CFBC Boiler and

1 no. Turbine 535 ⁰C at 105 Kg/Cm² pressure.

3.1 Location

Proposed expansion is within the existing cement grinding unit plant premises located at

Village-Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand. Total area required is 3.0

Ha. available within 123 Acres. existing land. The proposed expansion site falls under the

Survey of India Toposheet No. 73 J/1 and the buffer zone falls under the Survey of India

Toposheet 73 J/2, 73 J/5 and 73 J/6. The Latitude and Longitude of the proposed site is

22°44’55.64”N and 86°15’02.9”E respectively.



3.2 Site Selection

The total project land area required is 3.0 Ha. available within the existing plant premises

of total 123 Acres. The site selection of Power Plant has been based on the following

considerations.

Plant availability.

Cooling Water availability.

Compatibility of grid to withstand sudden outage of unit.

Operating experience of the set size.

Thermodynamic cycle efficiency and specific input consumption viz. fuel, water etc..

Specific investment requirement & cost of generation.

3.3 Technology Selection

The proposed expansion is installation of 1 X 27 MW Coal Based Captive Power Plant

based on Conventional Steam Cycle Operating in Rankine Cycle, consisting of 120 TPH CFBC

Boiler and 1 no. Turbine 535 ⁰C at 105 Kg/Cm² pressure.

3.4 Raw Material Requirement

The annual coal requirement considering E/F grade Indian coal for 1 X 27 MW unit is

estimated to be about 700-720 TPD will be consumption) as the proposed coal for the plant

would be having an average calorific value of 3200 kCal/kg. Coal would be made available from

the nearby mines of Open market purchase.

Table.1.1 Raw Material Requirement & Source

S. No. Raw Materials SourceTransportationMode

RequirementMTPA

Coal Based Supercritical Thermal Power Plant

1 Coal Open Market purchase Rail / Road 0.216 MTPA

2 LDO / HSDIOCL/HPCL/BPCL Localdepots

RoadApprox

…80.KLPY



3.5 Water & Power Requirement

The water requirement for the proposed CPP plant works out to be approximately 360m3/

day. In addition, water requirement for Fuel gas Desulfurization is 216m3/day. The total water

requirement shall be 576m3/day. Agreement made with JUSCO is for 0.5 MGD

The water requirement for free- fighting and service application has not been considered

because their intermittent requirement and can be met from the cement plant.

Start up power of total 2000 KW will be supplied by JUSCO.

3.6 Waste Generation and Management

The principal solid wastes would be fly-ash and bottom ash apart from neutralization tank

sludge, which would be dried and stored within the Plant. The fly ash and bottom ash generation

would be in the range of 43-45% of coal consumption. It will be completely reused in the cement

manufacturing process.

4.0 SITE ANALYSIS

4.1 Connectivity

The site is well connected to NH - 33 (approx. 8.0 km in NE direction from the plant site)

and SH - 6 (approx. 3.5 km in WNW direction from the plant site). Nearest city is Jamshedpur

(approx. 6.5 km in NW direction from the plant site). Nearest Airport Ranchi is approx. 112 km

in NW direction from the plant site. The site is well connected with communication facilities like

telephone, fax, wireless and as such, no constraints are envisaged in this aspect as the tehsil and

district headquarters are near to the site.

4.2 Present Land Use

Existing plant area is 123 Acres(49.77 Ha.) and the proposed expansion will be done

within the existing premises; hence, no additional land is required for the proposed expansion

project.

4.3 Topography

The topography of the area is not flat and have minor undulations; consisting of series of

hummocks having an average elevation of 175 metres. A detailed analysis of slope in the area

has been carried out. It has been observed that topography of the area is undulating with a



hummock running in the NE-SW direction. The general drainage is parallel to sub parallel. The

drainage in surrounding area is dendritic in nature and the drainage density ranges from moderate

to poor thus indicating low run-off.

4.4 Existing Infrastructure

Total existing plant area is 123 Acres(49.77 Ha.) and the proposed expansion will be

done within the existing plant premises area. All basic infrastructure viz. canteen, Administrative

building, Store, Sheds are available within the existing plant premises.

4.5 Climatic data from secondary sources

The district receives an annual rainfall of 1500 mm. and most of it occurs during the

rainy season. Mean annual temperature is above 26 C. The temperature ranges from 16 C in

winter month to 44 C in summer months. The Climate of the district is tropical. Average rain

fall is 800 mm per year. Average relative humidity being 70%.

5.0 PLANNING BRIEF

5.1 Planning Concept

Technical Concept

This technical concept indicates the plant capacity, size and type of main machinery,

storages, design of systems, plant layout, flow sheets etc. It covers process, mechanical,

electrical, instrumentation and civil engineering aspects. The concept has considered quality,

pollution control, operation, maintenance and utility services.

Process Control, Instrumentation and Automation

Integrated & Distributed Microprocessor based, Control & Instrumentation system has

been considered for effective control of various process variables.

Human Resources

Human Resource is the most valuable asset in any industry. The accelerating pace of

technology advancement and fierce competition in the market has led to the increasing

importance of human resources. Continuous skill updating of the existing human resources and

generating new talents in consonance with the needs of the industry are vital for the progress of

the industry.



5.2 Land Use Planning

Total existing plant area is 123 Acres (49.77 Ha.)and the proposed expansion will be

done within the existing plant premises area.

6.0 PROPOSED INFRASTRUCTURE

The setting up of the thermal power plant, their auxiliary equipments, coal storage areas,

electrical power receiving and evacuation substation, administrative buildings is envisaged.

6.1 Green Belt

16.42 Ha. (Approx. 33 % of total plant area) has already been developed under greenbelt

/ plantation.

6.2 Others

1. A garland drain around the plant is envisaged to collect surface run-off during rainy season.

2. Drinking water facilities will be provided for employees as well as nearby villagers.

3. Existing road and rail network will be utilized for raw material and final products

transportation. However existing road network will be strengthened.

4. Drinking water facilities will be provided for employees as well as nearby villagers.

5. Existing road and rail network will be utilized for raw material and final products

transportation. However existing road network will be strengthened.

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

Proposed expansion will be done within the existing plant premises and no additional

land is required for the same; hence R & R is not applicable.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

The unit will be completed in 22 months. An effective project team has been formulated

with an experienced Project Manager as its leader.



8.2 Project Cost

An indicative estimated capital cost of the proposed power plant is 163.28 Cr. Including

the Pre-operative expanses, contingency and interest during construction.

9.0 ANALYSIS OF PROPOSAL

The benefits of the proposed unit as follows,

1. Improving and building road network in the adjoining villages.

2. Strengthening local school buildings with playgrounds.

3. Social awareness programme will further improve by the local authority such as sanitation

and hygiene, HIV Prevention Program.

4. Through this project, adult education and female education will be provided to the

illiterate adults and backward females of the villages in the project surrounding area.

Sponsor the education to Poor Students of the Proposed Area.

Plus additional jobs generated by local business in the supply of raw materials, finished

products and services. Development of the local area in terms of an enlarged market will

provide the farmers with a good outlet of their agricultural products to enjoy the price effect,

which is likely to be strong enough to offset the impending local inflations through real-balance

effect. Thus, the proposed project will be ushered in the social and economic upliftment of the

persons living in the vicinity of the Project i.e. of society at large.



CHAPTER – 02

INTRODUCTION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT



Cement Grinding Unit within existing plant premises of 123 Acres(49.77 Ha.) and CPP over an



hereafter refer as NVCL entered the Indian market in 1999. Lafarge has four cement plants in

India: two plants in the state of Chattisgarh (Sonadih and Arasmeta) and grinding units in

Jharkhand (Jojobera) and cement plant in Chhattisgarh. NVCL have cement grinding capacity of

4.6 MTPA at Jojobera & are planning to increase production capacity to 6.6 MTPA. The power

demand of the plant at present is met from JUSCO.



grinding plant.

Table 2.1 Background of the Project

Sl. No. Description Date

1 Environmental Clearance for Proposed expansion

Cement Grinding Unit from 3.4 MTPA to 4.6

MTPA

Issued by MoEF &CC vide F.

No. J-11011/638/2008-IA II

(I) on dated 19.12.2008

2 Amendment in Environmental Clearance for

Proposed expansion Cement Grinding Unit from

3.4 MTPA to 4.6 MTPA

Issued by MoEF &CC vide F.

No. J-11011/638/2008-IA II

(I) on dated 16.03.2016

3 Application for getting EC for proposed

expansion of Cement Grinding Unit from 4.6

MTPA to 6.6 MTPA.

Applied on 12.07.2016.

Proposal No.

IA/JH?IND/57393/2016

MoEF &CC File No. J-



11011/638/2008-IA.II(I)

2.2 DESCRIPTION OF NATURE OF THE PROJECT



Cement Grinding Unit within existing plant premises of 123 Acres (49.77 Ha.)and CPP over an


Table 2.2 Project Profile

Sl. No. Units Production CapacityExisting Unit1 Cement Grinding Unit 4.6 MTPAProposed Expansion Unit1 1 X 27 MW Coal Based CPP 27 MWProposed Interlinked Project applied for EC1 Cement Grinding Unit Expansion from 4.6 MTPA to 6.6 MTPA

2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/OR

REGION

Indian cement industry is large, growing and with consumption of 185kg/capita/yr in

2011 (compared to global average of ~300 kg/capita/yr) the country itself has the capacity to

demand significantly more cement as it develops.

In India, Jharkhand has around 40 per cent of the country’s mineral wealth such as coal,

limestone etc. In addition to the large raw material deposits, the strategic location of Jharkhand,

proximity to large markets in southern and central India (providing an opportunity to cater to

these markets) and 1805 kms of national highway passing through the State, have made

Jharkhand an ideal destination for establishing cement units.

Now with the government of India giving push to various infrastructure projects, housing

facilities and road networks, the cement industry in India is currently growing at an enviable

pace and further growth in the Indian cement industry is expected in the coming years.

Therefore, there is an urgent need to increase the production capacity in the country.

Hence, the proposal for expansion of Grinding Unit by NVCL will cater the increasing

demand of cement in the country and region of Jharkhand.



NVCL have cement grinding capacity of 4.6 MTPA at Jojobera & are planning to

increase production capacity to 6.6 MTPA. The power demand of the plant at present is met from

JUSCO.



grinding plant by installing 1 X 27 MW Coal based CPP.

Demand-Supply Gap

Power Demand Analysis and Justification Of Project

India is one of the largest growing economies of the world. It is the fourth largest

economy and has shown consistent GDP growth over the past few years. It has been seen from

the historical data that the growth in GDP has a direct relation with the sustained growth of all

area of electricity– Generation, Transmission and Distribution. Therefore to maintain the

projected level of growth in country’s economy, it is to be ensured that rapid growth in power

sector is maintained. Availability of power is one of the major infrastructure requirements for

overall development of a nation. Rapid industrial growth, ever increasing demand in domestic,

manufacturing and service sectors coupled with progressive extension of power transmission and

distribution system have led to the rapid growth of electricity demand. Despite appreciable

capacity additions in Power Sector, the demand for power has outstripped the availability in

many parts of the country. Unlike the ideal conditions where the system should have some

spinning reserves to meet unforeseen outages and surges of demand, Power demand in India has

always outstripped the availability. The demand analysis and justification for setting up of a

power plant at any part of the country needs to be corroborated with the facts and figures of the

existing as well as future demand-supply scenario of the area concern in light of India’s

perspective.

From the below provided monthly report, the deficit and available power details of entire

India are provided, in which Gujarat is seen to have 2.1% deficit every month. The demand was

41,184 MW against a supply of 40,331 MW. The demand for power requirement is more and

produced power is less. Hence, this project would reduce the deficit to certain extent.



Table 2.3 Peak Demand and Peak Met in India

Installed Capacity and Production

The Proposed expansion project is intends to produce 27 power by installing 1 X27 MW

coal based Thermal Power plant.

Imports vs. Indigenous production.

Since the Project is Power generation, only indigenous production envisaged. The

proposed power plant will use the Indian coal supplied from Open Market Purchase.



2.4 Employment Generation

Direct and indirect employment will be generated to the local population, the total man

power requirement during construction phase for the project will be 200-250, out of which 8 are

the permanent senior level persons and rest will be the casual workers for construction, erection

gardening, packing, cleaning etc.

Similarly, during operation expected additional employment to the existing plant will be

43 and total employment after expansion will be 1390.

Table 2.4 Manpower Requirement-Existing

Sl. No. Particulars Existing

1 Skilled 794

2 Semi – Skilled /

Unskilled553

Total 1347

Table 2.5 Manpower Requirement-Proposed Expansion

Manpower DetailsArea Manager Engineer Supervisor Technicians Operator

&Chemist

Total

TopManagement

1 - - - - 1

Operations - 4 8 - 12 24Maintenance - 4 - 14 - 18Total People 1 8 8 14 12 43

Training of Personnel

Training of the required manpower for the proposed project shall be planned, well in

advance. The key personnel shall be selected and trained suitably. The training shall be carried

out in the following manner:

1. Onsite training during the construction phase of the Project

2. On job training during the commissioning phase of the project.

3. On job training during operation of the plant immediately after commissioning.

The training of the key engineering personnel such as Process Engineer, Mechanical

Engineer, Electrical Engineer and Instrumentation Engineer shall be carried out in all the facets.



The training of the key operating personnel such as boiler operator, mechanic,

welder, fitter and electrician shall be suitably carried out during the construction, erection and

operation phases.

The training program shall include the following aspects among others so as to impart

knowledge and training to the key personnel in relevant aspects of the plant design, operation

and maintenance:

1. Understanding the functions of various units.

2. Understanding the equipment in respective sections and the

3. Important parts and control in each equipment.

4. The hazards in respective sections and precautions to be taken for safety of the equipment &

personnel.

5. Inspection, preparation and start up of equipment in respective sections.

6. Routine operation of respective sections.

7. Shut down procedures for respective sections.

8. Procedure for attending to emergency stoppage due to failure of power, water and air supply.



CHAPTER – 03

PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

NVCL proposed for the expansion of its 4.6 MTPA Cement Grinding Unit by installing 1

X 27 MW Coal based Captive Power Plant with in its existing plant premises over an area of 3.0

Ha. At Village-Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand.

3.2 LOCATION

Proposed expansion is within the existing cement grinding unit plant premises located at

Village-Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand. Total area required is 3.0

Ha. available within existing 123 Acres(49.77 Ha.) of land. existing land. The proposed

expansion site falls under the Survey of India Toposheet No. 73 J/1 and the buffer zone falls

under the Survey of India Toposheet 73 J/2, 73 J/5 and 73 J/6. The Latitude and Longitude of the

proposed site is 22°44’55.64”N and 86°15’02.9”E respectively.

3.2.1 Plant Location

Figure 3.1 Index Map



Figure 3.2 Topo Map (10 Km Radius)

3.2.2 Land Requirement


of total 123 Acres.

Table 3.1 Land Use Breakup

Sl. No. Particulars Area in Ha. Total Area inHa.Existing Expansion

1 Clinker Grinding Unit 26.06 -- 26.062 CPP -- 3.0 3.03 Greenbelt/Plantation 16.96 -- 16.964 Railway Siding 3.75 -- 3.75

Total 49.77

3.2.3 Plant Layout

M/s Nuvoco Vistas Corporation Limited (Formerly Lafarge India Limited)Pre-Feasibility Report on Proposed Installation of 1 X 27 MW Coal based Captive Power Plant in the Existing 4.6 MTPA Cement GrindingUnit at Jojobera, Dist- East Singhbhum. Jharkhand

Visiontek Consultancy Services Private Limited Page 17Figure 3.3(a) Plant Layout-Exisitng

M/s Nuvoco Vistas Corporation Limited (Formerly Lafarge India Limited)Pre-Feasibility Report on Proposed Installation of 1 X 27 MW Coal based Captive Power Plant in the Existing 4.6 MTPA Cement GrindingUnit at Jojobera, Dist- East Singhbhum. Jharkhand

Visiontek Consultancy Services Private Limited Page 18Figure 3.3 (b) Plant Layout- Proposed Expansion



3.3 SITE SELECTION


of total 123 Acres. The site selection of Power Plant has been based on the following

considerations.

Plant availability.

Cooling Water availability.

Compatibility of grid to withstand sudden outage of unit.

Operating experience of the set size.

Thermodynamic cycle efficiency and specific input consumption viz. fuel, water etc..

Specific investment requirement & cost of generation.

3.4 TECHNOLOGY SELECTION

The selected configuration consist of 1 x 27 MW power plant with CFBC boiler with

a continuous rating of 120 tph connected to a single turbo-generator of 27 MW nominal

capacity.

The type of turbine & boiler are discussed below:

Pulverised fuel firing (PF)

Fluidised Bed Combustion (FBC)

Following aspects are considered while selecting the type of fuel firing system:

The boiler type and size are to be chosen considering the fact that the coal

supply to the power plant can vary in quality, over a period of time.

Some of the salient features of PF and FBC types of boilers are given below:

PF Boiler

The pulverised coal firing gives marginal improvement efficiency compared

to fluidized bed firing. However, for a power project with boiler size of 120 tph, PF

boilers are not techno-commercially viable. In addition, PF boiler are designed for

specific fuel characteristics and cannot accept large variations in coal fuel quality as such

are considered for Power plant having fixed mine coal characteristics. In addition, PF

boiler operation on petcoke is constrained.



Hence, pulverised coal firing option is not considered.

FBC

In the last two decades, the concept of “fluidized bed combustion” has been

extensively adopted for boilers in our country. As on date, there are more than 400 nos. of

fluidized bed boilers upto 450 tph working in World wide. Some of the advantages

are as follows:

The fluidized bed combustion can work with lower levels of excess air because of

the excellent turbulence created by high velocity air steams in the combustion zones.

The fluidized bed combustion requires larger size coal particles i.e. approx. 6 to 8 mm

as compared to pulverised coal firing and hence consumes lesser auxiliary power.

Due to the intense mixing created in the combustion zone, the fluidized bed

boilers tolerate much wider variety in the properties of fuel fired as compared to pulverised

coal fired boilers.

Considering the above, FBC Boiler option is being considered for the proposed

Thermal Power Plant.

3.4.1 Selection Recommendation

Based on the above analysis, following configurations shall be adopted for the each

units:

Table 3.2 Proposed Configuration

A Steam Generator

a. No. and ratings of Boiler 1 no. with Maximum Continuous

rating 120 tph & 540oCb. Type of Boiler CFBC

c. No. of Boiler fans 2 X 60 % duty for ID & SA & SA Fan

d. Type of Atmospheric pollution

control system

Electro static precipitators withoutlet dust concentration less

than 30 mg / Nm3 & So2 as100mg/Nm3 by considering FGD

B Steam Turbine Generator

a No. and ratings of turbine 1 no. for each unit of inletparameters,105 kg & 535oC



b Capacity 27 MW Max. Continuous rating

c No. of controlled extractions 4 nos. 2 HP, 1 MP and 1 LP

D Type of exhaust steam cooling With Air Cooled Condenser

The proposed expansion is installation of 1 X 27 MW Coal Based Captive Power Plant

based on Conventional Steam Cycle Operating in Rankine Cycle, consisting of 120 TPH CFBC

Boiler and 1 no. Turbine 535 ⁰C at 105 Kg/Cm² pressure.

3.5 PROCESS DESCRIPTION

3.5.1 Mechanical Equipment and System

The selection covers selection of Mechanical equipment and system for efficient

operation of the power plant.

3.5.1.1 Steam Generator

The steam generating system for each unit of 27 MW power plant will consist of one

no. 120 TPH capacity boiler with all the auxiliaries. The boilers shall be of circulating

fluidized bed type, natural circulation, balanced draft, and membrane wall radiant furnace

design with three (3) stage super-heaters and inter-stage de-super heater.

Table 3.3 Steam Generator Design Parameter

Maximum continuous rating (MCR) (T/hr) 120

Super-heater outlet pressure (kg/cm2 (g)) 110

Super-heater outlet temperature (oC) 540 +5

Feed water inlet temperature (oC) at eco inlet 230

Excess air (%) Not more than 25

Boiler outlet flue gas temperature (oC) 150 (max.)

Dust concentration at chimney (mg/Nm3) 30 (max.)

The steam generator shall be provided with a steam drum and the drum shall be of

fusion-welded type. The steam drum shall be with necessary nozzle connections for the



steam outlets, safety valves, feed water inlets, down-comers, continuous blow down, level

indicators, chemical dosing, sampling connection, drains and vents to assure the required

steam purity.

3.5.1.2 Furnace

The furnace envelope shall be constructed of fully water-cooled membrane/fin welded

walls and the construction shall be gas pressure tight.

The furnace bottom shall be covered with an air nozzle tube plate, below which the

fluidizer air plenum shall be located. The coal / pet coke of properly graded size shall

be brought to the furnace through over bed feeding system.

3.5.1.3 Super Heater

Super-heater system shall be of three (3) stage design with inter-stage de-

superheating to achieve the rated steam temperature over 60% to 100% MCR load. The

super-heater shall be combination of convection and radiation type.

The inter-stage attemperator or a de-super-heater of spray type shall be located

between the two super-heater stages, to control the final steam temperature at 540 + 5oC

between 60% to 100% MCR load.

3.5.1.4 Economizer

The economizer shall be located downstream of the super-heaters and evaporator

sections. The economizer shall be of bare tube construction, inline arrangement, counter

flow type and the economizer shall be designed for inlet temperature of 230 oC.

3.5.1.5 Air Heater

Air heater shall be arranged as the last heat recovery section downstream of

economiser. Air heater shall be recuperative type with flue gas flowing inside the tubes

and the combustion air flowing over the tubes. Considering usage of the pet coke the last

bank of air heater is corton steel.



3.5.1.6 Draft System

The draft system for the steam generator shall be suitable of producing a balanced

draft with sub-atmospheric pressure condition in the furnace.

The system shall be comprising of:

2 X 60% PA Fan

2X 60% ID Fan

2 X 60% SA Fan

3.5.1.7 HP & LP Dosing System

Steam generator shall be with High Pressure (HP) dosing and Low Pressure (LP)

dosing system. The HP dosing system shall be based on ‘tri-sodium phosphate’ dosing

and this shall be dosed in boiler water to take care of the ingress of the hardness salts

and to increase the boiler water pH. The LP dosing system shall be based on ‘hydrazine’

dosing and this is dosed in the feed water to scavenge the last traces of oxygen and to

increase the feed water pH.

3.5.1.8 Blow Down Tank

One Continuous Blow Down tank (CBD) and one Intermittent Blow Down tank

(IBD) shall be provided for each of the boiler. The flash steam from the CBD tank shall

be piped to the de-aerator and outlet of the IBD tank shall be vented to the atmosphere.

3.5.1.9 De-Aerator

One De-aerator of de-aerating capacity equal to twenty percent (20%) higher than the

gross MCR steam generation capacity of boiler with a de-aerated water storage tank of

minimum 10 minutes operation.

3.5.2 Steam Turbine & Auxiliaries

3.5.2.1Steam Turbine

This project envisages 27 MW multi extraction-cum-condensing turbo-generators.



The turbine shall be designed for the operation with the inlet steam parameters at 105

ata and 535 deg C and shall be with automatic controlled extraction steam.

The turbine shall be horizontal, single cylinder, triple extraction-cum-condensing

type. All casings and stator blade carriers shall be horizontally split.

The controlled extraction steam from the turbine shall be delivered to the

heaters/de-aerators in saturated condition.

A de-superheater to bring the steam temperature from the extraction steam

temperature down to the required level is envisaged.

3.5.2.2 Lubrication System

A pressure lubrication and control oil system shall be provided for the turbo-generator

unit to supply oil at the required pressure to the steam turbine, gearbox, generator and

governing system. The lubrication oil system shall supply oil to the turbine generator

under all the load conditions, including the turning gear operation.

The oil system shall be with the following:One hundred percent (100%) capacity centrifugal/gear type, main oil pump.

One (1) no. of one hundred percent (100%) capacity auxiliary oil pump of

centrifugal type, arranged to cut in automatically if the oil pressure falls to a preset value.

This pump shall also meet the requirements during the start up and shut down.

One (1) no., centrifugal type, DC emergency oil pump to provide adequate

lubrication in the event of a failure of the main driven pump. This pump also shall cut in

automatically at a preset value of the oil pressure.

Emergency gravity lube oil system comprising of overhead tank with SS lining and

complete interconnecting SS oil piping.

2x100% capacity (one working and one standby) water-cooled air coolers.

2x100% duty oil filters

3.5.2.3 Turbine Governor

The turbine governing system shall be electro-hydraulic type, designed for high

accuracy, speed and sensitivity of response. The governor shall ensure controlled

acceleration of the turbo generator and shall prevent over-speed without tripping the unit



under any operating condition or in the even of maximum load rejection. The governor shall

be configurable in the field.

The governing system shall have the following important functions:Speed Control

Over Speed Control

Low Control

Steam Pressure Control

The governing system shall be digital governor with all parameter control from plant DCS

system.

3.5.2.4 Air Cooled Condenser

The waste heat produced in the thermal process of the plant has to be transferred to

the atmosphere by using adequate cooling system. Environmental concern and climatic

conditions are the main factors in the selection of the most suitable power station process.

Since water availability is concern as such to save natural resources & to have

sustained generation Air cooled Condenser is considered with Air Cooled Condenser approx.

90% of the water is saved. The basic Configuration of Air cooled condenser is as follows

Figure 3.4 Air Cooled Condenser



3.5.2.5 Turbine Control

The turbine control shall be through the centrally located Distributed Control System.

The control system shall provide redundancy for key functions by use of separate sensors

and monitors. The control system shall include all the standard control monitoring and

alarming.

In addition to centralized monitoring, some of the essential parameters mounted in

local shall be :

Inlet steam pressure temperature and flow

Controlled extraction steam pressure and temperature

Exhaust steam pressure, temperature and flow

Lube oil header pressure

Control oil header pressure

Steam turbine/generator speed indicator

Steam turbine/generator stop push button

Turbine back propose controlEmergency shutdown push button

3.5.3 Flue Gas De Sulfurization System (FGD)Wet limestone scrubbing systems are designed for high SO2 removal efficiencies that

are needed to meet the desired outlet SO2 level. As well as the wet limestone process is

controlled based on SO2 in a closed loop operation, in which fresh water is added to the

system only as makeup water for water lost by evaporation and lost with the gypsum flakes.

The flue gas is brought into contact with the limestone slurry in a spray

tower. Chemical reaction of limestone with SO2 in the flue gas produces gypsum, which

must be removed continuously from the scrubbing loop. Theses gypsum solids are separated

in a hydro cyclone and then dewatered in a Rotary Vacuum Drum/Belt Filter to produce

semi dry Gypsum which can be used in Cement industries.

3.5.3.1 Process Control

The primary functions of a wet limestone FGD process control

To bring SO2 emission within the required limits

To achieve optimum limestone utilization and energy consumption

To achieve continuous and reliable operation



3.5.3.2Exhaust Gas Control

The exhaust gases from boiler shall enter the FGD plant through Diverter Valve OR

Guillotine damper and the Booster Fan shall provide the necessary head for

overcoming the pressure drop through FGD plant.

The speed of the Booster Fan is varied to maintain the set pressure at inlet of Booster

Fan. FGD can be bypassed by using Guillotine Dampers by closing the Dampers (i.e. –

open to existing chimney) under any of the following conditions

Booster Fan is off Boiler is unhealthy

3.5.3.3 Lime Slurry Preparation

The process water flow to slurry tank is regulated by Flow Control Valve to maintain

steady level in Slurry Preparation Tank with input signal from Level Transmitter.

The process water flow to Slurry Preparation Tank is measured using the Water Flow

Meter and the flow signal is used for modulating the rotary limestone feeder through the

variable speed drive.

The process water flow for slurry preparation is diverted to either of the Slurry

Preparation Tank through pneumatically actuated isolation valves.

3.5.3.4 Limestone Feed Control Pump

Limestone slurry feed rate is one of the factors that determines the extent of

limestone dissolution in the Oxidation Tank and thus pH of the slurry in the tank,

which in turn affects the SO2 removal. The pH level can be used in a simple feedback

control loop to regulate the flow of limestone feed to the Oxidation tank. Value of pH 7 is

considered as neutral , less than 7 is acidic & 7 to 12 as alkaline

All operational systems control the limestone feed rate with a feedback loop using pH

as the controlled variable. A pH electrode probe activates a signal that regulates the VFD of

Pump to control the rate of limestone feed.

For pH control, dip-type electrode probes, which are inserted into a in-line, flow-

through probes, located in a section of piping. Flow-through sensors must be removed

and kept wet if the sample line is drained when the Plant is shut down.



3.5.3.5 Colour of Gypsum

In FGD process the Gypsum is generated from reaction of SO2 (pollutant) and alkali

reagent (Limestone, CaCO3) in presence of Water. The exhaust gases going to FGD process

are from ESP exhaust; hence it also contains fly ash particles in the range of 50 to 150

mg/Nm3 (depending upon the ESP Performance). These fly ash particles being insoluble in

water goes into gypsum as impurity. Hence, colour of Gypsum in FGD Process is

uncontrollable factor.

The colour of Gypsum can be brownish gray and the whiteness cannot be

predicted or guaranteed even if the whiteness of limestone is known and assured.

3.5.3.6 Utilization of FGD Gypsum in Cement Production

The whiteness of Gypsum should be minimum 90% to make it suitable for use

in cement production.

Hence whether FGD Gypsum can be utilized in cement or not is a matter of

experience and can be confirmed only after actual FGD Gypsum is produced from the FGD

Plant.

However, it is evident that the FGD Gypsum having purity around 65-70%

(comparable or higher than mined gypsum) is 100% utilized in grey cement

production.



Figure 3.5 Process Flow Diagram-FGD



Figure 3.6 Process Flow diagram

3.5.4 Utilities & Services

3.5.4.1 Ash HandlingThe ash generated from the above shall be about 18 T / hr. maximum while using

washery rejects. Out of this 30% is expected to be Bed Ash and rest 70% shall be Fly-ash to be

collected from Boiler EP/ Economizer/ Cyclone. The details of quantity are as furnished below:-

➢ Fly ash shall be transported pneumatically with the help of dense phase pneumatic to the

fly ash silo from Economizer, Cyclone and EP. The fly ash from the silo shall be used in

PPC cement production inside plant.

➢ Bed Ash will be collected from overflow spouts into ash cooler hoppers. Ash from the

hoppers, after sufficient cooling will be discharged through ash vessel of pneumatic

conveying system to bed ash silo. bed ash shall be disposed through trucks.



➢ Flyash silo has been considered of capacity of 300m3.

➢ Bed ash silo has been considered of capacity 100m3.

Water System

Raw intake system of the plant shall be from the JUSCO (water supplier).The water shall

only be used for the input to RO/ DM plant, auxiliary circuit for generator cooling, lube oil

cooler, cycle water make up.

Source of Water System

JUSCO (Water supplier) shall be used for water requirement of the power plant.

Dematerialized water system

To cater to the make-up water requirement of the steam generator turbine cycle, a

dematerialized water of 12 m3/hr capacity is required.

To meet operation requirement, start-up and load throw lot of venting is there. To

overcome such requirement the RO water reserve of above 200m3 is proposed at plant.

Compressed air system

Compressed air is required for meeting the needs of various mechanical equipment’s and

for instruments. A Centralised compressor is envisaged for this economizing the overall cost.

The compressors shall be fitted with all auxiliaries like receivers, dryers, moisture and oil

separators and also necessary control panels. The compressor dew point shall be restricted to -

20° C. Outlet from service air compressor shall be routed to various areas like steam generator,

TG Hall extension, coal handling etc. In addition to this separate compressor for cleaning and

other miscellaneous purposes.

HP & LP Piping

The piping for the Power Plant has been divided as follows :-

➢ Power cycle piping

➢ Low pressure utility piping

➢ Cooling water piping

➢ Fire water piping

➢ Compressed air piping



Power cycle piping

The power cycle piping of each unit shall consist of mainly the following:

➢ Main stream piping from generator to turbine inlet

➢ Interconnection between main steam piping and auxiliary steam header through a

Pressure Reducing and DE superheating Station (PRDS)

➢ Boiler feed water pump suction piping

➢ Boiler feed water suction piping and common feed water header

➢ Boiler feed water pump recirculation piping

➢ Condensate extraction pump discharge piping

➢ Condensate extraction pump suction piping

➢ Heat Exchanger piping

➢ Boiler blow down piping

Low pressure utility piping

➢ Raw Water

➢ R.O Plant Water

Cooling water piping

➢ Heat Exchanger for Main Plant Area

➢ Heat Exchanger for Compressed Air System

Fire fighting piping

➢ For fire Hydrants

Compressed air piping

➢ Instrument air

➢ Service air

Fire protection system

Fire protection in the proposed power plant is envisaged for the following purposes:

➢ Early Detection

➢ Alarm

➢ Suppression of Fire

The entire fire protection shall be designed to meet above requirement effectively and

quickly as per the guidelines set out by the Tariff Advisory Committee.



For detection of fire, necessary smoke and heat detectors and manual call buttons with

centralised zonal control room have been envisaged. Suitable alarm system shall also be

provided along with detection system.

Fire protection system shall consist of:

➢ Fire Hydrants

➢ Portable Fire Extinguishers

➢ Heat sensing cable for cable trays

➢ Spray system for power transfer & lube oil system

The hydrant system shall consist of one electric driven water pump and one diesel engine

driven standby pump along with necessary length of hose to be laid around vulnerable points.

Various water pumping points shall be provided along the length of hose as per requirement.

Portable fire extinguishers shall consist of a combination of different type of

extinguishers like foam type, CO2 type etc.

Air conditioning

Air conditioning has been considered for the following

➢ Control room

➢ Group level controller and Electronic panel room

➢ UPS panel room

➢ SWAS room

Based on estimated heat load, the capacity of air-conditioning unit works out to:

➢ 20 TR for controller and electronic panel room

➢ 15 TR for Control room

➢ 5 TR for UPS room and SWAS room

Based on the heat load, operational ease, flexibility and reliability of the system air

cooled package type is being considered.

Ventilation

The Pressurise & ventilation system for turbine building is provided to evacuate the heat

liberated from the operating equipment and to prevent ingress of atmospheric dust.

For effective draft, induced draft ventilation system shall be provided for turbine building

by installing sufficient roof exhausters. All the air entering the turbine building shall rise through

various floor grills/gratings and the hot air shall finally be exhausted through roof exhausters.



For switchgear/MCC room, clean air is required for protection of the equipment. Air

filters are used in supply air and dampers are provided to maintain positive pressure of 3-

4mmWG inside the room.

In order to have controlled atmosphere, the ventilation system shall consist of :

➢ Air intake louvers

➢ viscous and fine filters

➢ Centrifugal blower

3.5.5 Electrical Equipment And System

GeneratorThe Generator will be coupled to the steam turbine and shall match with turbine

maximum output.

The Generator will be of 6.6 KV, 3 phase, 50 Hz, 0.8 p.f. (lap), Class ‘F’ insulation for

Stator and Rotor with temp. rise limited to Class ‘B’.

The Generator shall be with brush-less excitation. The excitation system will have

automatic voltage regulator to maintain steady generator terminal voltage under varying load

conditions.

HT switchgear6.6 KV single bus switchboards shall be provided at power plant.

6.6 KV switchgear will be motor operated vacuum circuit breaker.

The Circuit Breaker shall be used for synchronizing purpose and providing unitized

protection for Generator, Station Transformer and Outgoing Feeders.

Switchgear shall be located in Electrical Room with Air Conditioned system.

6.6 kV bus ductConnection from 27 MW Generators to 6.6 KV Switchboard will be through 6.6 KV Bus

bar segregated in sheet steel suitable for Indoor installation as required by Layout consideration

Outgoing feeder and auxiliary transformer will be connected to 6.6 KV Switchgear by

armoured Aluminum conductor XLPE cable.



0.415 kV motorsGenerally, motors shall be squirrel cage induction motors suitable for 0.415KV +10%, 50

Hz +3%, Class ‘F insulation with temperature rise limited to Class ‘B’. Motor for boiler feed

pump, ID, SA fan ,PA fans & ACC fans shall be suitable VVVF Drives.

Neutral grounding resistor (NGT)➢ For 6.6 KV system, low resistance grounding is envisaged so as to facilitate selective

clearance of ground circuit earth fault current.

➢ The ground resistance of Generator shall restrict earth fault current. Neutral grounding

transformer / neutral grounding resister is envisaged.

Control and relaying➢ For protection of the equipment against abnormal condition, adequate protective relay

shall be considered.

➢ Proper discrimination will be provided to isolate the faulty elements incase of any fault.

LT auxiliary transformer3 nos. LT auxiliary transformers of 2000KVA, 6.6/0.415 KV ONAN have been

envisaged for supplying power-to-power plant LV auxiliaries at each location.

415V auxiliary distribution➢ Secondary of Auxiliary Transformer to 415 V Power Control Center shall be through

bus-duct.

➢ LT switchboard shall be fully draw-out, motor operated circuit breaker with necessary

protection features to facilitate safe operation and easy maintenance.

➢ Section-wise distribution to plant LT load shall be made through down stream MCC.

DC system➢ A 110V DC system is envisaged for the Plant

➢ DC shall cater to DC loads of HV, LV switchgear, AVR, relay system and DC

emergency lighting

➢ Alarm and annunciation of the plant condition during emergency

➢ Emergency lube oil pump for turbine

UPS systemRedundant mode UPS with its own battery will be provided to feed following loads:

➢ Burner Management System

➢ Turbine Supervisory Instruments



➢ Plant Communication System

➢ DCS System

➢ Fire Alarm System

Station illumination systemAn efficient illumination system is necessary to ensure safety of operating personnel.

Suitable numbers of lighting panels are envisaged. Power to same shall be fed from main

lighting board. Metal Halide Lamps shall be used for Indoor/Outdoor illumination.

Provision shall also be kept for emergency 24V AC/110 V DC lighting in key areas. For

outdoor lighting, photocell / PLC based control lighting has been considered.

Plant communication system

Communication system shall be provided in plant for quick communication among

operating personnel in field and CCR of power plant. Multi-channel communication with

paging/private mode is envisaged with necessary interface.

Adequate stations for each zone shall be provided.

3.5.6 Power Evacuation and Interconnection System

Mode of Operation

Thermal Power Plant shall be operated in:

➢ Isolated mode

➢ Parallel mode with JUSCO GRID

Isolated Mode

It is possible to operate system in isolated mode wherein proposed power plant shall

supply power to plant auxiliaries & Cement plant load . The start up shall be trough dedicated

DG sets. However it is preferred to operate Power plant in parallel with Utility Grid to take care

of Shock load during starting of big drives. The Configuration has also advantage as distribution

system is not effected at Cement Plant.

Parallel Mode

Under this mode of operation, generator shall be operating in parallel with UTILITY

GRID at 33 KV. The synchronization of the UTILITY GRID supply forward and back

synchronization shall be carried at power plant. The switchgear at main sub-station is of suitable

for parallel operation.



Power transfer from Power plant to sub-stations

The proposed interconnection between thermal power plant and the power evacuation

shall be by stepping up power from 6.6 kv to 33 kV using power transformer of 35/40 MVA.

Synchronising facilities

Synchronization shall be carried out from power plant control room. The load

management and control shall also be carried from the power plant.

Necessary synchronization check relay, double voltmeter, double frequency meter etc.

shall be provided in the control room.

Table 3.4 Basic Technical Parameters

Sn. Parameter Unit

Data Sn.

Parameter Unit

Data

A Steam Turbine

1Generation

capacityMW 1 x 27 0 Deaerator No 1

2 No of Generatingunits

No 1 11 DeaeratorStorage time

min 10

3Generating voltage kV 6.6 12 FW temp at

economizerinlet

oC 230

4Steam pressure atthe Turbine

ata 105 13 Type ofCEP -- 2x100%(1w+1s)

5 SteamTemperature

oC 535 + 5 14 Dumpingsystem

% 30

6 Type of Condensercooling

AirCooledCondenser

15 Hot wellpump

Nos 2 x 100%

7Turbine exhaust

pressureata 0.20 16 Governor Woodward

505

8LP heater No 1 17 TG vibration

monitoringsystem

BentleyNevada

make 3500

9HP heater No 2 18 Sox / Nox

emission100 ppm

/ 200ppm

B BOILER



1Type of boiler CFBC 10 Coal Bunker

capacity(storage hours)

m3 2X 300 (20hours)

2

No of boilers No 1 11 Bunker SSLiner

2mm thkSS liningat bunkerconicalportion3 Boiler MCR TPH 120 12 No of SA

fansNos 2 x60%

VFD

4Steam temp at

SH outletoC

540± 5 13 No of PAfans

Nos 2 x60%VFD5 Pressure at SH

outletata 110 14 No of ID

fansNos 2 x60%

VFD6

Super heatedtemperature

control range

%60-100 15

ESP outletemissionSPM

30

mg/Nm3

Sn. Parameter Unit Data Sn. Parameter Unit Data

7Flue gas temp at

APH outoC

140-160 16 Fuel AnalysiskCal/k g Refer

Chapter-4

8 Fuel to be used

Pet Coke /coal/Anycombination

17

Sulphurcapture

%>95 withFGD

9 Guaranteed fuel Pet Coke /Coal

C Oil firing System1 LDO/ HSD tank Nos 1 4 Type of

pumpsScrew/cen

trif ugaltype

2 Capacity of tank kL 25 5 Duty Unloading/Transfer

3Number of pumps Nos 2x100%

(1w+1s) 6Oil burner reqcapacity forHAG

% 20 of Boilercapacity

D BFP



1No of Boiler feedpumps

No 2 x100%(2w+1s)

3 Type of pump Ringsectiontype, multistage2 Method of

start/VoltageVVVF 4 Type of

BalancingDisc/Drum

E AIR COOLEDCONDENSER

1Type A-

Frame,Dir. aircooled

4Design ambientTemp

oC 45

2No. of ACCassembly

1 no. 5 Turbine BackPressure

ata 0.2

3Fin Type Serpentine 6 Fans VVVF

F AUXILLARY COOLING TOWER

1Type of coolingtower

Induceddraft,Crossflow,splash

grid typefill

6 Range oC 8

2 Capacity 450 m3/hr 7No of ACWpumps

1W + 1S

3No of Cells (1w +1S)

1W+1SB 8 Type of ACWPumps

Horizontal

4 Temp of Hot wateroC

40

9 Type of fills Gridtype

Sn. Parameter Unit

Data Sn. Parameter Unit Data

5Inlet cooling watertemp

oC32 10 Basin construction RCC

G WATER SYSTEM

1DM water tankcapacity m3

200 3 DM plantconfiguration

DMF-SBA-SAC-MB2 DM plant capacity 1X12

m3/hrs



H INSTRUMENT AIRCOMPRESSORS

1Type ofcompressors

Non-lubscrew

4 No. of Airreceiver

m3

1x10m3main plant1x5mr3serviceair1x3m3CHP

2 No ofcompressors

2 x100%

3 Air dryer typeAdsorption/refrigerantI EOT CRANE

1Capacity of mainhook

T 402

Capacity ofAux hook T 5

J FUEL HANDLING

1 Coalreclaimingcapacity

TPH 1254 Out put size

from secondarycrusher

mm 6 to 8

2 Secondary crushercapacity

1X125TPH

5 Primary screencapacity

1X125 TPH

3Coal input sizefor secondarycrusher

mm 75 6Secondary

screencapacity

1X125TPH

K ASH HANDLING

1 Type of system Pneumatic

5 Bed ashdisposal

Dry

2Fly ash silocapacity m3 300 6

No. ofAsh

Conveying

Compressors

2 x100%(1W+1S)

3Bed ash silocapacity M3 100 7

Bed ashoutlettemperature

C 200

L AC / VENTIALTION

1Turbine hall,ventilation

DryType/WetType

5

Electricalswitch gear

room ,Control room

,I/O room

CentralizeAC

M FIRE PROTECTION

Sn. Parameter Unit

Data Sn.

Parameter Unit

Data



1Fire detection

systemAs perlocal

regulation

2 Hydrantsystem

Required

N CHIMNEY

1No of chimney 1 3 Chimney

constructionRCC

2 Height of Chimney m Min 90mtr

4 ChimneyDiameter

m Asrequired

O TG Building Elevator Required

3.6 HEAT & MASS BALANCE

Figure 3.7 Heat & Mass Balance

3.7 RAW MATERIAL

The annual coal requirement considering E/F grade Indian coal for 1 X 27 MW unit is estimated

to be about 0.216 million tonnes (MTPA) as the proposed coal for the plant would be having an



average calorific value of 3200 kCal/kg. Coal would be made available from the nearby mines of

open market purchase.

Table.3.5 Raw Material Requirement & Source

S. No. Raw Materials SourceTransportationMode

RequirementMTPA

Coal Based Supercritical Thermal Power Plant

1 Coal Open market purchase Rail / Road 0.216 MTPA

2 LDOIOCL/HPCL/BPCL Localdepots

Road 80KLPY

3.7.1 Raw Material Analysis

Table 3.6 Chemical Analysis

Sl. No. Parameter Unit Value

Proximate Analysis

1 Fixed Carbon % 24.5

2 Volatiule Matter % 20.5

3 Ash % 45

4 Moisture % 10

Ultimate analysis

1 Carbon % 36.20

2 Hydrogen % 1.70

3 Oxygen % 6.00

4 Moisture % 10

5 Sulphur % 0.30

6 Nitrogen % 0.30

7 Ash % 45.20

8 Fuel Gross Calorific Value Kcal/Kg 3200



3.8 WATER & POWER REQUIREWMENT

The water requirement for the proposed CPP plant works out to be approximately 360m3/

day. In addition, water requirement for Fuel gas Desulfurization is 216m3/day. The total water

requirement shall be 576m3/day. Agreement made with JUSCO is for 2472 m³/Day.

The water requirement for free- fighting and service application has not been considered

because their intermittent requirement and can be met from the cement plant.

Table 3.7 Water Requirement

Sl. No. Particulars Quantity in m³/Day

Existing Plant

1 Process 535

2 Drinking & Greenbelt 470

Proposed Expansion

1 1 X27 MW CPP 360

2 Glue Gas Desulfurization Plant 216

Total 1583

3.9 WASTE GENEARTION AND ITS MANAGEMENT PLAN

3.9.1 Waste Water

Water would be required for steam generation and condenser cooling purpose. The hot

water would be taken to cooling towers and after cooling it would be recycled back for

condenser cooling. The cooling tower blow down would be taken to Common Monitoring Basin

(CMB).

DM plant regeneration waste water would be taken to neutralization pit and then to

Common Monitoring Basin. Boiler blow down would be taken to CMB. The quality of water

from CMB would be checked and then it would be used for coal dust suppression and ash

handling. Run-off water generated from coal stockyard would be collected in sump followed by

settling tank where the coal dust particulates would be separated out and clear water would be

stored in surface impoundments for reuse within the plant. The water used for ash conveying to

ash pond would be recycled back after solids settling in the ash pond. No waste water would be

discharged outside the plant premises.



The plant sanitary waste water including canteen effluent would be treated in a sewage

treatment plant for separation of floating oil and reduction of BOD and the treated effluent would

be partly used for plant greeneries, road washing etc. and the balance would be taken to the pond.

3.9.2 Solid Waste

The principal solid wastes would be fly-ash and bottom ash apart from neutralization tank

sludge, which would be dried and stored within the Plant. The fly ash and bottom ash generation

would be in the range of 43-45 % of coal used. It will be completely reused in the cemen

manufacturing process.

Table 3.8 Air Quality Environment & Management (Air Environment – Mitigation

Measures) Source of air pollution and control measures

Sl.No SOURCES POLLUTANTS MITIGATIVE MEASURES

Coal Handling Section

1. TransferPoints/JunctionHouse

Fugitive Dust All transfer points will be fully enclosed withprovision for access doors. Spillages will beperiodically removed. Dry fog dust suppressionsystem would be provided. Air borne dust at alltransfer points will be extracted through dustextraction system to the bag filters.

3. Belt Conveyers Fugitive Dust All the belt conveyers will be covered and it will beconnected to Bag Filter.

4. Weigh feederdischarge

Fugitive Dust The weigh feeder vents will be connected to bagfilters.

5. Raw materialshoppers

Fugitive Dust The vents of the hoppers will be connected to dustextraction system i.e. bag filter.

Crusher House &Bunker

Fugitive Dust dust extraction system i.e. bag filter & BunkerVentilation System will be provided.

Power Plant

1 Boiler PM ESPs would be provided to control the emissions.Dry low NOx burners(DLNB) would be installed forcontrol of NOx.

ROADS



1. Internal Roads Fugitive Dust The internal roads will be made of Concrete/ Blacktopped.

Manual sweeping/vacuum sweeping will be carriedout regularly followed by water sprinkling.

3.10 NOISE LEVELS

The noise generation from the power plant can be broadly categorized into two type’s

viz. Area and Point sources. All the equipment used can be categorized as point sources and the

vehicular traffic movement can be treated as area source. All the equipment is designed to

comply with the International Norms, Rules and Stipulations on not exceed 75 dB (A).

All these noise generating equipment will be within the buildings and the presence of

workers at these equipment is either not required or Intermittent. People required for intermittent

work near high noise generating equipment will be provided with earplugs and their working

hours in these areas will be regulated.

The noise levels at the periphery of the plant will be well within the stipulated norms of

noise pollution.



3.11 Schematic representations of the feasibility drawing which give information of EIA purpose.



CHAPTER-04

SITE ANALYSIS

4.1 General

M/s Nuvoco Vistas Corporation Limited (Formerly M/s Lafarge India Limited) proposed

for the expansion of its 4.6 MTPA Cement Grinding Unit by installing 1 X 27 MW Coal based

Captive Power Plant with in its existing plant premises over an area of 3.0 Ha. At Village-

Jojobera, P.O- Rahargora, Dist- East Singhbhum, Jharkhand.

4.2 Connectivity


and SH - 6 (approx. 3.5 km in WNW direction from the plant site). Nearest city is Jamshedpur

(approx. 6.5 km in NW direction from the plant site). Nearest Airport Ranchi is approx. 112 km

in NW direction from the plant site. The site is well connected with communication facilities like

telephone, fax, wireless and as such, no constraints are envisaged in this aspect as the tehsil and

district headquarters are near to the site.

4.3 Present Land Use

Existing plant area is 54.147 ha and the proposed expansion will be done within the

existing premises; hence, no additional land is required for the proposed expansion project.

Table 4.1 Environmental Setting of the Area

S.NO.

PARTICULARS

DETAILS

(with approximate aerial distance & direction from the

plant site)

1. Nearest Town / City Jamshedpur (6.5 km in NW direction)

2. Nearest National Highway /

State Highway

o SH- 6 (3.5 km in WNW direction)

o NH - 33 (8.0 km in NE direction)

3. Nearest Railway station Tatanagar Railway Station (4 km in WNW direction)

4. Nearest Airport Ranchi Airport (112 km in NW direction)

5. National Parks, Wildlife

Sanctuaries, Biosphere

Reserves within 10 km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve

exists within 10 km radius of plant site.



S.NO.

PARTICULARS

DETAILS

(with approximate aerial distance & direction from the

plant site)

6. Reserve Forests (RF) /

Protected Forests (PF) within

10 km radius

Patches of RF and PF exist in North to NE direction within

10 km radius study area.

7. River / Water Body (within 10

km radius)

o Hitkujuri Nala (3.5 km in S direction)

o Harkarjuriya Nala (4.5 km in SSE direction)

o Subarnarekha River (5.5 km in NNE direction)

o Kharkai River (7.0 km in WNW direction)

o Dimna Jhor (7.0 km in N direction)

o Dudh Nala (8.0 km in SSE direction)

o Garra Nala (8.0 km in SSE direction)

8. Seismic Zone Zone III [as per IS 1893 (Part-1): 2002]

4.4 Topography

The topography of the area is not flat and have minor undulations; consisting of series of

hummocks having an average elevation of 175 metres. A detailed analysis of slope in the area

has been carried out. It has been observed that topography of the area is undulating with a

hummock running in the NE-SW direction. The general drainage is parallel to sub parallel. The

drainage in surrounding area is dendritic in nature and the drainage density ranges from moderate

to poor thus indicating low run-off.

4.5 Existing Infrastructure

Total existing plant area is 54.147 ha and the proposed expansion will be done within the

existing plant premises area. All basic infrastructure viz. canteen, Administrative building, Store,

Sheds are available within the existing plant premises.

4.6 Climatic data from secondary sources

The district receives an annual rainfall of 1500 mm. and most of it occurs during the

rainy season. Mean annual temperature is above 26 C. The temperature ranges from 16 C in

winter month to 44 C in summer months. The Climate of the district is tropical. Average rain

fall is 800 mm per year. Average relative humidity being 70%.



CHAPTER – 05

PLANNING BRIEF

5.1 Planning Concept

5.1.1 Technical Concept

This technical concept indicates the plant capacity, size and type of main machinery,

storages, design of systems, plant layout, flow sheets etc. It covers process, mechanical,

electrical, instrumentation and civil engineering aspects. The concept has considered quality,

pollution control, operation, maintenance and utility services.

5.1.2 Power to be produced

Electric power of total 27 MW will be generated which will be used in existing plant.

5.1.3 Human Resources

Human Resource is the most valuable asset in any industry. The accelerating pace of

technology advancement and fierce competition in the market has led to the increasing

importance of human resources. Continuous skill updation of the existing human resources and

generating new talents in consonance with the needs of the industry are vital for the progress of

the industry. The human resource requirement for the project, organization structure and HR

Strategies for success of the project is hereby defined.

5.1.4 Organization Structure

An organization structure has been developed for the management of the Project. The

project will be headed by Managing Director who will be the overall in charge and Project will

be implemented by experienced Project Leader with a core team having extensive experience in

thermal power plant execution and operation. The entire project activities have been divided into

four broad functions,

Project Design, Engineering and coordination

Project Execution and site management.

Project commercial services

Project financial services



Each of the above functions is headed by a Functional Head having substantial exposure

and experience in management of large thermal power projects.

5.2 Project Engineering

The basic engineering of the project will be done with in house resources for which an

organization structure has already been put in place. The Detailed Engineering for the project

will be done with the help of experienced Designers and Consultants in the following areas

Environmental Impact assessment.

Geo Technical Soil Investigations and site survey

Civil Structural Design

Mechanical Plant Design

Electrical and Instrumentation Systems Design.

5.2.1 Project Conceptualization

This would consist of formulating the project, defining the project objectives and scope,

examining the preliminary feasibility with respect to markets, location, infrastructure,

environmental conditions and aspects, social infrastructure etc.

5.2.2 Project Planning

Preparing overall plans and schedules and identifying resources requirement for various

activities related to the project

5.2.3 Budgeting

This activity entails working out a detailed budget for the defined project scope, taking

necessary approvals and sanctions as per company’s policies, and controlling all activities, to

ensure that the project is completed within the sanctioned budget amount.

5.2.4 Procurement

The procurement function would consist of developing detailed specifications for the

required plant, machinery and equipment and services, evaluation of bids, coordination with

bidders and provide support for finalization of contract.



5.2.5 Design and Engineering

This function starts with the selection of consultants, development of basic engineering,

concepts, plant layout, general arrangement drawings and floor plans, civil design of structures,

mechanical and electrical designs etc.

5.2.6 Project Execution

This activity will consist of developing specifications for site works related to civil

mechanical, electrical and other installation work, tendering activities and evaluation and

selection of various contractors, and developing works contract.

5.2.7 Coordination with Site Management

Coordination with site management shall be done on regular and ongoing basis, to ensure

continuous flow of construction drawings and interactions with consultants and suppliers

5.2.8 Overall Time and Cost control

Develop and implement management reporting system, periodic review of the project

schedule and other objectives and initiate preventive and corrective action.

5.2.9 Project Site Management

The organization for the site management function will be headed by a Project Manager

who will be overall responsible for all the site functions. The technical functions will be divided

into three groups i.e. Civil, Mechanical and Electrical and Instrumentation each headed by highly

experienced Personnel and assisted by a group of Engineers and Supervisors.

Personnel for highly specialized nature of work will be drawn from the supplier of

respective equipment. It is also proposed to deploy experienced personnel from power plant

Operations during the project implementation so as to facilitate the transition from project to

operations phase.

A separate team of commissioning Engineers will be deployed who would eventually be

responsible for the operation of the plant. The Project Manager will also be assisted with

adequate numbers of personnel for materials management, accounting and administration



functions. The materials management function will be responsible for Receipt, Storage and issue

of various plant and machinery. The administration function will be responsible for Safety,

HR&IR, Liaoning and Security.

5.2.10 Commercial and Financial Services

The Procurement and Logistics functions will be carried out with the help of in-house

resources. The commercial functions will comprise of a) Procurement and Ordering. b)

Inspection and Expediting and c) Logistics management.

5.3 Organizational Structure for Operational Phase

The organizational structure that would be required for the Plant operations has been given

due consideration. The total man power requirement for the project will be 200-400 during

construction phase, The total requirement of manpower including management staff and

workmen for complete operations and maintenance of the power plant unit will be about 43. The

manpower requirement has been planned keeping in view the following:

Smooth & efficient running of the plant with optimum manpower.

Capacity utilization with optimum energy consumption.

Effective coordination

Rational distribution of responsibilities

The organizational development would be started from the project phase itself as those

involved with the project would also be trained for Operations.

5.3.1 Training

The training, be it induction training or on the job training for skill up-gradation, will be

given due importance. The sources for training will be

Main machinery suppliers

In house training programs

On the job Training



CHAPTER – 06

PROPOSED INFRASTRUCTURE

6.1ndustrial Area (Processing Area)

Following infrastructure will be provided as following:

Workshop

The mechanical and electrical workshop will be provided to take care of the regular

maintenance/ repair jobs in the plant.

Machinery stores

A store building needed for storing tools, spare parts, consumables, etc. Open area for

storing machinery and construction materials for the proposed plant.

Cranes, Monorails and Pulley blocks

Adequate sized maintenance cranes/ hoists, monorails and pulley blocks at all suitable

locations at the plant for ease of maintenance and operation.

Bags go down

Space will be provided in the packing plant area for the storage of bags.

Parking

Adequate parking space will be provided in the plant premises for the parking of vehicles.

(i) Residential Area (Non-processing area)

Manpower hired is from the local village and / or nearby city; hence, no residential facility

is envisaged.

(ii) Green Belt

16.96 ha (approx. 33 % of total plant area) has already been developed under greenbelt /

plantation.

(iii) Social Infrastructure

Proposed expansion project will result in growth of the surrounding areas by increased

direct and indirect employment opportunities in the region including ancillary development

and supporting infrastructure.



(iv) Connectivity


and SH - 6 (approx. 3.5 km in WNW direction from the plant site). Nearest city is

Jamshedpur (approx. 6.5 km in NW direction from the plant site). Nearest Airport Ranchi

is approx. 112 km in NW direction from the plant site.

(v) Drinking Water

Existing drinking water requirement is 470 KLD and additional 130 KLD water will be

required for proposed expansion; thus, total drinking water requirement after expansion

will be 600 KLD, which is being / will be sourced from JUSCO.

(vi) Sewage Treatment System

Domestic wastewater generated from unit is being / will be treated in existing STP of 140

KLD and treated water is being / will be utilized in greenbelt development / plantation.

(vii) Industrial Waste management

Water used for cooling at various stages of cement manufacturing is being / will be

partially subjected to evaporation and partially recycled; hence, no waste water is being

discharged from the unit.

(viii) Solid Waste Management

Dust collected from various air pollution control equipments is being / will be recycled

back to the process.

Sludge generated from STP is being / will be used as manure in greenbelt development/

plantation.



CHAPTER – 07

REHABILITATION AND RESETTLEMENT (R & R) PLAN

Proposed expansion will be done within the existing plant premises and no additional land is

required for the same; hence R & R is not applicable.



CHAPTER – 08

PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

The project will start only after obtaining Environmental Clearance and other clearances

from statutory authority. Project will be completed in 22 months period after getting all the

regulatory approvals.

8.2 Project Cost

The total project cost including IDC, financing charges is estimated at Rs163.28 Cr for the

1 x27 MW capacity.

Table 8.1 Project Cost

Estimated Cost Of The Project

S.no ParticularsEstimated cost

in Rs. Cr

1 Land & site Development 3.17

2 Buildings and others civil Structures 13.94

3 Plant & Machinery 124.96

4 Technical know-how Fees 2.45

5 Expenses on training 0.15

6 Miscellaneous Fixed Assets 5.05

7 Pre-Operative Expenses 8.35

8 Provision of Contingency 4.54

9 Working Capital 0.67

TOTAL 163.28



8.3 Environment Cost

Table 8.2 Expenditure on Pollution Control Measures

S. No. Particulars Estimated cost inRs. Lac

Recurring cost inRs. Lac/Annum

1 Air pollution control 1950 2102 Water & Noise Pollution 650 1453 Occupational Health 265 110

4 Environmental Monitoring& Measurement

110 35

5 Green Belt 120 110

TOTAL 3095 610



CHAPTER – 09

ANALYSIS OF PROPOSALProposed expansion project will result in growth of the surrounding areas by increasing

direct and indirect employment opportunities in the region including ancillary development and

supporting infrastructure. Special emphasis on financial and social benefits are being/ will be

given to the local people including tribal population, if any, in the area.

Development of social amenities will be in the form of medical facilities, education to

underprivileged and creation of self help groups.

Jharkhand state will get revenues in terms of taxes and local people will get direct &

indirect employment. Business opportunities for local community will be available like transport

of cement to market, fly ash transport from power plant, maintenance & house-keeping contract

work etc.

Visiontek Consultancy Services Pvt. Ltd.(An Enviro Engineering Consulting Cell)

Committed For Better Environment

m/s. nuvoco vistas corporation ltd. ( formerly …€¦ · 8 proposed capacity 1x27mw captive...

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