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  • 1. Presentation for Environmental Clearance before the esteemed members of Karnataka State Level Expert Appraisal Committee Proposed Project 32 MW Captive Power Plant in Existing Ferro Alloy Unit Proponent M/s. Star Metallics & Power Pvt. Ltd. Hospet, Karnataka.
  • 2. PROJECT HIGHLIGHTS The existing Ferro alloy plant is not operational since last 10 years due to unavailability of feasible power source. Activity status Vyasankere, Ta: Hospet, Dist.: Bellary District: Karnataka Location 95 Acre Plot Area Ferro alloy plant Project EXISTING PROJECT DESCRIPTION Vyasankere, Ta: Hospet, Dist.: Bellary District: Karnataka Location EIEL, India & ETA group, Dubai. Promoter of company M/s. Star Metallics & Power Pvt. Ltd Name of company
  • 3. Contd……. PROJECT HIGHLIGHTS Silicomanganese (SiMn ) Product 44,700 MTPA (SiMn ) Capacity of plant Two ( Submerged Arc Furnace) No. of Furnace (Type) Manganese ore, Metallurgical coke, Limestone & Quartz. Raw Materials 33 MVA Total Connected Load 24000 KW Projected operating load of ferroalloy plant 1 x 15000 KVA, 1 x 20000 KVA Rating of furnace
  • 4. Contd……. PROJECT HIGHLIGHTS GESCOM Grid (It is used to run 15,000 MVA furnace only, untill the proposed CPP will not be operational) Source of power 46 m 3 / day Gardening & dust suppression Effluent Generation & Disposal 148 m 3 / day, Tungbhadra dam reservoirs Water requirement and Source
  • 5. Contd……. PROJECT HIGHLIGHTS 1,30,000 MTPA Fuel Consumption Rate Low sulphur containg Indonesian Coal Fuel 140 TPH Capacity of boiler Fluidized Bed Combustion type Type of Boilers One No of Boilers 25 Acre ( Within existing plant) Area for proposed plant 32 MW Power generation Within existing ferro alloy unit. Location Installation of new 32 MW Captive Power Plant in existing ferro alloy unit. Project PROPOSED PROJECT DESCRIPTION
  • 6. Cont. 102.78 crore Cost Of Project 245 m3/ day Effluent Generation 418.4 m3/ day (Tungabhadra Dam) Water Requirement for CPP (Source) Straight Condensing With Air Cooled Condenser Type of Turbogenerator One No of Turbogenerator
  • 7. LOCATION OF PROJECT STAR METALLICS AND POWER PVT. LTD.
  • 8. EXISTING SCENERIO
  • 9. EXISTING UNIT Water requirement of the existing unit is 148 m3/ day and it will be fulfilled by Tungabhadra dam reservoir. WATER Power requirement of ferroalloy industry i.e. 181 million KW will be provided by GESCOM Grid ( It is only for 15,000 MVA furnace and untill proposed CPP will not be operational) Power Manganese ore, Metallurgical coke, Limestone & Quartz. All these material are locally available Raw Material 44,700 MTPA Production Capacity Silicomanganese Product
  • 10. MAJOR REQUIREMENT RAW MATERIAL: 1,150 T Electrode paste 11,000 T Quartz 30,000 T Coke 9,120 T Lime stone 1,07,000 T Manganese ore Qty/year Unit Raw Materials /Consumables
  • 11. WATER CONSUMPTION AND EFFLUENT GENERATION 46 148 TOTAL Nil 12
    • Gardening
    Nil Nil - DM back wash 15 100 - Cooling tower Nil Nil - Boiler Nil Nil - Washing Nil Nil
    • Process
    - - (2) Industrial 31 36
    • Domestic
    Effluent Generation Water Consumption Quantity (m3/ day) Usage
  • 12.
    • 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.
      • PRODUCTION PROCESS
  • 13.
    • 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.
    Cont.
  • 14. MATERIAL FLOW CHART FOR SILICOMANGANESE 1 3725 44700 0.95 3540 42460 0.05 186 2240 MANGANESE ORE T/T TPM TPY 0.588 2200 26300 COKE 0.025 92 1100 ELECTRODE PASTE 00.2 740 8900 LIME STONE Kwh/T GWH/M GWH/YWH/Y 168 14.0 3750 ELECTRIC POWER SMELTING 300 1.1 13 ELECTRIC POWER AUXILLIARY 4050 15.1 181 TOTAL CUM/T CUM/M CUM/Y 13.06 48649 583782 WATER T/T TPM TPY 1 3725 44700 FURNACE GAS DAY BINS RAW MATERIAL STOCK PILE LIQUID SILICO MANGANESE LADLES SUBMERGED ARC ELECTRIC FURNACE - SMELTING CONSUMER SILICO MANGANESE SILICO MANGANESE CRUSHING & SCREENING CASTING PROCESS TPY TPM T/T 31300 2600 0.7 SLAG 31300 2600 0.7 BAG HOUSE 1700 150 0.04 FINES 1800 150 0.04 REPROCESS 1180 150 0.04 2.25 8300 100000 0.23 850 10300 QUARTZ BACTH REPROCESS
  • 15. SOURCE OF POLLUTION IN EXISTING PROCESS EFFLUENT:
    • There is no process effluent generation.
    • Only domestic effluent i.e. 31 m 3 /day and cooling tower blow down i.e. 15 m3 /day will be generated.
    • The quality of cooling tower blow down will be as per the standards prescribed by Pollution Control Board for discharging into inland for irrigation.
    • Sewage (31 m 3 /day) from various buildings of the unit will be conveyed through separate drains to septic tank connected to soak pit.
  • 16. AIR POLLUTANT :
    • 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
    GASEOUS EMISSION : DUST EMISSION :
    • Dust will be produced during product sizing ,finishing and packing will be managed by dust extraction system
  • 17. SOLID WASTE
    • Raw material handling fine( 7800 TPA) , product fine( 2240 TPA) and furnace slag ( 31300 TPA) will be the main solid waste in the existing process
    • The dust and ash generated during operation will be collected, packed in bags and finally disposed off for commercial usage.
    • The slag will be reprocessed and finally reused for commercial purposes
  • 18. PROPOSED PROJECT 32 MW CAPTIVE POWER PLANT
  • 19. 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.
  • 20. PROPOSED PROCESS Fluidized bed combustion type of 140 TPH capacity. Boiler Water requirement of the proposed unit is 418.4 m3/ day and it all will be provided by Tungabhadra dam. Water 1,30,000 TPA Fuel Consumption Rate Indonesian coal with vary little percentage of sulphur.( Calorific value 5250 kcal/kg) Raw Material 32 MW Production Capacity Power Product
  • 21. POWER PLANT PERFORMANCE INDICES About 1,52,716 Annual Make-Up Water Requirement, m 3 10. 1300 Annual Ash Generation (Total), Tons 9. Calorific value of 5250 kcal/kg Grade Of Coal To Be Used 8. 1,30,000 Annual Imported Coal Consumption, Tons 7. 208.14 Annual Send Out Power, Million Units 6. 28.38 Auxiliary Power Consumption Of Power Plant, Million Units 5. 236.52 Annual Power Generation, Million Units 4. 90 Plant Load Factor, % 3. 262.8 Rated Capacity, Million Units/Annum 2. 32 Plant Rated Capacity, MW 1. Index Description Sr. No.
  • 22. GENERAL LAYOUT OF PROPOSED POWER PLANT
  • 23. WATER CONSUMPTION AND EFFLUENT GENERATION 245 418.4 TOTAL - - - Gardening 86 86.4 - Dm plant back wash 25 188 - Cooling tower 114 120 - Boiler Nil Nil - Washing Nil Nil - Process - (2) Industrial 20 24 (1) Domestic Effluent generation Water requirement Usage
  • 24. SCHEMATIC DIAGRAM FOR WATER SYSTEM
  • 25. 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.
  • 26. AIR POLLUTENT :
    • 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 SO 2 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.
    GASEOUS EMISSION :
  • 27.
    • Raw material handling process is one of the main sources of dusting. Coal will be drawn from stockyard and ground in hoppers leads to dusting.
    • The dust would be captured by dust extraction (DE) system and taken to a bag filter to separate out the dusts and clean air finally vented through a stack.
    • For open yard operation, provision will be made to spray water to reduce the dust generation during handling operation.
    DUST EMISSION :
    • Fly ash generated from the boiler will be collected in dry form and disposed for commercial utilisation.
    FLY ASH :
  • 28. The major noise producing equipment such as turbogenerator will be provided with acoustic enclosures, pumps, fans, compressor etc. and will be run at speeds less than 1500 rpm. Equipment will be statically and dynamically balanced. Safety blow off valves, discharge pipes; relief valves etc. will be equipped with silencers. Pipe lines will be liberally sized for low velocities NOISE POLLUTION: SOLID WASTE: Power plant ash, 1700 TPA will be the main solid waste in proposed plant and will be collected, packed in bags and finally disposed off for commercial usage.
  • 29. ENVIRONMENTAL MANAGEMENT SYSTEM
  • 30. WASTE WATER EFFLUENT GENERATION FROM EXISTING AND PROPOSED UNIT 291 245 46 TOTAL 86 86 Nil - DM plant discharge 40 25 15 - Cooling tower blow down 114 114 Nil - Boiler blow down Nil Nil Nil - Washing Nil Nil Nil - Process Nil Nil Nil (2) Industrial 51 20 31 (1) Domestic TOTAL Proposed Existing Effluent Generation (m 3 / day) Usage
  • 31. 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.
  • 32. Soak pit TOTAL WATER CONSUMPTION TOTAL EFFLUENT GENERATION Domestic water 36 m 3 / day Total Water Requirement 566.4 m 3 / day Cooling tower 100 m 3 / day Gardening 12 m 3 / day Ferro alloy unit 148 m 3 / day Domestic water 24 m 3 / day Boiler 120 m 3 / day DM Backwash 86.4 m 3 / day Cooling tower 188 m 3 / day 15 m 3 / day 31 m 3 / day Septic tank (51 m 3 / day) 20 m 3 / day 114 m 3 / day 86.0 m 3 / day 25 m 3 / day CPP 32 MW 418.4 m 3 / day 240 m 3 / day Gardening 12 m 3 / day Dust supression12 m 3 / day Ash handling 216 m 3 / day ZERO DISCHARGE WATER BALANCE CHART FOR BOTH EXISTING AND PROPOSED UNIT
  • 33. AIR POLLUTANTS SMELTING FURNACE : Hot SAF off gas emissions contain dust particulates, Sulphur dioxide, oxides of nitrogen, carbon monoxide and traces of oxides of silica FINISHED PRODUCT SIZING & PREPARATION: The cast product would be cooled, ground and screened for final bagging. Such operation would generate fugitive dust . BOILER EMISSION : The flue gases from the boiler exhausted into the atmosphere carry with them considerable quantities of pollutants such as SPM, SO2, NOx, CO etc. Following measures are provided to control flue gas emissions: DG SET : Two DG set will be used as power back up. The flue gas emission from DG sets contains significant proposition of SO2 since HSD will be used as fuel.
  • 34. AIR POLLUTION MANAGEMENT SMELTING FURNACE : Hot off gases from submerged arc furnace (SAF) and tap hole secondary emissions laden with fine product dust would be cooled to 150-250oC by air dilution prior to passing it through fume extraction system. The exit gases would be cleaned by dry gas de-dusting system. Bag filters are provided to remove fine particulate matter will settle in the settling chamber. Resultant clean gas will be vented out to atmosphere at appropriate height. FINISHED PRODUCT SIZING & PREPARATION: Significant amount of fugitive emission mainly in form of dust will be envisaged during coal and raw material handling. Dust extraction system will be provided at all material transfer points The dust would be captured by dust extraction (DE) system and taken to a bag filter to separate out the dusts and clean air finally vented through a stack
  • 35. BOILER & DG SET EMISSION : Electro Static Precipitator (ESP) will be provided to control dust emission from the boiler. Further low sulphur content coal will be used to reduce SO2 generation. The flue gas will be dispersed into the atmosphere through a stack of around 60 meter height for effective dispersion of pollutants. DG set are also provided and will be used in case power emergency. Stack of adequate height is provided for effective dispersion of pollutants. For open yard operation, provision will be made to spray water to reduce the dust generation during handling operation. Cont.
  • 36. Max. Conc. Zone of Pollutants from Stack discharge at above height Simulation. 18.49 11.60 32.27 1357 19.05 11.95 33.25 1297 19.56 12.27 34.14 1237 20.00 12.54 34.90 1177 20.32 12.75 35.4768.53 1117 20.50 12.85 35.77 1057 20.47 12.83 35.71 997 20.16 12.65 35.19 937 19.52 12.24 34.06 877 18.44 11.57 32.18 817 SPM NO 2 SO 2 Pollutant concentration (microgram/m 3 ) Distance w.r.t. stack discharge (m)
  • 37. The dispersion of pollutants in the atmosphere is determined using Gaussian plume dispersion model. For the present study, this model is used for the prediction of maximum ground level concentration (GLC). The different air emissions from the unit are PM, SO2, NOx and CO from boiler and process vent. Maximum ground level concentration is predicted using dispersion model. The maximum ground level concentration for different parameters is shown in Table 6.3 for proposed scenario. Equal concentration contour plots for the PM, NO2, and SO2 are shown in Figure 6.1 to 6.5 for the proposed scenario. Based on KSPCB limit of pollutants, calculated ground level concentration is superimposed on existing ambient air quality to obtain proposed scenario for the purpose of prediction and evaluation of impact of stack and process emission on surrounding GAUSSIAN PLUME DISPERSION MODEL
  • 38. OTHER MEASURES
    • Regular ambient air quality monitoring should be carried out within premises and nearby area for PM, RSPM, SO2, NOX and CO.
    • Occasionally ambient air quality should also to be monitored for work area to check fugitive emissions, if any.
    • A greenbelt around the factory and near the possible source of fugitive emissions should be developed for reducing the air pollution and attenuation of noise.
  • 39. 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.
  • 40. All equipments and pipelines whose surface temperature is 50 0C and above will be provided with thermal insulation. Further the plant building will be designed for adequate air circulation through natural ventilation. In addition, air conditioning systems will be provided for specific areas. Man coolers will be installed at hot work spots. THERMAL POLLUTION MANAGEMENT
  • 41. 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. NOISE MANAGEMENT
  • 42. SOCIAL ENVIRONMENT MANAGEMENT: The plant site is in the existing ferroalloy industry. The project did not involve displacement of population as the project site is within the existing plant. Instead of displacement project provides employment to about 45 persons in power plant. SMPPL has also constructed a full-fledged colony consisting of houses for the benefit of employees. Most of the employees shall be from the local area. Hence, the influence of influx on environment is insignificant. It is anticipated that the project would bring following benefits to the people of the surrounding villages
    • Generation of employment and improved standard of living
    • Establishment of small and medium scale engineering ancillaries, agro
    • based industries with cascading employment opportunities
    • Superior communication and transport facilities etc.
  • 43. 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. WORK ZONE POLLUTION MANAGEMENT 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.
  • 44. Plant safety measures would form an integral part of the environmental management plan of the proposed plant. Workers’ safety would be given highest priority so as to avoid any form of personal injury or lost-time accident. In-built safety features of the plant and machinery would help avoid hazardous events causing damage to the life and property. 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 . GREEN BELT DEVELOPMENT
  • 45. 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. POST PROJECT MONITORING
  • 46. THANKS