Reply to Essential Details sought on 15-10-2016...

Reply to Essential Details sought on 15-10-2016

EDS:

Kindly apply at MoEF&CC.

Reply:

As per the amendment in the EIA Notification vide S.O. 1599 (E), dated 25th June 2014, the criteria for

General Condition has been changed to 5 km from 10 km.

We have applied at state level because after the said amendment, general conditional is not applicable to

our project for amendment in EC for existing polyester chips manufacturing plant at GIDC, Sarigam.

Reply of Essential Details sought on 29/09/2016

EDS:

Please specify the distance from interstate boundary.

Reply:

The approximate distance of our site boundary from the boundary of Daman & Diu (U.T.) is 8.30 km

please refer Figure-1 for your ready reference.

The approximate distance of our site boundary from the boundary of Dadra & Nagar Haveli (U.T.) is

7.20 km please refer Figure-2 for your ready reference.

Figure-1: Map indicating the approximate distance of our site boundary from boundary of Daman &

Diu (U.T.)...

Figure-2: Map indicating the approximate distance of our site boundary from boundary of Dadra &

Nagar Haveli (U.T.)...

PROJECT PRE FEASIBILITY REPORT

For

AMENDMENT IN EC For

Existing Polyester Chips Manufacturing Plant For

Change in Fuel For

9.9MW Captive Power Generation

AT

Plot No 11, 12& 215 to 231, GIDC, Sarigam - 396155 Dist.: Valsad, Gujarat.

Project proponent:

Project Pre-feasibility Report

1

Project: Amendment in EC for Change in Fuel for 9.9 MW Captive Power Generation

CONTENTS

CHAPTERS S.NO. PARTICULARS PAGE NO.

CHAPTER 1 EXECUTIVE SUMMARY 4-6 1.1 Project Summary 4 CHAPTER 2 INTRODUCTION OF THE PROJECT 7-10 2.1 IDENTIFICATION OF THE PROJECT AND PROJECT

PROPONENT 7

2.1.1 IDENTIFICATION OF THE PROJECT 7 2.1.2 PROJECT PROPONENT 8 2.1.3 NATURE OF THE PROJECT 9 2.1.4 NEED OF PROJECT & DEMAND-SUPPLY GAP 9 2.1.5 IMPORTS VS. INDIGENOUS PRODUCTION 10 2.1.6 EXPORT POSSIBILITY 10 2.1.7 DOMESTIC / EXPORT MARKETS 10 2.1.8 EMPLOYMENT GENERATION DUE TO PROJECT 10 CHAPTER 3 PROJECT DISCRIPTION 12-32 3.1 TYPE & LOCATION OF PROJECT 12 3.1.1 TYPE 12 3.1.2 LOCATION 12 3.2 DETAILS OF THE ALTERNATIVE SITE 16 3.3 SIZE & MAGNITUDE OF OPRATION 16 3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS 16 3.4.1 CAPITIVE POWER PLANT 16 3.4.2 AUXILIARY SYSTEMS 18 3.4.2.1 COAL HANDLING SYSTEM 18 3.4.2.2 LIME DOSING SYSTEM 18 3.4.2.3 ASH HANDLING SYSTEM 18 3.5 RAW MATERIAL FOR FINISHED PRODUCTS 20 3.6 HAZARDOUS CHEMICAL STORAGE & HANDLING 20 3.7 RESOURCE OPTIMIZATION &AVALABILITY 20 3.7.1 LAND & BUILDING REQUIREMENT 20 3.7.2 EQUIPMENT 20 3.7.3 POWER REQUIREMENT 21 3.7.4 FUEL REQUIREMENT 21 3.7.5 WATER REQUIREMENT 22 3.7.6 MAN-POWER REQUIREMENT 22 3.8 QUANTITY OF WASTE TO BE GENERATED 23 3.8.1 WASTE WATER GENERATION & MANAGEMENT 23 3.8.2 WASTE CHARACTERSTICS 25 3.8.3 WASTE WATER TREATMENT &DISPOSAL 26 3.8.4 AIR EMISSIONS & CONTROL 29 3.8.4.1 PROCESS EMISSION 29 3.8.4.2 UTILITY EMISSION 29 3.8.4.3 FUGITIVE EMISSION 30 3.8.5 HAZARDOUS/NON-HAZARDOUS WASTE MANAGEMENT 30 3.8.6 NOISE CONTROL 30 3.9 HEALTH AND SAFETY MEASURES 31


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3.10 ENVIRONMENTAL HEALTH & SAFETY CELL 32 3.11 POST PROJECT MONITORING PLAN 32 CHAPTER 4 SITE ANALYSIS 33-35 4.1 CONNECTIVITY 33 4.2 LAND FORM, LAND USE & LAND OWNERSHIP 33 4.3 TOPOGRAPHY 33 4.4 SALIENT FEATURES 33 4.5 EXISTING INFRASTRUCTURE 34 4.6 SOIL CLASSIFICATION 34 4.7 CLIMATE & METEROLOGY 34 4.7.1 TEMPERATURE 35 4.7.2 HUMIDITY 35 4.7.3 RAINFALL 35 4.7.4 WIND PATTERN 35 4.8 SOCIO INFRASTRUCTURE 35 CHAPTER 5 PLANNING BRIEF 36-37 5.1 PLANNING CONCEPT 36 5.2 POPULATION PROJECTION 36 5.3 AREA STATEMENT 36 5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL &

SOCIAL) 37

5.5 AMENITIES/FACILITIES 37 CHAPTER 6 PROPOSED INFRASTRUCTURE 38-39 6.1 INDUSTRIAL AREA 38 6.2 RESIDENTIAL AREA 38 6.3 GREENBELT 38 6.4 SOCIAL INFRASTRUCTURE 38 6.5 CONNECTIVITY 38 6.6 DRINKING WATER MANAGEMENT 38 6.7 SEWERAGE SYSTEM 39 6.8 INDUSTRIAL WASTE MANAGEMENT 39 6.9 SOLID WASTE MANAGEMENT 39 6.10 POWER REQUIREMENT & SOURCE OF SUPPLY 39 CHAPTER 7 REHABILITATION & RESETTLEMENT (R&R) PLAN 40 7.1 POLICY TO BE ADOPTED 40 CHAPTER 8 PROJECT SCHEDULE & COST ESTIMATES 41 8.1 TIME SCHEDULE OF THE PROJECT 41 8.2 ESTIMATED PROJECT COST 41 CHAPTER 9 ANALYSIS OF PROPOSAL 42 9.1 FINANCIAL & SOCIAL BENEFITS 42

LIST OF TABLES S.No. Particulars Page No. TABLE 1.1 PROJECT SUMMARY 4 TABLE 2.1 LIST OF PRODUCTS 8 TABLE 2.2 LIST OF DIRECTORS 9 TABLE 2.3 JUSTIFICATION FOR PROPOSING THE FUEL CHANGE &

FINANCIAL FEASIBILITY 10

TABLE 3.1 LIST OF PROPOSED EQUIPMENT 21 TABLE 3.2 DETAILS OF FUEL 21 TABLE 3.3 TOTAL WATER CONSUPTION (KLD) 22


3


TABLE 3.4 MAN-POWER REQUIREMENT 23 TABLE 3.5 CATEGORY-WISE WASTEWATER GENERATION (IN KLD) 23 TABLE 3.6 EXPECTED CHARACTERISTICS OF WASTEWATER 25 TABLE 3.7 ADEQUACY OF EXISTING ETP 28 TABLE 3.8 DETAILS OF UTILITY EMISSION 29 TABLE 3.9 DETAILS OF HAZARDOUS WASTE GENERATION & DISPOSAL 30 TABLE 3.10 POST PROJECT MONITORING PLAN 32 TABLE 4.1 SALIENT FEATURES OF THE PROJECT SITE 33 TABLE 4.2 SUMMARY OF METEOROLOGICAL DATA AT NEAREST IMD

STATION DAHANU 34

TABLE 5.1 AREA STATEMENT 36 TABLE 8.1 TOTAL CAPITAL COST PROJECTION 41

LIST OF FIGURES S. No. Particulars Page No. FIGURE 3.1 PROJECT SITE 13 FIGURE 3.2 BASE MAP OF STUDY AREA 14 FIGURE 3.3 LAYOUT OF PROJECT SITE 15 FIGURE 3.4 FLOW DIAGRAM OF COAL FIRED 9.9 MW CPP 17 FIGURE 3.5(a) EXISTING WATER BALANCE DIAGRAM ( IN KLD ) 24 FIGURE 3.5(b) PROPOSED WATER BALANCE DIAGRAM ( IN KLD ) 25 FIGURE 3.6 FLOW DIAGRAM OF ETP 27

LIST OF ANNEXURES S. No. Particulars Page No. ANNEXURE-1 (a) COPY OF EXISTING EC WITH AMENDMENTS 1-9 ANNEXURE-1 (b) FORWARDING LETTER TO EC COMPLIANCE REPORT

SUBMITTED TO RO BHOPAL 10

ANNEXURE-2 COPY OF EXISTING CC&A 11-14 ANNEXURE-3 TECHNICAL SPECIFICATION OF COAL HANDLING PLANT 15-17 ANNEXURE-4 TECHNICAL SPECIFICATION OF ASH HANDLING

SYSTEM 18

ANNEXURE-5 MoU WITH COAL SUPPLIER 19-20 ANNEXURE-6 DISPERSION MODELING REPORT 21-46 ANNEXURE-7 MoU WITH BRICK MANUFACTURERS FOR FLY ASH 47-48


4


CHAPTER 1

EXECUTIVE SUMMARY The project is summarized in the below table: Table1.1: Project Summary

PARTICULARS DETAILS NAME OF THE UNIT

M/s. JBF Industries Ltd.

OCCUPIER Mr. R. K. Srivastava (Vice President)

PRODUCTS Sr. No.

Name of the Product Quantity Existing Proposed

Additional Total

1. Polyester Chips of various types & grades

*49500MT/Month - *49500MT/Month

2. Power Generation through Captive Power Plants

**9.9 MW - --

3. Power Generation through Coal fired Captive Power Plant

- @9.9 @9.9

Note: 1. * = EC has been obtained for 49500 MT/Month Polyester chips of various types & grades and 8.7 MW power generations through Captive Power Plants in 2012. 2. ** = An amendment in EC for dual fired power engine of 1.2 MW capacities & for change in existing fuel, i.e. Coal instead of Natural Gas by installing 4 Coal fired thermic fluid heaters has been obtained in 2014. 3. @ = After obtaining amendment in EC for installation of 9.9 MW Coal fired Captive Power Plant, existing Captive Power Plants shall be stand by till suitable/ acceptable customers are found/available for sale/disposal. Even after proposed amendment is granted the company will not generate more than 9.9 MW net effective power

LOCATION Plot No. 11, 12& 215 to 231, GIDC Estate, Sarigam-396155, Dist. Valsad (Gujarat)

NATURE OF PROJECT

Proposed Amendment in EC for existing polyester chips manufacturing plant for change in fuel for 9.9 MW captive power generation.

RESOURCES Resource type Requirement Source Land Existing Land: 59907 m2

Original GIDC Land 46603 m2 Plus Plot No. 12 13304 m2

Additional Land for Proposed Amendment Project:1350 m2

GIDC Sarigam

Water Existing (Fresh Water): Domestic: 55 KLD Industrial: 1023 KLD

After Proposed Amendment (Fresh Water): Domestic: 57 KLD Industrial: 1019 KLD

GIDC Water supply

Power Existing Average load utilization: 9.5 MW After Proposed Amendment: 10.4MW ( 900 KW is Auxilliary power comsumption)

Existing:DGVCL After Proposed Amendment: 9.9 MW coal fired power plant & DGVCL


5


PARTICULARS DETAILS Fuel Existing:

Natural Gas* 150000SCM/day Indian Coal - 77 MT/day Indonesian Coal 173 MT/day FO 650 lit/hr HSD* 250 lit/hr After Proposed Amendment: Natural Gas* 150000SCM/day Indian Coal - 77 MT/day Indonesian Coal 323 MT/day FO 650 lit/hr HSD* 250 lit/hr

NG from GSPC Coal Shree Hari Coal Corporation, Adani Enterprizes FO from HPCL/BPCL HSD from petrol pump Natural gas based equipments will be stand by only due

to techno commercial reasons, issues regarding uncertainty of continuous supply and pricing factors.

POLLUTION POTENTIAL & MITIGATION MEASURES Parameter Potential Mitigation Wastewater Existing:

Domestic: 50 KLD Industrial: 675 KLD

After Proposed Amendment: Domestic: 50 KLD Industrial: 707 KLD

In existing operations, the total domestic wastewater generated @50 KLD andis treated along with the industrial effluent and discharged into GIDC U/G drain.

Wastewater generated from industrial activities @675 KLD is treated in ETP. All the domestic sewage shall also be treated along with the industrial effluent to meet the discharge standards. Out of which 190 KLD is treated in RO. Permeate from RO @131 KLD is recycled to cooling tower makeup. Remaining treated effluent @485 KLD & RO reject @59 KLD is discharged through GIDC underground drainage from where ultimately it is conveyed into the deep Arabian Sea.

After proposed amendment project, waste water generated @32 KLD will be addition to the existing quantity of industrial waste water. Hence, total 707 KLD waste water will be treated in ETP. Out of which 227 KLD will be treated in RO. Permeate from RO @161 KLD will be recycled to cooling tower makeup. Remaining treated effluent @474 KLD & RO reject @70 KLD will be discharged through GIDC underground drainage from where ultimately it will be conveyed into the deep Arabian Sea.

Air Emissions Existing continous Installations: Gas Turbine with WHR System - 4.5 MW Gas based Power Engine - 2 MW 1.2 MW Dual fired engine FO fired Genset - 2.2MW Thermic Fluid Heater -14 M.KCal/hr (2 Nos) Thermic Fluid Heater -10 MCal/hr (2 Nos) (1

working + 1 standby) Thermic Fluid Heater -10 MKCal/hr (NG fired-4

Nos all standby/idle)

Proposed continous Installations after Proposed amendment: Steam Boiler - 45 TPH

In Existing operations, the company has 2 Nos. of Coal fired Heaters of capacities @14 M.kCal/Hr and 2 Nos. @10 M.kCal/Hr in operating condition.

Captive Power Plant comprising of 4.5 MW Gas Turbine, 2.2 MW and Gas Engine, 1.2 MW Dual fired engine and 2 MW FO based generator are all stand-by.

Naturl gas fired 4 Nos old Thermic Fluid Heater -10 Lakh.KCal/are standby/idle)

After proposed amendment project for installation of 9.9 MW coal based power plant, one boiler of 45 TPH will be installed.

All existing power generation systems will be stand-by arrangement till suitable/ acceptable customers are found/available for sale/disposal.

Out of 2 Nos. of coal fired Heaters of capacities @14 M.kcal/Hr and 2 Nos. @10 M.kcal/Hr, 3 nos. is operating under standard working conditions and one is kept as standby.

Three field ESP followed by stack of 63m & lime dosing in furnace is provided to meet the emission standards in existing thermic fluid heaters of 10 M.kcal/Hr& 14 M.kcal/Hr

In proposed amendment four fields ESP with supporting


6


PARTICULARS DETAILS systems will be installed for the proposed coal fired 9.9.MW power plant.

Dry Fly ash shall be collected and conveyed through dense phase pneumatic conveying system to silos and disposed in compliance with the Fly Ash Rules.

Proper dust arrestors/suppressor and extraction system will be installed to prevent spread of dust with the wind

All conveying /handling will be done using enclosed conveyors

Good housekeeping will be maintained in the plant. Hazardous & solid waste

Non - Hazardous Waste Existing: Fly Ash : 50 MT/day. After Proposed Amendment: Fly ash: 75 MT/day

The Hazardous wastes are handled, stored,transported & disposed ofas per CPCB/ MoEF Guidelines and GPCB Authorization

No increase in Hazardous waste generation percived. Fly ash is being disposed in compliance with the Fly Ash

Rules. Same practice will be followed after proposed

amendment. Noise Expected levels

Inside the plant: <85dB(A) For the proposed installation of 9.9 MW power plant, suitable silencers and insulation will be provided at the vent of boilers and turbine to reduce the noise level to below 85 dB level.

Regular maintenance will be done


7


CHAPTER 2

INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

2.1.1 IDENTIFICATION OF THE PROJECT JBF has manufacturing facilities located at Sarigam & Silvassa in India. The Sarigam plant is

engaged in the manufacturing of Polyester Chips of Various Types & Grades. The plant is

located at Plot No. 11, 12 & 215 to 231, GIDC Estate, Sarigam-396155, Dist. Valsad (Gujarat).

JBF had obtained Environmental Clearance from Ministry of Environment and Forest in 2012 for

expansion of project by capacity enhancement of Polyester Chips (36000 TPM to 49500 TPM)

& Captive Power Generation Capacity (4.5MW to 8.7MW) dated 16th Aug 2012.

Earlier, JBF has obtained two amendments in EC

1) For installation of 1.2 MW dual fired power engine as a standby arrangement. EC

amendment has been obtained for the same on 7th Jan 2014.

2) For change in existing fuel i.e. Coal instead of Natural Gas by installing 4 Coal fired

heaters. EC amendment has been obtained for the same on 25th Sep 2014.

The copy of existing EC letter with all the amendments is attached as Annexure-1 (a).

Now, JBF is planning for an amendment in EC for existing polyester chips manufacturing plant

for change in fuel for 9.9 MW captive power generation. The existing captive power plants will

be standby till suitable/ acceptable customers are found/available for sale/disposal after the

proposed amendment. The company is not going to generate net effective power more than 9.9

MW even after proposed amendment.

The list of products is mentioned in Table no. 2.1.


8


Table 2.1: List of Products Sr. No.

Name of the Product Quantity Existing Proposed

Additional Total

1. Polyester Chips of various types & grades

*49500 MT/Month - *49500 MT/Month

2. Power Generation through Captive Power Plants

**9.9 MW - --

3. Power Generation through Coal fired Captive Power Plant

- @9.9 MW @9.9 MW

Note: 1. * = EC has been obtained for 49500 MT/Month Polyester chips of various types & grades and 8.7 MW power generations through Captive Power Plants in 2012. 2. ** = An amendment in EC for dual fired power engine of 1.2 MW capacities& for change in existing fuel, i.e. Coal instead of Natural Gas by installing 4 Coal fired thermic fluid heaters has been obtained in 2014. 3. @ = After obtaining amendment in EC for installation of 9.9 MW Coal fired Captive Power Plant, existing Captive Power Plants will be standby.

The copy of existing CC&A is attached as Annexure 2.

2.1.2 PROJECT PROPONENT

JBF Industries Ltd., today, stands on a gleaming pinnacle of success as an industry leader in

Polyester Chips & as one of the top 5 players in the Polyester Partially Oriented Yarns (POY) in

India.

The company conceived as a private limited company in 1982, attained the corporate status by

becoming public limited company in the year 1986.

JBF Industries Limited is a Public Limited Company promoted by Mr. B.C. Arya. All the board of

directors have experience of over a decade in the various fields in textile business. Under the

leadership of Mr. Arya and the contribution of individuals and the teamwork has made this fast

paced growth possible.

The list of the board of directors are given below:


9


Table 2.2: List of Directors Sr. No. Name of Directors Designation Nationality

1. Mr. Bhagirath C. Arya Exe. Chairman& Promoter Indian 2. Mrs. Veena B. Arya Non-Exe. Director& Promoter Indian 3. Mr. Rakesh Gothi Managing Director Indian 4. Mr. N K Shah Director Commercial Indian 5. Mr. Prakash Mehta Non-Executive Director Indian 6. Mr. B R Gupta Non-Executive Director Indian 7. Mr. Sunil Diwakar Non-Executive Director Indian 8. Mr.Brij Mohan Bansal Non- Executive Director Indian 9. Mr. Banvar.A. Prabhakar Non-Executive Director Indian 10. Mr. Nikhil kumar Srivastava Non-Executive Director Indian 11. Mr. Vijay S.Bapna Non-Executive Director Indian

2.1.3 NATURE OF THE PROJECT

The Project proponent is seeking amendment in Environmental Clearance for existing polyester

chips manufacturing plant for change in fuel for 9.9 MW captive power generation. The existing

captive power plants will be standby till suitable/ acceptable customers are found/available for

sale/disposal, after proposed amendment. Even after proposed amendment the company is not

going to generate net effective power more than 9.9 MW.

2.1.4 NEED OF PROJECT & DEMAND-SUPPLY GAP

Present requirement of electrical energy is met through the 66 KV (10 MVA contract

demand) power utility connection from DGVCL.

The existing CPP is mostly Natural gas based turbine/generators. But currently it is not

operating due to very high cost of natural gas.

The current energy cost of power supplied by DGVCL is Rs. 7.61 per unit which has

substantial impact on operational cost of the company.

Power generation using natural gas is not economically viable, power supply from DGVCL

which is currently used is also becoming increasingly also. Hence, both conditions are not

viable under current domestic & export market scenario.

Considering the inconsistencies in assured NG supply & economic feasibility, JBF

proposes a fuel change from gas to coal based 9.9 MW CPP to make the manufacturing

cost effective and sustainable.


10


After proposed fuel change for captive generation by installing a 9.9 MW coal based

steam power plant, the electrical energy cost can be reduced upto Rs. 5.00 per unit

considering interest and depreciation and would be viable by continuous operation.

However, while proposing switch-over of fuels, JBF also intends to ensure that the

proposed installations will meet the permissible norms by installing the required APCD like

ESP and lime dosing system.

Most of our competitors are either located in UT of DNH or Daman who have the privilege

of lower power cost (Rs 4.2/unit) or in Gujarat have their own coal base power plant. This

makes our operation difficult and put our sales under lot of pressure.

After the proposed amendment the company will not add any load on the state power grid,

the surrendered power to DGVCL can be beneficial for other power starved industries.

Also, most of the power in grid supply is based on coal so proposed change in fuel for

captive power generation will not increase the overall coal load as the quantity of grid

power consumption will reduce.

The financial feasibility due to proposed change in fuel is provided in below given table 2.3.

Table 2.3: Justification for proposing the fuel change & financial feasibility

S. No.

Description Cost factors:9.9MW CPP with Existing fuel profile

Cost factors: 9.9MW CPP after the Proposed fuel change

4.5 MW Gas Turbine + 2 MW Gas based Power Engine - A Type of fuel Natural Gas -- B. Natural Gas Consumption per

day 54000 SCM/day --

C. Cost of Natural gas per SCM 23 Rs./ SCM -- D. Cost of Natural gas per day 1242000 Rs./day -- 1.2MW Dual fired engine E. Type of fuel HSD -- F. HSD Consumption per day 6000 lit/day -- G. Cost of HSD per lit 50 Rs./lit -- H. Cost of HSD per day 300000 Rs./day -- 2.2MW FO Genset I. Type of fuel Furnace Oil -- J. Furnace Oil Consumption per day 15600 kg/day -- K. Cost of Furnace Oil per kg 23 Rs./kg -- L. Cost of Furnace Oil per day 358800 Rs./day -- After the proposed fuel change M. Type of fuel -- Coal N. Coal Consumption per day -- 1,50,000 kg/day O Total effective power

generated/day 1,90,000 units

P. Cost of power generations @ -- Rs. 950000/-


11


S. No.

Description Cost factors:9.9MW CPP with Existing fuel profile

Cost factors: 9.9MW CPP after the Proposed fuel change

Rs.5.00 / unit Power Output 9.9 MW 9.9 MW Q. Estimated Cost profile 1900800 Rs./day Rs. 950000/day R. Projected Cost/benefit Rs.950800/day Difference in Cost = Total cost per day for Existing Power Plant - Total cost per day for

Proposed Power Plant = 1900800 - 950000= 950800 Rs./day

= 950800 x 330 days = 313764000 Rs./Annum Current cost of power from DGVCL @ Rs.7.61/unit After proposed amendment in fuel change, generation cost from coal will Rs.5.00 Differential cost of Rs.2.61 / unit x 190000 units x 330 days = Rs.16,36,47,000/- per annum Therefore after fuel change from gas to coal and power purchase from DGVCL, the company shall have projected benefit of Rs.31.37 Cr. and Rs.16.36 Cr/Annum respectively

2.1.5 IMPORTS VS. INDIGENOUS PRODUCTION

In-house requirements of power will be fulfilled by proposed 9.9 MW coal fired power plant as in

existing operations it is sourced from DGVCL due to high cost of natural gas.

2.1.6 EXPORT POSSIBILITY Not applicable. It is project for amendment in EC conditions for existing polyester chips

manufacturing plant for change in fuel for 9.9 MW captive power generation to cater in-house

power requirements.

2.1.7 DOMESTIC / EXPORT MARKETS Not applicable. It is project for amendment in EC conditions for existing polyester chips

manufacturing plant for change in fuel for 9.9 MW captive power generation to cater in-house

power requirements.

2.1.8 EMPLOYMENT GENERATION DUE TO PROJECT It is project for amendment in EC conditions for existing polyester chips manufacturing plant for

change in fuel for 9.9 MW captive power generation. However there is scope for about 20

employment.


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CHAPTER 3

PROJECT DESCRIPTION

3.1 TYPE &LOCATIONOF THE PROJECT

3.1.1 TYPE The proposed project for amendment in EC conditions for existing polyester chips

manufacturing plant for change in fuel for 9.9 MW captive power generation.

3.1.2 LOCATION The existing unit of M/s. JBF Industries Ltd. located at plot no. 11, 12 & 215 to 231, GIDC

Estate, Sarigam, and District: Valsad & the proposed 9.9 MW power plant will be installed in the

existing as well as additional adjoining plots 7/12& 7/13.The location of the project is given in

the figure 2.1.

There is cluster of profuse large-scale, medium scale and small-scale industries, engaged in

manufacturing of pharmaceuticals, organic pigments, organic and inorganic chemicals, textiles,

plastic items, etc.

The GIDC area has a Disaster management cell set up by Sarigam Industrial Association.

Sarigam Waste & Effluent Management Co. Ltd. is affiliated with Vapi Waste & Effluent

Management Co. Ltd., Vapi for the disposal of hazardous waste at its common hazardous waste

disposal site at Vapi. Also, there is proper underground drainage system & a 15MLD CETP

available for further treatment and disposal of the treated effluent to Arabian sea from the

industries.

Location of project site is shown in figures 3.1 & 3.2 and Layout with key plan is shown in figure

3.3.


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Figure 3.1: Project Site


14


Figure 3.2: Base map of study area


15


Figure 3.3: Layout of Project Site


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3.2 DETAILS OF THE ALTERNATIVE SITE

Not applicable because proposed project will be located on existing site as well additional land

which is closer to the existing site.

3.3 SIZE & MAGNITUDE OF OPERATION The total magnitude of operation will be 9.9 MW.

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS

3.4.1 Captive Power Plant

The process comprises, the generation of steam in the boiler and utilization of energy content of

steam in the steam turbine for doing the work on turbine blades to generate mechanical energy.

The mechanical energy is converted to electrical energy by the generator coupled to the steam

turbine.

The steam is generated in a 45 Ton capacity AFBC boiler at a working pressure of 87 bar and

515 OC temp.

The major system and components of boiler includes feed water system, coal feeding system

with combustion control, FD & ID fan, air pre-heater, ESP, ash removal &handling system.

The steam generated in the boiler is piped to the inlet of steam turbine and pass through the

nozzles where pressure energy of steam is converted to kinetic energy and directed towards a

series of moving and stationary blades to do the work on the turbine wheel and expands to a

lower pressure and finally to vacuum in the range of 0.186 (abs) bar. The outlet steam from the

turbine is passed to air cooled condenser, where it is condensed back to water in the range of

54OC and water is further re-utilized for continuous feed supply to boiler and cycle is repeated.


17


Figure 3.4: Flow Diagram of Coal Fired 9.9 MW CPP


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3.4.2 Auxiliary Systems

Auxiliary system contains of coal handling system and Ash handling system.

3.4.2.1 Coal Handling System

The design criteria for receipt of Indonesian coal/ Indian Coal are by covered trucks. The coal is

delivered in fully covered coal yard and stacked by the stackers. The stacker loader, load the

coal in coal hopper. From hopper, coal is fed through vibratory feeder to the belt conveyor,

crusher and sieving screen and particles of less than 10 mm size is fed through a series of belt

conveyors to the coal bunkers.

Conveyer belts will be as per the Indian Standards IS: 1891 (Part I) 1994, Nylon nylon type

with suitable top & bottom cover. The number of plies will be suitably selected with due regard

to load/ flexibility of toughing & shall be not less than operating tension of the belt at specified

full load & shall not exceed 90% of the rated strength. However, the number of plies shall not be

less than 3 & the grading shall be suitable for heavy duty application. All belts shall be joined by

vulcanized splicing. The clearance between the return side of the belt & the conveyor floor shall

be adequate to avoid fouling of the return belt with the spilled coal. The technical specifications

for Coal Handling System are attached as Annexure 3.

Suitable and adequate water sprinkler system will be provided over dust generation points, to

contain and minimise possible dusting during to coal handling. It is proposed to utilize treated

effluent for water sprinklers.

GPCB guidelines for Coal handling is being followed.

3.4.2.2 Lime Dosing System

Every feed zone in boiler shall be provided with lime feeding system to control the SO2

generation from coal burning. There will be provision for online dosing of quality lime stone in

the FBC boiler for control and containment of Sulphur dioxide emissions into atmosphere

3.4.2.3 Ash Handling System

The flue gas will pass through economizers, air pre heaters, and electrostatic precipitators and

ID fan to the chimney. The collection vessels will be provided at the bottom of the economizers,


19


air pre heater and the electrostatic precipitator hoppers. The dry ash collected in vessels will be

conveyed to ash silos by the application of compressed air. The ash accumulated in ash silos

will be loaded in to tankers/covered trucks given to the manufacturer of Bricks and ready mix

concretes for promoting fly ash utilization, in compliance with the Fly Ash Rules. The technical

specifications for Ash Handling System are attached as Annexure 4.

Ash handling will be done by dense phase pneumatic conveying.

Dense Phase Conveying System

One major concern for operating a Coal based Thermal power plant is the proper management

of Ash generated after combustion of Coal, which is generally generated in the furnace itself

and is trapped by the ESP. If proper system is installed for handling this ash, major hurdle of

ash management can be overcome.

The Dense Phase Conveying System is the most reliable; efficient to minimize particularly the

problems for handling the wide and adequate range of dry bulk solids up to 200 TPH capacities

at the exceeding terminal distances - 1,200 mtrs. This system includes weighing, batching,

blending, lump breaking, storage, master control equipments etc. through Dense Phase

Conveying System for bulk material handling in the plant.

Dense Phase System is applicable to push the highly dense concentration of bulk solids

effectively at a low constant speed inside the conveying pipe lines. Any type of material (heavy,

abrasive or, fragile, crystalline or granular) can be conveyed without causing the degradation

due to low velocity and less wear to the system components. This type of conveying is reliable,

flexible and maintenance free due to less number of moving parts and it can be easily installed

at places where space availability is very less specially for installing conventional conveying

systems.

The limited volume of air is utilized at the transporting vessel to move the material into the line

at maximum density while the balance air quantity is added along the conveying line through

coupling unit provided at starting on the pipeline to overcome the pipeline frictional losses; thus

pumping material at the highest obtainable efficiency. The Coupling Unit ensures a uniform

gradient and helps to maintain the material at maximum density. It also helps in maintaining the

desired velocity and overcoming the pipeline / bend's friction and helps to restart the flow of


20


blocked material if any along the conveying line regardless of length. This Coupling Unit also

helps in minimizing the compressed air consumption and pipe abrasion.

The plugging problem is prevented by improving the ratio of the material to air throughout the

system to convey the material at the highest obtainable efficiency and degree of reliability. The

highly abrasive materials can be conveniently conveyed at lowest possible velocities consuming

nominal quantity of air with the help of these systems. The highly flexible check valve provided

with Coupling Unit fittings are very responsive to any back feeding due to changes in conveying

line pressure thereby allowing throttling of the air supply pressure and volume automatically.

The designing of the system depends upon the properties of the material like convey ability,

moisture contents, product degradation, bulk densities etc.

3.5 RAW MATERIAL FOR FINISHED PRODUCTS Not applicable. The project is for amendment in EC conditions for existing polyester chips


3.6 HAZARDOUS CHEMICAL STORAGE & HANDLING

Not applicable. It is project for amendment in EC conditions for existing polyester chips


3.7 RESOURCE OPTIMIZATION& AVAILABILITY The major resources for the proposed project will be plant & machinery, raw-materials, power,

fuel, water, man-power, etc.

3.7.1 Land & Building Requirement

The proposed installation will be accommodated in the existing land & some part of proposed

installation will be done on additionally adjoining plots 7/12 & 7/13.The existing plots and

additional land are taken on lease from the GIDC.

3.7.2 Equipment Based on process necessity, list of the proposed and machinery is as below


21


Table 3.1: List of Proposed Equipment

S. No. Name of Equipment Quantity 1. 45 TPH FBC Boiler with auxiliaries 1 2. 9.9 MW steam turbine with 11 KV Alternator 1 3. Coal conveying system 1 set 4. Ash Conveying system 1 set 5. Air cooled condenser 1 set 6. ESP 1 7. Chimney: 63 metre 1

3.7.3 Power Requirement In existing operations, the unit has a power requirement of 9.5MW. The total requirement is

fulfilled by DGVCL.

For the proposed amendment project, total 10.4 MW power will be required. Out of which 9.5

MW for process plant & the auxiliary power requirement @0.9 MW for power plant. From

DGVCL contract demand 10 MVA will be reduced to 4.50 MVA after implementation of

proposed amendment.

3.7.4 Fuel Requirement

The fuel requirement is given below in Table no. 3.2.

Table 3.2: Details of Fuel Sr. No.

Particulars Requirement Source Remarks Existing Proposed

amendment Total

1. Natural Gas*

1,50,000 scm/ day

-- 1,50,000 scm/ day

GSPL

Require for power generation (shall be standby after proposed amendment f 9 9 MW l fi d2. Indian Coal 77 MT/ day -- 77 MT/

day Shri Hari Coal Corporation

Required in existing TFH

3. Indonesian Coal

173 MT/ day

150 MT/ day 323 MT/ day

Adani Enterprise Ltd.

Required in existing TFH & proposed CPP

3. Furnace Oil 650 kg/Hr -- 650 kg/Hr HPCL/BPCL Required for power generation as standby

4. HSD* 250 Lits/Hr -- 250 Lits/Hr

Petrol pump Required for power generation as standby

Note: *Natural gas based equipment will be stand by only due to techno commercial reasons, issues regarding uncertainty of continuous supply and pricing factors.


22


The MoU with Coal Supplier is attached as Annexure 5.

3.7.5 Water Requirement

The water requirement for the existing unit is catered through the GIDC Water Supply Dept.

Total water consumption is 1154 KLD out of which fresh water consumption is 1023 KLD.

Remaining 131 KLD water requirements is fulfilled by recycled water.

After proposed amendment project, there will be increase in water requirements by 98 KLD.

Hence, total water requirement will be 1252 KLD out of which fresh water consumption is

1091KLD. Remaining 161 KLD water requirements is fulfilled by recycled water. The source of

water will be GIDC Water Supply Dept.

Table 3.3: Total Water Consumption (KLD) Sr. No. Details Existing Qty Proposed

Additional Qty Total Qty

1 Domestic 55.00 2.00 57.00 2 Gardening 15.00 -- 15.00 3 Industrial 1084.00 96.00 1180.00 a Process 80.00 -- 80.00 b Process Steam Makeup Water

from WHRB 48.00 -- 48.00

c Boiler -- 69.00 69.00 d DM regeneration 5.00 3.00 8.00 e Cooling make-up 745.00 24.00 769.00 f Washings 206.00 -- 206.00

Total 1154.00 98.00 1252.00 Note:

In existing operations, total cooling tower requirement 745 KLD = 614 KLD fresh water + 131 KLD recycled water

After proposed amendment project, total cooling tower requirement 769 KLD = 608 KLD fresh water + 161 KLD recycled water

(Source: JBF Industries Ltd - Sarigam)

3.7.6 Man-Power Requirement

It is project for amendment in EC conditions of existing polyester chips manufacturing plant for

change in fuel for 9.9 MW captive power generation. However, there is scope for about 20

employment.


23


Table 3.4: Man-power Requirement

S. No. Level of Employee Numbers 1. First class Boiler Operator (3 + 1) 4.00 2. Turbine Operator (3 + 1) 4.00 3. Helper for Operation & Maintenance 12.00

3.8 QUANTITY OF WASTE TO BE GENERATED

3.8.1 Waste Water Generation & Management There will be marginal increase in quantity of waste water generation due to the proposed

amendment. However, the quantity of wastewater disposal will remain same.

After proposed amendment project, the wastewater generated @707 KLD will be treated in the

existing ETP and 161 KLD will be reused as partial cooling water makeup after passing through

RO. The rejects from the RO plant @70 KLD & remaining 474 KLD ETP treated water will be

discharged through GIDC underground drainage from where ultimately it will be conveyed into

the deep Arabian Sea.

The category wise bifurcation of the waste water generation is given in Table 3.5. Table 3.5:Category-wise Wastewater Generation (in KLD) Sr. No. Details Existing Qty Proposed

Additional Qty Total Qty

1 Domestic 50.00 -- 50.00 2 Gardening -- -- -- 3 Industrial 675.00 32.00 707.00 a Process *325.00 -- *325.00 b Blow down of Process Steam

from WHRB 14.00 -- 14.00

c Boiler blow down -- 26.00 26.00 d DM regeneration 5.00 3.00 8.00 e Cooling blow down 125.00 3.00 128.00 f Washings 206.00 -- 206.00

Total 725.00 32.00 757.00 *Reaction water from Esterification


24


Figure 3.5 (a): Existing Water Balance Diagram (in KLD)


25


Figure 3.5 (b): Proposed Water Balance Diagram (in KLD)

3.8.2 WASTE WATER CHARACTERISTICS The wastewater characteristic of effluent before treatment in ETP is given below in Table No.

3.6.

Table 3.6: Expected Characteristics of Wastewater

Sr. No.

Parameter

Characteristics Untreated Treated Permissible Limits

(Sea Discharge through CETP) 1. pH 4.5 to 6 7 to 8.5 6.5 to 8.5 2. SS 50 to 200 10 to 50 <300 3 TDS 500 to 1000 700 to 1600 <2100 4. COD 5000 to 8000 100 to 200 < 750 5. BOD 1500 to 2500 20 to 60 < 300 Note: All above values in mg/ lit except pH or where specified

(Source: JBF Industries Ltd - Sarigam)


26


3.8.3 WASTE WATER TREATMENT & DISPOSAL

In existing operations, the total domestic wastewater generated @50 KLD and is treated

along with the industrial effluent and discharged in to GIDC u/g drain

Wastewater generated from industrial activities @675 KLD is treated in ETP. Out of which

190 KLD is treated in RO.

Permeate from RO @131 KLD is recycled to cooling tower makeup.

Remaining treated effluent @485 KLD & RO reject @59 KLD is discharged through GIDC

underground drainage from where ultimately it is conveyed into the deep Arabian Sea.

After proposed amendment project, there will be no increase in domestic waste water.

Whereas, wastewater generated from industrial activities @707 KLD waste water will be

treated in ETP. Out of which 231 KLD will be treated in RO.

Permeate from RO @161 KLD will be recycled to cooling tower makeup.

Remaining treated effluent @474 KLD & RO reject @70KLD will be discharged through

GIDC underground drainage from where ultimately it will be conveyed into Arabian Sea.

Effluent Treatment Scheme The existing effluent treatment plant consists of pre-treatment, primary, secondary and tertiary

treatment units.

The existing operation have adequate ETP infrastructure to meet all the consent standards.

The ETP has, Oil & grease traps, 2 collection/equalization & neutralization tanks, primary

clarifier, 2 UASBs, settling tank, 2 ASP based aeration tanks, secondary clarifier, over flow

collection tank, tertiary clarifier, tertiary clarifier over flow tank, Sand beds, Activated beds, UF &

RO unit, treated effluent tank-Guard pond, sludge drying beds, sludge decanters and ETP

waste storage shed etc. The treated effluent with due quality assurance is metered through

magnetic flow meter and discharged into the GIDC drain. The quality of the discharged effluent

is assured through daily checks and analysis of critical parameters. The company has installed

continuous online monitoring system for pH, COD, BOD and TSS and is up liked to CPCB. The

discharged effluent is further processed through 15 MLD CETP Sarigam and finally discharged

into Arebian sea through marine diffuser.

The proposed amendment does not have any potential to generate any additional organic load

The existing ETP is capable to take the load of the additional effluent.


27


Figure 3.6: Flow diagram of ETP

SPECIFICATIONS: 1.a. Stripper column 12 m3/hr 1.b. Stripper column 12 m3/hr 1.c. Stripper column 9 m3/hr 2. Oil & grease trap (RCC) 20m3 3. Collection cum equalization tanks(2nos)(RCC) 400m3 each. 3a. Process stream holding/cooling tank (MS) 160 4. Primary clarifier (RCC) 140m3 5. Buffer tank (RCC) 40m3 6a. UASB 1 (RCC) 460 m3. 6b. UASB 2 (SS) 340 m3. 7. Anaerobic settling tank(RCC) 40 m3 8. Aeration tanks 2nos (RCC) 540 m3 each. 9. Secondary clarifier (RCC) 160 m3. 10. Secondary Clarifier overflow tank (RCC) 72 m3. 11. Tertiary Clarifier (RCC ) 96m3 12. Pressure sand filters (2 nos) (MS EPOXY) Dia= 3.0, Ht=2.0 mtr each. 13. Activated carbon filters 2 nos, (MS EPOXY) Dia= 3.0, Ht=2.0 mtr each ). 14. Tertiary Treated effluent holding tank (RCC) 96 m3. 15. Mixed bed filter (MS EPOXY ) Dia =3 mtr, H= 2 mtr. 16 UF Filtration 50m3/hr. 17 RO Unit 50m3/hr. 18. Treated Effluent tank-guard pond (RCC) 96 m3. 19 a &b. Decanters 5 m3 /hr. & 3m3/hr. 20. Sludge drying beds (4 nos) Brick masonry 15 m2 each. 21. Sludge storage area (Brick masonry with shed 25 m2 with impervious flooring & leachate collection system).


28


Table 3.7: Adequacy of Existing ETP

Sr. No.

Unit Quantity (Nos.)

Capacity/Holding volume (m3)

Retention Time/ Capacity/ Working volume

Remarks

Required Provided

Wastewater Flow: 707 KLD 1.

Stripping Column 2 1

12 m3/hr. 9 m3/hr

-- -- The total installed capacity of the strippers is 768m3/day which is more than adequate as there is no increase in production capacity or effluent generation

2. Oil & Grease Trap 1 20 m3 30 mints. 40.73 mints. Adequate 3. Collection Cum

Equalization cum Neutralization Tank

2 400 m3

400 m3

12 hrs. 27.15 hrs. Adequate

4. Primary Clarifier 1 140 m3 3.5 hrs. 4.75 hrs. Adequate 5. Holding Tank 1 40 m3 1 hr. 1.35 hrs. Adequate 6. UASB 1

1 460 m3

340 m3 -- -- Adequate

7. Anaerobic Settling Tank

1 40 m3 1 hr. 1.35 hrs. Adequate

8. Aeration Tank-I & II 2 1080 m3 1060 m3 1080 m3 Adequate 9. Secondary Clarifier 1 160 m3 3.5 hrs. 5.43 hrs. Adequate 10. Clarified water tank 1 96 m3 1 hr. 3.25 hrs. Adequate 11. Tertiary clarifier 1 96 m3 1 hr. 3.25 hrs Adequate 12 Pressure Sand

Filter 2 112 m3/hr 707 m3/day 2688 m3/day Adequate

13. Activated Carbon Filter

2 140 m3/hr 707 m3/day 3360 m3/day Adequate

14. Treated water tank 1 96 m3 2 hrs. 3.25 hrs. Adequate 15. Mixed Bed Filter 2 112 m3/hr. 707 m3/day 2688 m3/day Adequate 16. UF Filtration 1 50 m3/hr 707 m3/day 1200 m3/day Adequate 17. RO Unit 1 50 m3/hr 707 m3/day 1200 m3/day Adequate 18. Recycled Effluent

Holding Tank 1 72KL 2 hrs. 2.44 hrs. Adequate

19. Sludge Decanter 2 5 m3/hr. 3 m3/hr

54 m3/day 100 m3/day Adequate

20. Sludge drying beds 4 60 m2 -- -- Stand by unit. 21. Sludge Storage

Area 1 25 m2. -- -- The capacity of sludge handling

&storage facility is adequate as there is no increase in production capacity or ETP waste generation due to the proposed fuel change of 9.9MW CPP


29


3.8.4 AIR EMISSIONS & CONTROL

3.8.4.1 Process Emission There will be no process emissions due to proposed amendment project as it is a project for

amendment in EC conditions for existing polyester chips manufacturing plant for change in fuel

for 9.9 MW captive power generation.

3.8.4.2 Utility Emission The details of utility emissions are given below in table 3.8.

Table 3.8: Details of Utility Emission

Particulars Fuel & its Consumption

Stack details

Emission Parameters

APCD Remarks

Existing Installations 4.5 MW Gas Turbine with WHR system

Natural Gas @40000 scm/day

H: 30 m D: 1.5 m

PM, SO2, NOx -- Will be standby till suitable/ acceptable customers are found/ available for sale/disposal, after proposed amendment.

2 MW Gas based Power Engine

Natural Gas @14000 scm/day

H: 30 m D: 0.6 m

PM, SO2, NOx --

1.2 MW Dual Fired Power Engine

Natural Gas 6000 scm/day or HSD 250 ltr/hr

Common chimney: H: 65 m D: 2.2 m

PM, SO2, NOx --

2.2 MW FO based Genset FO @650 kg/Hr PM, SO2, NOx -- Thermic Fluid Heaters 2 Nos. Capacity: 10 M.kcal/hr.

Indian Coal @0.844 MT/hr + Imported Coal @1.876 MT/hr. (for each)


PM, SO2, NOx ESP, Lime dosing

Under normal operating conditions 3 TFH shall be working and one TFH standby. There will be no change after the proposed amendment.

Thermic Fluid Heater - 2 Nos. Capacity: 14 M.kcal/hr.

Indian Coal @1.182 MT/hr. + Imported Coal @2.626 MT/hr. (for each)



Proposed additional installation for amendement by installation of 9.9 MW Power Plant Steam Boiler Capacity: 45 MT/hr

Imported Coal @5.4 MT/hr.

H: 63 m D: 2.2 m


--

Note: 1. H = Height of stack from ground level, D = Top diameter of stack 2. Besides above installations, 4 nos. of old Natural gas fired TFHs (10 M.kCal/hr. each) are also stand-by. There will be no change after the proposed amendment.

The air dispersion modeling report is attached as Annexure 6.


30


3.8.4.3 Fugitive Emission Fugitive emissions are likely to be generated in form of dust while unloading, grinding, handling

and conveying the Coal & ash handling. Loading/unloading of Coal is/ will be done in completely

closed environment. All conveying /handling is/ will be done using enclosed conveyors. Ash is/

will be collected in vessel from the bottom of the economizers, air pre heater and the

electrostatic precipitator hoppers & conveyed to ash silo by the application of compressed air.

Ash handling will be done by dense phase pneumatic conveying. From silo, it will be loaded in

to tankers or covered trucks to the manufacturer of Bricks and ready mix concretes

Properly closed of storage facilities and dust arrestors/suppression & extraction system will be

installed to contain and minimize spread of dust. Adequate water sprinkling system will be

installed in the Coal storage area as well as covered coal conveyance system.

3.8.5 HAZARDOUS/NON-HAZARDOUS. WASTES MANAGEMENT The hazardous wastes are generated, handled, stored, transported and disposed as per CPCB/

MoEF guidelines and incompliance with the GPCB Authorization. The company has

membership of TSDF Site - Saurashtra Enviro Projects Pvt. Limited. There will be no increase in

generation of hazardous waste due to proposed installation. However, fly ash will be generated

from the burning of coal in the boiler. Fly ash will be given to brick manufacturers and the

remaining utilized for cement brick/ready to use cement aggregate manufacturers and civil

construction in compliance with Fly ash rules. The MoU with brick manufacturers for utilization

of fly ash is attached as Annexure-7.

Table 3.9: Details of Hazardous Waste Generation & Disposal

Particulars Existing Qty Proposed

Additonal Qty

Total Qty Disposal

Fly Ash 50 MT/day 25 MT/day 75MT/day Fly ash from boiler will be given to the brick manufacturers/ and the rest utilised in compliance with Fly ash rules.

3.8.6 NOISE CONTROL In existing operations, noise generated in the process area is mainly from operation of heavy

duty motors, chip cutters, blowers and compressors in various sections of the manufacturing


31


plant area. The compressors and operation in utility area also result in high noise

generation viz. above 85 dB (A). Due to power plant operations, noise pollution is arising from

turbine, compressor, generator room, etc. The control measures to be taken for reduction in

noise levels are as below:

The turbine is provided with an acoustic enclosure.

The plant and equipment is specified and designed with a view to minimize noise

pollution.

The major noise producing equipment such as turbine is provided with acoustic

enclosure.

Sturdy foundation & pads to all the noise generating equipment is/ will be provided.

Ear Plugs and Ear muffs is/ will be provided to the workers in Utility Section.

Regular maintenance of is/ will be carried out to minimize the noise

generated by the .

Regular monitoring of noise levels at all areas is/ will be carried out.

Greenbelt will be maintained.

For the proposed installation of 9.9 MW coal fired power plant, acoustic enclosure will be

provided for turbine and silencers will be provided at vent of boilers to reduce the vibration &

noise <85 dB level. Also there will no generation of noise from soot blowing.

3.9 HEALTH AND SAFETY MEASURES The company is concerned about occupational health and safety among its

work force as the man power is the biggest asset to the company.

The following key safety measures are implemented in the existing operation & same will be

practiced after proposed amendment project:

All the electrical fittings shall be flameproof.

Applicable PPEs is provided to all workers in the plant.

Standard First Aid Box is available in each department.

Dedicated Occupation Health Centre is provided to deal with any emergency.

List of emergency contact numbers is displayed at all strategic locations.

Emergency alarm is provided at each individual unit.

Maximum handling of material with the help of stacker and forklift to minimize manual handling.


32


Safety / Health records and MSDS are maintained.

3.10 ENVIRONMENTAL HEALTH & SAFETY CELL The company has a full-fledged environment health & safety cell (EHS) in order to keep a close

watch on the performance of the pollution control equipment, emissions from the sources and

the quality of surrounding environment in accordance with the monitoring program. The cell is

also entrusted with the responsibilities of regulating the safety measures inside the plant

campus. The cell is also responsible for maintaining the records of all data, documents and

information in line within the legislative requirement. The company is committed to comply with

ISO 9001; ISO 14001; IOHSAS 18001certifications and all the statutory requirements.

3.11 POST PROJECT MONITORING PLAN The company has developed in-house facilities for monitoring all major components. Where it is

not possible to establish such facilities, the same has been done by appointing external

recognized/approved agencies. The proposed post-project monitoring plan is given below:

Table 3.10: Post Project Monitoring Plan

Components Parameters Frequency of in house monitoring

Frequency of third party monitoring

Waste water monitoring

pH, TSS, TDS, BOD, COD, Oil & Grease

Daily (At all stages of ETP)

Quarterly(treated and untreated)

Air-ambient monitoring

PM10, PM2.5, SO2, NO2 -- Quarterly

Stack monitoring PM, SO2, NOx -- Quarterly Noise monitoring Noise levels in dB (A) -- Once in a month at

different locations inside the plant site.

Workplace monitoring PM10 -- Quarterly.


33


CHAPTER 4

SITE ANALYSIS

4.1 CONNECTIVITY The existing unit located at Plot No. 11, 12 & 215 to 231, GIDC Estate, Sarigam-396 155, and

District: Valsad & the proposed power plant will be set up in the existing site & additional

adjoining plots near the existing site. The Site is 1.10 km from Sarigam. The site is 4.2 km from

National Highway. The land and infrastructure is already available and the raw material is easily

available through the easy transport via road connectivity. The nearest Railway station is Bhilad

railway station which is 4 km and Surat airport is 91.90 km from the project site.

4.2 LANDFORM, LAND USE & LAND OWNERSHIP

The proposed installation will be accommodated in existing as well as the additional adjoining

plot no. 7/12& 7/13.The existing plots and additional land are/will be taken on lease from the

GIDC.

4.3 TOPOGRAPHY

The proposed site for installation of turbine is flat.

4.4 SALIENT FEATURES Table 4.1: Salient Features of the Project Site

Particulars Details Approx. Geographical Co-ordinates

SE Corner: 20°17'27.85"N, 72°51'15.50"E SW Corner: 20°17'25.26"N, 72°51'11.48"E NW Corner: 20°17'37.26"N, 72°51'9.40"E NE Corner: 20°17'37.90"N, 72°51'15.08"E

Village Sarigam ( 1.10 kms-SE) Nearest Town Vapi ( 10.3 kms-NE) Rivers/ streams River Damanganga ( 7.8 kms-E), Damanganaga Canal ( 0.76

kms-E) River Darotha ( 3.74 kms-NNE)

Nearest Highway NH-08 ( 4.2 kms- SSE), SH-185 ( 2 kms-NE) Nearest Railway station Bhilad Railway Station ( 4.0 kms-SEE) Nearest Airbase/ Airport Daman Coast Airbase ( 15 kms-N), Surat Airport ( 91.9 kms-N) Tourist places Dadra 12 kms NE, & Silvassa ( 15.54 kms-E), Dudhani 34

kms-SE, Daman 14 kms-N) Reserved Forest Patches of reserved forest exist witin 5 kms radius.


34


Particulars Details Protected areas (National parks/ sanctuaries)

None within 10 km radial periphery

4.5 EXISTINGINFRASTRUCTURE

Well-developed infrastructure is available at site and around the site.

4.6 SOIL CLASSIFICATION

Not applicable as application for amendment in EC for existing polyester chips manufacturing

plant for change in fuel for 9.9 MW captive power generation.

4.7 CLIMATE& METEROLOGY The year can be divided into four seasons. Climate is warm and dry from mid-March to June,

during season of summer, climate remains warm and dry, while during rainy season, from mid-

June to end of September, climate is humid and pleasant. From October to November mild

warm climate prevails, and from December to February climate is cold.

The Table 4.2 indicates the summary of meteorological pattern at the nearest observatory of

IMD, Dahanu published by IMD.

Table 4.2: Summary Meteorological Data at nearest IMD Station Dahanu

Location: In the compound of Old Girdhardhas Dispensary, DAHANU, Maharashtra ( Lat: N 19o o Aerial Dist from Project Site: Approx.40.48 km (SSW) Height of installation: 11m above MSL, Month Temperature (oC) Relative

Humidity (%)

Cloud Cover (Oktas)

Mean Wind Speed

(m/s)

Pre-dominant Wind

Direction

Rainfall (mm)

Max. Min. Mor. Eve. Max. Min. January 27.7 16.5 67 69 1.3 1.1 11.3 N 0.2 February 28.3 17.4 66 69 1.1 0.8 11.7 N 0.2 March 30.3 20.7 68 67 1.4 1.1 12.9 N 0.1 April 32.2 24.0 74 69 2.1 1.4 13.7 W 0.1 May 33.1 26.8 77 73 3.8 2.3 15.5 W 5.2 June 32.2 26.3 85 80 6.1 5.6 17.7 SW 522.1 July 30.1 25.0 89 84 7.1 6.8 22.6 SW 771.7 August 29.5 24.7 88 83 6.9 6.7 22.6 W 502.3 September 30.0 24.0 87 79 5.4 4.9 14.6 W 319.1 October 32.1 23.1 77 72 2.8 2.4 10.0 E 44.4 November 32.1 20.5 67 71 1.9 1.9 9.4 N 17.1 December 29.8 18.0 67 71 1.6 1.5 10.0 N 0.3

in India (1951 -


35


4.7.1 TEMPERATURE

The summer season from March to May is a one of continuous increase in temperatures which

decreases during monsoons, increases slightly during the post-monsoon season and again

decreases during the winter. May is generally the hottest month with the mean daily maximum

temperature recorded at 33.1 oC and mean daily minimum temperature recorded at 26.8oC.

January is the coldest month with the mean daily maximum temperature as 27.7 oC and mean

daily minimum temperature observed as 16.5 oC.

4.7.2 HUMIDITY

The climate of the region is characterized by a humid summer because of the closeness to

coastline. Humidity is usually high during the monsoon months, with average relative humidity

generally exceeding 80%. Humidity decreases gradually during the post-monsoon months and

for rest of the year i.e. the period of December to April, the average relative humidity ranges

around 50-70%.

4.7.3 RAINFALL

About 95% of the annual rainfall is received during the southwest monsoon season i.e. from

June to September, July being the month with highest rainfall. The total annual rainfall observed

from the historical data of year 1951-1980 is 2182 mm.

4.7.5 WIND PATTERN

The annual resultant vector for wind direction shows winds blowing from WSW. During

summers and monsoon, the winds blow mostly from the sea i.e. the SW or WSW direction. The

post-monsoon & winter seasons experience a change in direction, with the winds blowing from

NE, ENE or NNE. The wind speed is high during monsoon and post monsoon seasons, slightly

moderate during summer and winter seasons.

4.8 SOCIAL INFRASTRUCTURE




36


CHAPTER 5

PLANNING BRIEF

5.1 PLANNING CONCEPT The existing unit located at Plot No. 11 & 215 to 231, GIDC Estate, Sarigam-396 155, and

District: Valsad & the proposed power plant will be installed at additional plot No. 12. The

nearest town from the project site is Vapi.

The region is well planned with all the basic infrastructural facilities like internal roads, water

supply, arrangements for power, streetlights, solid waste disposal sites etc.

5.2 POPULATION PROJECTION



5.3 AREA STATEMENT The proposed installation will be accommodated in the existing open area of 1712m2as well as

additionally acquired land of 1350 m2. The total area of the plot is 59907m2& the new acquired

area will be 1350 m2. Hence, the total area after proposed installation will be 61257 m2.out of

which Green belt area of the plant is 6562.74m2which is 10.95%. The bifurcation of the same is

given below in table no. 5.1.

Table 5.1: Area Statement

Particular Area (m2) Existing Proposed Addition/

Reduction Total

Plant area 5596.89 3062.00* 8658.89 Utility area 9191.65 ------ 9191.65 ETP area 3780.5 -------- 3780.50 Finished goods area 8007.00 ------- 8007.00 RM storage area 5826.34 -------- 5826.34 Parking area 3540.00 -------- 3540.00 Greenbelt area 6562.74 -------- 6562.74 Internal roads 8638.91 --------- 8638.91 Open area 8762.97 (-1712.00)* 7050.97 Total Plot Area 59907.00 1350.00 61257.00 Note: *Proposed 9.9 MW coal fired power plant will be established in total area of 3062 m2 includes new additional plot of 1350 m2 land&1712 m2land from open area (8762.97 m2) of existing premises.


37


5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)



5.5 AMENITIES/FACILITIES




38


CHAPTER 6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA The total area of the plot after obtaining lease of additional land will be 61,257 m2, out of which,

greenbelt area of the plant is 6562.74m2, which will be10.95% of the total area. Area

requirement for the proposed installations will be 3062 m2.

6.2 RESIDENTIAL AREA In the said proposal no Residential area has been proposed for workers and/or for staff.

6.3 GREENBELT 6562.74 m2 of total plot area is developed as greenbelt.

6.4 SOCIAL INFRASTUCURE Existing infrastructure will be sufficient to accommodate the existing load from the proposed

project which is very low.

6.5 CONNECTIVITY

The existing unit located at Plot No. 11, 12 & 215 to 231, GIDC Estate, Sarigam-396 155, and

District: Valsad & the proposed power plant will be installed at existing plots & additionally

acquired plot No. 7/12& 7/13. The Site is 1.10 km from Sarigam. The site is 4.2 km from

National Highway. The land and infrastructure is already available and the raw material is easily

available through the easy transport via road connectivity. The nearest Railway station is Bhilad

railway station which is 4 km and Surat airport is 91.90 km from the project site.

6.6 DRINKING WATER MANAGEMENT The source of drinking water is/ will be GIDC water supply.


39


6.7 SEWERAGE SYSTEM Domestic waste water generated from the existing operations @50 KLD is treated along with the

industrial effluent and discharged into GIDC U/G drain in compliance with the consent standards and is

finally discharged into Arebian sea through Marine diffusers No additional sewage will be generated.

6.8 INDUSTRIAL WASTE MANAGEMENT Industrial Effluent will be treated in the Effluent Treatment Plant at the site. Details are explained

in Chapter 03, Section 3.7.3.

6.9 SOLID WASTE MANAGEMENT Existing operations generate about 50 MT/day fly ash and is regularly disposed/utilised in

compliance with Fly ash rules. The proposed project amendment has the potential to generate

about 25 MT/day. This also will be utilized/disposed in compliance with Fly ash rules.

6.10 POWER REQUIREMENT & SOURCE OF SUPPLY In existing operations, the unit has a power requirement of 9.5MW. The total requirement is

fulfilled by DGVCL.

After proposed amendment project, total power requirement will be 10.4 MW power. Out of

which 9.5 MW for process plant will be met by proposed power& the auxiliary power

requirement @0.9 MW will be fed from DGVCL source.


40


5CHAPTER 7

REHABILITATION &RESETTLEMENT (R &R) PLAN 7.1 POLICY TO BE ADOPTED




41


CHAPTER 8

PROJECT SCHEDULE & COST ESTIMATES 8.1 TIME SCHEDULE OF THE PROJECT The installation/ construction will be started after getting approval for Environmental Clearance and NOC from authorities. 8.2 ESTIMATED PROJECT COST The approx. capital cost for proposed project of amendment in EC for existing polyester chips

manufacturing plant for change in fuel for 9.9 MW captive power generation will be 3590 Lakhs.

The bifurcation is as below - Table 8.1: Total Capital Cost Projection

Sr. No.

Purpose Capital Cost (Lakhs)

1. Land (Lease Cost) 15.00 2. Building 100 3. Plant & Machinery 3000 4 Electrification and Administrative set-up 25 5. Environment Protection (including ETP, APCD etc.)

ETP 0.00 ESP 225 Chimney 150 Env. Monitoring expenses 20

6. Safety instruments 25 TOTAL 3590


42


CHAPTER 9

ANALYSIS OF PROPOSAL 9.1 FINANCIAL & SOCIAL BENEFITS The project benefits from amendment in existing EC conditions for existing polyester chips

manufacturing plant for change in fuel for 9.9 MW captive power generation are as below -

In existing operations, the unit has a power requirement of 9.5 MW. The total

requirement is fulfilled by DGVCL.

After proposed amendment project, total 10.4 MW power will be required. Out of which

9.5 MW for process plant will be met by proposed power plant & 0.9 will be fed from

DGVCL.

Thus electrical energy cost can be reduced in the range of Rs. 5.95 per unit after

considering interest and depreciation.

There will be reduction in the total load on the electricity department which is also

generating electricity by Coal.

A

Annexure 1(a): Copy of Existing EC with Amendments

1. EC for amendment for change in existing fuel i.e. Coal instead of Natural Gas by installing 4 Coal fired heater

Page 1

B

Page 2

C

2. Amendment in EC for installation of 1.2 MW dual fired power engine as a back-uparrangement

Page 3

D

Page 4

E

3. Existing EC for expansion of project by capacity enhancement of Polyester Chips (36000 TPM to 49500 TPM) & Captive Power Generation Capacity (4.5MW to 8.7MW)

Page 5

F

Page 6

G

Page 7

H

Page 8

I

Page 9

J

Annexure 1(b): Forwarding Letter for EC Compliance Report Submitted to RO Bhopal

Page 10

K

Annexure 2: Copy of Existing CC&A

Page 11

L

Page 12

M

Page 13

N

Page 14

O

Annexure 3: Technical Specifications of Coal Handling System

Page 15

P

Page 16

Q

Page 17

R

Annexure 4: Technical Specifications of Ash Handling System

Page 18

S

Annexure 5: MoU with Coal Supplier

Page 19

T

Page 20

Air Dispersion Modeling Report for Amendment in EC for Existing Polyester Plant for Change in Fuel for 9.9 MW CPP by M/s. JBF Industries Ltd., GIDC, Sarigam

Page | 1

Air Dispersion Modeling

For

Amendment in Existing EC for Existing PolyesterManufacturing Plant for Change in fuel for 9.9 MW Captive Power GenerationAtPlot Nos. 11, 12 & 215 to 231, GIDC, Sarigam

Client:JBF INDUSTRIES LTD. June 2016

Precitech Laboratories Pvt. Ltd.1st Floor, Bhanujyot Complex, Plot No. C5/27, Opp Oriental Ins. Co. Ltd., Nr. GIDC Char Rasta, Vapi 396195Telefax: (0260) 2425542, 2420995Email: [email protected]

Annexure 6

Air Dispersion Modeling Report for Amendment in Existing EC by installing Coal Fired 9.9 MW Power Plant by M/s. JBF Industries Ltd., GIDC, Sarigam

Page | 2

1.0 Precitech Laboratories Pvt. Ltd.

Precitech Laboratories Pvt. Ltd. is an Environmental Consultancy Firm engaged in the field of environmental engineering, testing/monitoring & consultancy services since 1991. Based at Vapi, it has its branch offices in Ankleshwar, Rajkot and Ahmedabad.

It holds the following Recognitions:

QCI-NABET accredited EIA Consultant Organization.Recognized Environmental Laboratory under EPA Act 1986 from MoEF.An ISO 9001: 2000 and OHSAS 8001: 2007 certified Laboratory.Recognized Environmental Auditors with GPCB.

.

2.0 Scope of Work

The detailed scope of work is as below:

2.1 Maximum GLC for a radius of 10 km will be predicted on the Gaussian plume model in ISC-AERMOD (by Lakes Environmental, Canada)

computer user-interface based on the ISCST3 model developed by USEPA.

2.2 The details of various stack emissions detail to be furnished by the client.

2.3 The output will be provided in form of a report with the results in tabular and contour forms.


Page | 3

3.0 Details required from the Client

The following details were requested from the client:

Stack emission details:

Stack height, Stack internal diameter at top, Exit gas velocity, Exit gas temperature, Characteristics of the fuels to be used and their consumption rates,Site layout with stack locations for assigning the coordinates.

4.0 The Dispersion Software -

The dispersion of pollutants in the atmosphere is a function of several meteorological parameters viz. wind speed, direction, stability class, etc. A number of models have been developed for the prediction of pollutant concentration at any point from an emitting source. The Industrial Source Complex Short Term (ISCST3) dispersion model is a steady-state Gaussian plume model. It is most widely accepted for its interpretability. It gives reasonably correct values because this obeys the equation of continuity and it also takes care of diffusion, which is a random process. It is also accepted by the Ministry of Environment & Forests, Govt. of India.

For the present study, the software-graphical user interface - , developed byLakes Environmental, Canada, using the ISCST3 model, was used for the prediction of maximum ground level concentration (GLC).


Page | 4

5.0 The Methodology

The dispersion modeling for prediction of GLC was carried out based on following considerations:

For the existing scenario, the model has been run for 3 nos. of stacks as below:

Stack-1: Common stack attached to 2 installations as below:oFO based Genset @2.2 MW - a stand-by facility, but considered for modeling for

worst case scenario during power failure.

oDual fired engine @1.2MW HSD considered as fuel for worst case scenario

during power failure.

Stack-2: Gas turbine with WHR system @4.5MW currently as standby facility due

to increase in NG rates, but considered for modeling for worst case scenario during

power failure.

Stack-3: Gas based Power Engine @2MW currently as standby facility due to

increase in NG rates, but considered for modeling for worst case scenario during

power failure.

Stack-4: Common stack attached to 2 nos. of Coal fired heaters of capacity 14 Lakh.kCal/hr.

Stack-5: Common stack attached to 2 nos. of Coal fired heaters of capacity 10 Lakh.kCal/hr. only 1 no. considered for modeling as 1 no. to act as a standby

facility.

For the proposed scenario, the model has been run for 5 nos. of stacks as below:

Stack-4: Common stack attached to 2 nos. of Coal fired heaters of capacity 14 Lakh.kCal/hr.

Stack-5: Common stack attached to 2 nos. of Coal fired heaters of capacity 10 Lakh.kCal/hr. only 1 no. considered for modeling as 1 no. to act as a standby

facility.

Stack-6: Steam Boiler @45 TPH to be attached to the turbine.The GLC have been predicted for 3 parameters, namely PM10 (Particulate Matter less than 10 Micron in size), NOx (Oxides of Nitrogen), SO2 (Sulphur Dioxide).


Page | 5

5.1 Input Parameters

The input parameters for the preparation of mathematical model consist of, baseline values, meteorological data and source emission details. The details are discussed below:

5.1.1 Baseline Values

The baseline status of the ambient air quality data generated during March 2015 to May 2015 in 5 km radius for same region has been utilized to predict the ambient air quality status after the proposed project. The parameters monitored for AAQM included Particulate Matter 10 (PM10 i.e. PM<10 μ), Particulate Matter 2.5 (PM2.5 i.e. PM < 2.5 μ), Sulphur Dioxide (SO2), Oxides of Nitrogen (NO2) & TVOC (Total Volatile Organic Compound) at 8 locations.

Table 1: Ambient Air Quality of the Study Area (March-

Stn. Code Statistical Parameter Pollutant ParameterPM10 PM2.5 SO2 NO2 TVOC*

A1 Average 81 34 24 26 1.6Maximum 95 42 28 29Minimum 78 25 20 2398th percentile 94 41 28 29


A3 - Average 87 33 24 26 1.3Maximum 89 38 28 30Minimum 81 27 19 2298th percentile 89 38 28 30





A8 - Average 82 33 26 28 1.3Maximum 91 39 31 35Minimum 71 25 22 19


Page | 6

Stn. Code Statistical Parameter Pollutant ParameterPM10 PM2.5 SO2 NO2 TVOC*

98th percentile 90 39 31 34Note: 1. *indicates sampling once in study period. All results in ug/m3 except TVOC in ppm.

(Source: Primary monitoring survey by Precitech Laboratories pvt ltd March- )

5.1.2 Micro-meteorological data

Micro-meteorological data recorded for a period from March 2015 to May 2015 have been utilized for modeling. The following parameters were recorded at hourly intervals from the surface weather station for preparing the meteorological file

Wind velocity & Wind direction, Temperature, Relative humidity, Rainfall.The mixing heights required for input in the model, were determined by referring to the maps

pre-monsoon from the IMD publication - Atlas of hourly mixing height and assimilative capacity of atmosphere in India. In order to conduct a refined air dispersion modeling using ISCST3 short-term air quality dispersion model, the hourly meteorological data were pre-processed using the U.S. EPA PCRAMMET program. The wind-rose diagram is given in figure 1 and the wind class and stability class distribution charts are given in figure 2.

Figure 1: Windrose diagram of the Processed file

Legend:

Details:Total Hours: 2208Calm Hours: 0Avg. wind speed: 1.87 m/s.Period: March 2015 to May 2015


Page | 7

Figure 2: Wind Class & Stability Class Distribution Charts

5.1.3 Source emission details

The input data for source emissions i.e. the emission rates have been derived from the data provided by the client as below:

Emission rates for Particulate matter have been calculated on the basis of following considerations:

An ash content of 0.1% is considered in FO fired installations

An ash content of 0.05% is considered in HSD fired installations

Emission rates for installations where NG is used as fuel have been computed from the emission factors taken from AP-42 (USEPA) based on consumption rates of fuel.

A mixture of fuels (Imported Coal & Indian Coal in a ratio of 70:30) has been considered for each of the Coal fired thermic fluid heaters.

Imported coal has been considered as fuel for proposed steam boiler of 45 TPH to be attached to the turbine.


Page | 8

An Ash content of 5% and 34.18% has been considered for Imported Coal and Indian Coal respectively, for estimating the emissions for particulate matter.

It has also been assumed that 20% of the ash is retained in bed and 80% is the fly ash.

Moreover, all the particulate matter is assumed as PM10.

Furthermore, the %efficiency of ESP is considered as 99.5%

Emission rates for Sulphur Dioxide have been calculated on the basis of following considerations:

A sulphur content of 2.5% is considered in FO fired installations

A sulphur content of 0.5% is considered in HSD fired installations

Emission rates for installations where NG is used as fuel, have been computed from the emission factors taken from AP-42 (USEPA) based on consumption rates of fuel.

A mixture of fuels (Imported Coal & Indian Coal in a ratio of 70:30) has been considered for each of the Coal fired heaters.

Imported coal has been considered as fuel for proposed steam boiler of 45 TPH to be attached to the turbine.

A Sulphur content of 0.5% and 0.26% has been considered for Imported Coal and Indian Coal respectively, for estimating the emissions for Sulphur Dioxide.

It has also been assumed that 95% of the Sulphur in the fuel is converted to Sulphur Dioxide.

Furthermore, efficiency of 85% has been considered for Sulphur capture system i.e. lime dosing/blending in the furnace.

Emission rates for Nitrogen Dioxide have been calculated based on the permissible norms of 50ppm.

The details of source of air emissions are given in Table 2.

Air D

isper

sion

Mod

elin

g Re

port

for A

men

dmen

t in

EC fo

r Exi

stin

g Po

lyes

ter P

lant

for

Cha

nge

in F

uel f

or 9

.9 M

W C

PP b

y M

/s. J

BF In

dust

ries

Ltd

., G

IDC,

Sar

igam

Page

| 9

Tabl

e 2:

The

Sou

rces

Em

issi

on D

etai

ls

Stac

kno

.St

ack a

ttach

ed to

Carte

sian

co-o

rdin

ates

Base

Elev

atio

n ab

ove M

SL

(m)

Ht. &

Dia.

of

Stac

k, (m

)Ex

it Ga

s Ve

locit

y (m

/s)

& Te

mp.

(°C)

Fuel

Para

-m

eter

Pollu

tant

relea

se ra

tes

(g/

s)

With

out A

PCD

With

APC

DEx

istin

gSc

enar

ioS-

1FO

fired

Gen

set -

2.2MW

+ 1.2

MW D

ual fi

red

engin

e

-54.7

7,10

3.26

30.71

H: 65

mD:

2.2 m

V: 17

m/s

T: 28

0 °C

FO @

650 k

g/Hr+

HSD

@25

0 ltr/

hrPM

0.210

0N.

A.

SO2

9.617

0N.

A.

NOx

6.550

0N.

A.

S-2

Gas T

urbin

e with

WHR

Sy

stem

-4.5

MW-2

4.33,

113.9

430

.06H:

30 m

D: 1.

5 mV:

16.5

m/s

T: 29

0 °C

Natur

al Ga

s @40

000

scm/

day

PM0.0

560

N. A

.SO

20.0

040

N. A

.NO

x0.7

350

N. A

.S-

3Ga

s bas

ed P

ower

En

gine -

2 MW

-64.4

9,11

1.030

.68H:

30 m

D: 0.

6 mV:

19 m

/sT:

290 °

CNa

tural

Gas @

1400

0sc

m/da

yPM

0.020

0N.

A.

SO2

0.002

0N.

A.

NOx

0.257

0N.

A.

S-4

TFH-

14 La

khKC

al/hr

(2

Nos

)-9

.13,

-244

.6230

.06H:

63m

D:2.2

mV:

13.5

m/s

T: 15

0 °C

Impo

rted C

oal @

2626

kg/H

r +

Indian

Coa

l @11

82 kg

/Hr

(for e

ach)

PM23

7.915

1.189

SO2

17.10

32.5

66NO

x1.9

70N.

A.

S-5

TFH-

10La

khKC

al/hr

(1

No)

19.76

,-2

40.12

29.84

H:63

mD:

2.2m

V: 7

m/s

T: 15

0 °C

Impo

rted C

oal @

1876

kg/H

r +

Indian

Coa

l @84

4 kg/H

rPM

84.95

10.4

25SO

26.1

091.8

33NO

x1.7

63N.

A.

Prop

osed

Scen

ario

S-4

TFH-

14 La

khKC

al/hr

(2

Nos

)-9

.13,

-244

.6230

.06H:

63m

D:2.2

mV:

13.5

m/s

T: 15

0 °C

Impo

rted C

oal @

2626

kg/H

r +

Indian

Coa

l @11

82 kg

/Hr

(for e

ach)

PM23

7.915

1.189

SO2

17.10

32.5

66NO

x1.9

70N.

A.

S-5

TFH-

10 La

khKC

al/hr

(1

No)

19.76

,-2

40.12

29.84

H:63

mD:

2.2m

V: 7

m/s

T: 15

0 °C

Impo

rted C

oal @

1876

kg/H

r +

Indian

Coa

l @84

4 kg/H

rPM

84.95

10.4

25SO

26.1

090.9

16NO

x1.7

63N.

A.

S-6

Stea

m Bo

iler

45 T

PH79

.9,-2

27.51

28.02

H: 63

mD:

2.2m

V: 12

.5 m/

sT:

110 °

CIm

porte

d Coa

l @54

00 kg

/Hr

PM60

.000

0.300

SO2

14.25

02.1

38NO

x3.4

74N.

A.


Page | 10

5.1.3 The receptor area and assigning local coordinate system to the study area

The receptor area is generally defined to predict the impact of the emissions due to the defined sources, by superimposing the predicted GLC on the existing ambient air quality status for each of the parameter to derive at a resultant air quality value.

The receptors have been identified as below:

A uniform Cartesian grid of receptors has been defined within as below:

There are two Cartesian grid of receptors UCART1 and UCART2 has been defined within as below.

UCART1 - Consisting of 1681 receptors each at a distance of 500 m,

UCART2 - Consisting of 441 receptors each at a distance of 100 m,

Moreover, each of the 8 nos. of AAQM stations that were used in the earlier EIA report carried out by the industry in March 2015 to May 2015, has been identified as specific Cartesian receptor.

Hence, a total of 2130 receptors have been considered for modeling the GLC.The approximate center of the plant (at 20°17'30.76"N, 72°51'13.56"E) was considered at (0, 0) co-ordinates of the Cartesian grid and corresponding values of Cartesian co-ordinates were assigned to the stack sources by overlaying the site layout plant on the Cartesian grid. Similarly, the receptors were assigned the Cartesian co-ordinates by overlaying a map of the 10km radial periphery on the cartesian co-ordinate system.

5.1.4 The terrain

The terrain of the domain boundary was considered as Complex + Simple terrain. The terrain elevations have been assigned to the sources and receptors in the study area by processing in AERMAP by utilization of SRTM3 (Shuttle Radar Topography Mission Global Coverage maps ~90m resolution) maps.


Page | 11

Figure 3: Terrain Contours within the radial periphery of 5km

The GLC were predicted for over a 24-hour period, for ease of comparison with the 24 hourly ambient air quality standards.The output values of GLC were selected to be calculated in μg/m3.

5.2 Output Parameters

The GLC were predicted for over a 24-hour period, for ease of comparison with the 24 hourly ambient air quality standards.The output values of GLC were selected to be calculated in μg/m3.


Page | 12

6.0 The Results

The contour plots of the 24 hourly average GLCs for each of the pollutant are illustrated in figures 4 to 9. The outcome of ISC-AERMOD View Model is tabulated in table 2 as Incremental GLC with other necessary details for maximum values of GLC as well as for selected discrete Cartesian receptors. The results of the maximum GLCs for prediction of ambient air quality due to the proposed flue gas stacks are presented at Table 3.

Air D

isper

sion

Mod

elin

g Re

port

for A

men

dmen

t in

EC fo

r Exi

stin

g Po

lyes

ter P

lant

for

Cha

nge

in F

uel f

or 9

.9 M

W C

PP b

y M

/s. J

BF In

dust

ries

Ltd

., G

IDC,

Sar

igam

Page

| 13

Tabl

e3:T

hepr

edict

ed 24

hou

rly G

LC o

f Air

Pollu

tant

s

Pollu

tant

/ Re

cept

orX-

Axis

(m)

Y-ax

is(m

)Ba

seEl

evat

ion

abov

e MSL

(m)

Aeria

l dist

. & d

irect

ion

from

Site

(km

Fo

r Exis

ting

Proj

ect

(μg/

m3 )

Afte

r Pro

pose

d Pr

ojec

t (μg

/m3 )

Pred

icted

Incr

emen

tal G

LC

valu

es D

ue to

Pro

pose

d Pr

ojec

t (μ

g/m

3 )W

ithou

t

APCD

With

APC

DW

ithou

t

APCD

With

APC

DW

ithou

t A

PCD

With

APC

D

PM10

1st M

ax.

1000

.0040

0.00

43.2

--36

1.00

--43

6.00

2.18

75.00

0.16

1000

.0020

00.00

76.5

----

2.02

----

A1-2

70.51

-802

.6832

.55--

153.1

10.9

018

4.85

0.92

31.74

0.01

A231

9.33

444.8

033

.8110

7.89

0.61

129.0

40.6

521

.140.0

3A3

1585

.82-1

696.0

442

.915

4.42

0.89

186.5

30.9

332

.110.0

4A4

-114

2.02

-214

4.49

30.81

116.2

60.6

413

9.64

0.70

23.38

0.06

A5-7

28.46

1402

.6241

.0421

1.69

1.19

245.7

61.2

334

.060.0

4A6

91.99

-382

0.45

27.06

86.25

0.50

102.0

70.5

115

.830.0

1A7

-256

5.80

-99.1

347

.0919

2.12

1.06

229.3

51.1

537

.220.0

9A8

331.6

824

33.34

35.72

116.7

80.6

714

2.95

0.71

26.17

0.04

SO2

1st M

ax.

-100

0.00

3000

.0013

4.40

----

12.10

----

13.40

-9.92

1000

.0040

0.00

43.20

----

----

2.18

1000

.0020

00.00

76.50

--30

.60--

44.00

--A1

-270

.51-8

02.68

32.55

--13

.634.8

419

.400.9

25.7

7-3

.92A2

319.3

344

4.80

33.81

NE)

9.35

3.99

12.78

0.65

3.43

-3.35

A315

85.82

-169

6.04

42.90

13.94

5.03

18.75

0.93

4.81

-4.09

A4-1

142.0

2-2

144.4

930

.819.8

13.0

913

.920.7

04.1

1-2

.40A5

-728

.4614

02.62

41.04

17.68

5.61

23.33

1.23

5.65

-4.38

A691

.99-3

820.4

527

.068.1

33.1

29.9

70.5

11.8

4-2

.62A7

-256

5.8-9

9.13

47.09

16.13

6.04

22.67

1.15

6.54

-4.89

Air D

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sion

Mod

elin

g Re

port

for A

men

dmen

t in

EC fo

r Exi

stin

g Po

lyes

ter P

lant

for

Cha

nge

in F

uel f

or 9

.9 M

W C

PP b

y M

/s. J

BF In

dust

ries

Ltd

., G

IDC,

Sar

igam

Page

| 14

Pollu

tant

/ Re

cept

orX-

Axis

(m)

Y-ax

is(m

)Ba

seEl

evat

ion

abov

e MSL

(m)

Aeria

l dist

. & d

irect

ion

from

Site

(km

Fo

r Exis

ting

Proj

ect

(μg/

m3 )

Afte

r Pro

pose

d Pr

ojec

t (μg

/m3 )

Pred

icted

Incr

emen

tal G

LC

valu

es D

ue to

Pro

pose

d Pr

ojec

t (μ

g/m

3 )W

ithou

t

APCD

With

APC

DW

ithou

t

APCD

With

APC

DW

ithou

t A

PCD

With

APC

D

A833

1.68

2433

.3435

.7210

.554.5

114

.630.7

14.0

7-3

.79NO

x1s

t Max

.-1

000.0

030

00.00

134.4

--10

.05--

----

-1.17

N. A

.10

00.00

400.0

043

.20--

----

8.88

--A1

-270

.51-8

02.68

32.55

--4.8

4N.

A.

4.10

N. A

.-0

.74N.

A.

A231

9.33

444.8

033

.814.1

5N.

A.

2.70

N. A

.-1

.45N.

A.

A315

85.82

-169

6.04

42.90

SE)

4.55

N. A

.3.7

4N.

A.

-0.80

N. A

.A4

-114

2.02

-214

4.49

30.81

2.77

N. A

.2.7

7N.

A.

0.00

N. A

.A5

-728

.4614

02.62

41.04

5.77

N. A

.4.6

4N.

A.

-1.13

N. A

.A6

91.99

-382

0.45

27.06

2.73

N. A

.1.9

4N.

A.

-0.79

N. A

.A7

-256

5.8-9

9.13

47.09

5.36

N. A

.4.4

6N.

A.

-0.90

N. A

.A8

331.6

824

33.34

35.72

4.18

N. A

.2.9

4N.

A.

-1.24

N. A

.


Page | 15

Figure 4: 24 Hourly Contour Plot for PM10 without APCD for Existing Scenario

- AAQM stationsWindrose diagram for modeling Project:

Air Dispersion modeling report for proposed amendment by installation of 9.9 MW coal fired CPP by M/s. JBF Industries Ltd.

Sources:

5

Receptors:

2130

Maximum Conc.:

361 µg/m^3

Coordinates:

(1000, 400)


Page | 16

Figure 5: 24 Hourly Contour Plot for PM10 with APCD for Existing Scenario



Sources:

5

Receptors:

2130

Maximum Conc.:

2.02 µg/m^3

Coordinates:

(1000, 2000)


Page | 17

Figure 6: 24 Hourly Contour Plot for PM10 without APCD for Proposed Scenario



Sources:

3

Receptors:

2130

Maximum Conc.:

436 µg/m^3

Coordinates:

(1000, 400)


Page | 18

Figure 7: 24 Hourly Contour Plot for PM10 with APCD for Proposed Scenario



Sources:

3

Receptors:

2130

Maximum Conc.:

2.18 µg/m^3

Coordinates:

(1000, 400)


Page | 19

Figure 8: 24 Hourly Contour Plot for SO2 without APCD for Existing Scenario


Air Dispersion modeling report for proposed amendment by installationof 9.9 MW coal fired CPP by M/s. JBF Industries Ltd.

Sources:

5

Receptors:

2130

Maximum Conc.:

30.6 µg/m^3

Coordinates:

(1000, 2000)


Page | 20

Figure 9: 24 Hourly Contour Plot for SO2 with APCD for Existing Scenario



Sources:

5

Receptors:

2130

Maximum Conc.:

12.1 µg/m^3

Coordinates:

(-1000, 3000)


Page | 21

Figure 10: 24 Hourly Contour Plot for SO2 without APCD for Proposed Scenario

- AAQM stations

Windrose diagram for modeling Project:


Sources:

3

Receptors:

2130

Maximum Conc.:

44.0 µg/m^3

Coordinates:

(1000, 2000)


Page | 22

Figure 11: 24 Hourly Contour Plot for SO2 with APCD for Proposed Scenario

- AAQM stations



Sources:

3

Receptors:

2130

Maximum Conc.:

2.18 µg/m^3

Coordinates:

(1000, 400)


Page | 23

Figure 12: 24 Hourly Contour Plot for NOx without APCD for Existing Scenario

- AAQM stations



Sources:

5

Receptors:

2130

Maximum Conc.:

10.05 µg/m^3

Coordinates:

(-1000, 3000)


Page | 24

Figure 13: 24 Hourly Contour Plot for NOx without APCD for Proposed Scenario

- AAQM stations


Air Dispersion modeling report for proposed amendment by installationof 9.9 MW coal fired CPP by M/s. JBF Industries Ltd.

Sources:

3

Receptors:

2130

Maximum Conc.:

8.88 µg/m^3

Coordinates:

(1000, 400)


Page | 25

7.0 Discussion

An attempt has been made to predict the ambient air quality after the proposed project at the

AAQM results presented for the study carried out in March 2015 to May 2015. The same are compared with National Ambient Air Quality Monitoring Standards and presented at Table 4.

Table 4: Predicted Level of Pollutants at AAQM Stations after the Proposed Project

Stn.Code

Pollutant/ Receptor

Predicted Incremental GLC value Due to Proposed project

(μg/m3)

Existing concentration in ambient air

(Avg.) (μg/m3)

Predicted concentration in ambient air after

proposed Project (μg/m3)

*NAAQS

Without APCD

WithAPCD

Without APCD

With APCD

PM10

A1 Near Project Site

31.74 0.01 94 125.74 94.01 100

A2 Angam 21.14 0.03 94 115.14 94.03A3 Bhilad 32.11 0.04 89 121.11 89.04A4 Manda 23.38 0.06 83 106.38 83.06A5 Karanjgam 34.06 0.04 79 113.06 79.04A6 Daheli 15.83 0.01 91 106.83 91.01A7 Maroli 37.22 0.09 79 116.22 79.09A8 Kalgam 26.17 0.04 90 116.17 90.04SO2

A1 Near Project Site

5.77 -3.92 28 33.77 24.08 80

A2 Angam 3.43 -3.35 29 32.43 25.65A3 Bhilad 4.81 -4.10 28 32.81 23.90A4 Manda 4.11 -2.40 27 31.11 24.60A5 Karanjgam 5.65 -4.38 25 30.65 20.62A6 Daheli 1.85 -2.62 31 32.85 28.38A7 Maroli 6.54 -4.89 29 35.54 24.11A8 Kalgam 4.07 -3.79 31 35.07 27.21NOxA1 Near Project

Site-0.74 N. A. 29 28.26 N. A 80

A2 Angam -1.45 N. A 32 30.55 N. AA3 Bhilad -0.80 N. A 30 29.20 N. AA4 Manda -0.01 N. A 29 28.99 N. AA5 Karanjgam -1.13 N. A 34 32.87 N. AA6 Daheli -0.79 N. A 32 31.21 N. AA7 Maroli -0.90 N. A 33 32.10 N. AA8 Kalgam -1.24 N. A 34 32.76 N. ANote: All values are in μg/m3,

N.A. = Not AvailableNAAQS = National ambient air quality as per CPCB notification (98% - 24 hourly values),


Page | 26

The result of dispersion modelling show, that the emission of PM10, SO2 and NOx from the plant will partially increase the level of air pollutants.

It is noteworthy that predicted GLC values of SO2 indicate decrease in the levels of SO2

in ambient air due to the proposed project. This is due to use of imported coal which has a lower Sulphur content, instead of furnace oil/ HSD. Furthermore, lime dosing is also carried out during use of imported coal.

Similarly, the predicted GLCs for NOx also indicate a decrease in levels of NOx in ambient air due to the decrease in the number of operational utilities after the installation of the turbine.

However, as shown at the Table 4 when superimposed over the baseline concentrations the resultant concentrations viz. the predicted level of conventional pollutants in the ambient air are well below the National Ambient Air Quality Standards.

Thus, the impacts of conventional pollutants would not be significant from the proposed project during normal operation phase.

U

Annexure 7: MoU with Brick Manufacturers for Fly Ash

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