JSW Cement Ltd

NOTE ONENVIRONMENTAL IMPACTS

DUE TO USE OF PET COKE AS ALTERNATIVE FUELIN ADDITION TO COAL IN

KILN OF CEMENT PLANT AND BOILER OF CAPTIVEPOWER PLANT

FORAMENDMENT IN EC

((EECC GGrraanntteedd :: JJ--1111001111//888899//22000077--IIAA..IIII ((II)) DDaatteedd 0099..0033..22001166))AT

JJSSWW CCeemmeenntt LLttdd..aatt

BBiillaakkaallaagguudduurr ((VV)),, GGaaddiivveemmuullaa ((MM)),,KKuurrnnooooll DDiissttrriicctt,, AAnnddhhrraa PPrraaddeesshh..

Prepared By

< B.S. ENVI-TECH (P) LTD.

SECUNDERABAD-500017

Table Of ContentsPara Title

1 Introduction2 Need for use of pet coke3 Justification Of Proposal4 Location Of The Plant5 Project Description

5.1 Cement Plant5.2 Captive Power Plant6.0 Planning In Brief7.0 Proposed Infrastructure:8.0 Fuel-Requirement, Quality Availability & Transportation:9.0 Environmental Impacts

9.1.1 Air Environment9.1.2 Ground level Concentration9.1.3 Air Pollution Control Measures

9.2 Water Environment9.2.1 Water Consumption9.2.2 Wastewater Generation, Treatment And Utilisation

9.3 Land Environment9.3.1 Solid Waste Generation10.0 Budget For Environmental Management Plan11.0 Project Schedule & Cost Estimate12.0 Conclusion

LIST OF FIGURESFig – 1 Location map of the Plant Site.Fig – 2 Key mapFig – 3 Co-ordinates of the plant site on topo sheetFig - 4 The study area of 10 km radius around the Plant Site.Fig – 5 Schematic Of A CFBC BoilerFig – 6 Schematic View Of Flue Gas Desulphurization

Fig - 7 Predicted incremental ground level concentration of PM10 due touse of petcoke in kiln of cement plant and boiler of power plant

Fig - 8 Predicted incremental ground level concentration of SO2 due touse of petcoke in kiln of cement plant and boiler of power plant

Fig – 9 Predicted incremental ground level concentration of NOx due touse of petcoke in kiln of cement plant and boiler of power plant

LIST OF TABLESTable – 1 Basic information of the projectTable – 2 Salient features of Plant SiteTable – 3 50 High 24-hourly average ground level concentrations of PM10

Table – 4 50 High 24-hourly average ground level concentrations of SO2

Table – 5 50 High 24-hourly average ground level concentrations of NOx

1.0 INTRODUCTION

M/s JSW Cement Limited (hereinafter referred to as ‘JSWCL’) iscurrently operating a 4.8 MTPA capacity cement manufacturing unitat village Bilakalagudur, Gadivemula Mandal, Kurnool Distt. A.P.Environment Clearance for the above project was granted by the MoEFvide letter No J-11011/889/2007-IA.II (I) Dated 25.08.2008 and J-11011/159/2010-IA-II(I) Dt:13-05-2011 for slag grinding unit and J-11011/889/2007-IA.II (I) Dated 09.03.2016 for expansion of clinkermanufacturing capacity from 2.0 to 2.5 MTPA and change in productmix from 1.1 MTPA Ordinary Portland Cement (OPC) and 3.7 MTPAPSC to 1.1 MTPA OPC and 3.7 MTPA Portland Slag Cement (PSC)/Ground Granulated Blast Furnace Slag (GGBS)

The captive power plant could not be set up within the validity of theEC due to non-availability of linkage coal and therefore extension ofthe validity of the EC was requested and the same was granted by theMoEF vide letter no. J-11011/889/2007-IA.II (I) Dated 06.01.2014valid till 23.08.2018 and CFE from APPCB vide Letter No. Gen-5/PCB/RO/KNL/2013/336, dated 23.07.2013 valid till 05.01.2019.

Due to uncertainty in the availability of coal linkage and rising pricesof imported coal, it proposed to use pet coke as an alternative fuel inaddition to coal for which approval from MoEF&CC is being sought.The proposed fuel, i.e. Pet Coke is readily available in Indian market.

In light of the above, JSW seeks amendment of the EnvironmentalClearance for the following aspects

a. Use of Pet coke as alternative fuel in addition to coal in kiln ofcement plant and boiler of power plant

b. Change of Boiler technology from AFBC to CFBCc. Change of Condensate Cooling System from water cooled to air

cooledd. Addition of PPC as finished product.

The key amendments of the proposal are given below:

S.No.

Particulars ExistingEnvironmentalClearance (EC)

Proposed ECAmendment

Remarks

1 Kiln Imported coal Pet Coke/Imported coal

100% or incombination

2 CPPConfiguration

36 MW 2 x 18 MW EC title to be amendedas 2 x 18 MW.However, the initialproposal in our EIA

S.No.



Remarks

reports submitted wasfor 2 x 18.

3 Type of Fuel tobe used in CPP

Imported /indigenous coal

Pet Coke/Imported coal/Indian coal

100% or incombination

4 Survey Nos ofCPP

280, 273, 277 174, 175, 176,177, 178, 179,183

Within the existingpremises

5 Addition ofPPC as afinishedproduct in ECtitle

Clinker 2.5MTPACement 4.8MTPA (1.10 OPC+ 3.70 PSC/GGBS)

Clinker 2.5MTPACement 4.8MTPA (1.10OPC/PPC + 3.70PSC/ GGBS)

EC dated 25.08.2008,Sp. condition No. vii)states:“The fly ash generatedfrom the captive powerplant shall be utilized100% formanufacturing of PPC”.However ‘PPC’ is notreflected as a productin the EC title.

Basic information of the project is enclosed as Table – 1

A comparison of the statement showing the key parameters for ECgranted and EC amendments sought is given below

S.No.



Remarks

CEMENT PLANT1 Fuel Imported /

indigenous coalPet Coke/Importedcoal/ Indiancoal

Use of pet coke inaddition to coalas alternativefuel

2 Quantity of Fuel,MTPA

Coal - 0.375 Coal - 0.375OrPet coke –0.229

Use of pet coke inaddition to coalas alternativefuel

CAPTIVE POWER PLANT1. Type of Boiler AFBC CFBC CFBC is ideal for

Pet Coke firing.2. Type of

CondenserWater cooledcondenser

Air cooledcondenser

Waterrequirement willbe drasticallyreduced

3. Flue GasDesulphurization(FGD)

Not envisaged FGDproposed tobe installed

To capture SO2

in flue gases inthe form of

S.No.



Remarks

4. Limestoneinjection (TPD)

Not envisaged 312 TPD or13000 Kg/Hr.(12750 Kg/Hrin Boiler &250 Kg/Hr inFGD.

CaSO4.Limestone will besourced from thecaptive minesituated at 1 kmdistance from theCPP.

5. Landrequirement (Ha)

20.24 10 Land is availablewithin theexisting cementplant premises.No additionalland will beprocured. 10 Haincludes 33% ofgreenbelt to bedeveloped.

6. Waterrequirement(M3/day)

1800 600 Permission foruse of Groundwater alreadyobtained fromthe competentauthority

7. Waste watergeneration(M3/day)

685 216 Will be treated inETP and thetreated water willbe used for dustsuppression

8. Fuel requirement(4ones per day)

800 (coal) 314 (PetCoke)

9. Net Calorificvalue of fuel(Kcal/ Kg of fuel)

4700 (coal) 7670 (PetCoke)

10. Sulphur contentin fuel (%)

0.80 max. (Coal) 8.5% max.(Pet Coke)

11. Max. SO2 in stack flue gasesa) Kg/Hr 533.38 8.14 There will be a

common singlestack for both theunits.

b) Mg/Nm3 500 - 600 <10012. Max. NOx in

stack flue gases(mg/Nm3)

250-300 <100 CFBC boiler &low NOx burnerwill be providedto control NOxemission

13. Fly Ash 96 7.52 (with pet 100% fly ash will

S.No.



Remarks

generation (tpd) coke) be used incementmanufacturingprocess

14. Bottom Ashgeneration (tpd)

24 273 100% bottom ashwill be reused asraw mixingredient incementmanufacturingprocess

15. Gypsumgeneration (tpd)

0 10 100% gypsumwill be used incementmanufacturingprocess

16. Boiler stackheight (M)

95 (single) 30 Calculated as perCPCB norms

17. Stack dustemission(mg/Nm3)

<50 <30 High efficiencyESP (2 nos) willbe installed

18. Limestonefeeding system(capacity TPH)

Not envisaged 20

Overall Emissions Due To Use Of Pet coke in addition to coal In Kiln Of CementPlant And Boiler Of Power PlantS.No Parameter Existing

EnvironmentalClearance (EC)


Change in%

1 AirEmissions, *Kg/hr

ParticulateMatter

18.10 17.06 decreaseIn overallemissionsSulphur

Dioxide92.91 *56.9

Oxides ofNitrogen

404.1 399.06

2 IncrementalGroundLevelConcentrations (ug/m3)

ParticulateMatter 0.335 0.307 decrease

in groundlevelconcentrations

SulphurDioxide 2.11 1.29

Oxides ofNitrogen 7.77 7.67

Note : decrease increase*Sulphur Dioxide Control By Desulphurisation

Table – 1BASIC INFORMATION

1. Name of the project Use of Pet Coke as fuel in addition toimported/ indigenous coal in Cement Kilnand the proposed 36 MW (2x18 MW) CaptivePower Plant and addition of PPC as finishedproduct in the existing EC of M/s JSWCement Limited, village Bilakalagudur,GadivemulaMandal, Kurnool Distt., A.P. –Amendment in EC reg.

2. S. No. in the Schedule 3 (b)3. Registered Address JSW Cement Ltd., JSW Centre,

MMRDA Ground, BandraKurla Complex,Bandra (East) MUMBAI 400 051

4. Name of the Applicant JSW Cement Limited5. Present Business Cement manufacturing at Nandyal (AP),

Vijaynagar, Bellary (Karnataka) and Dolvi,Raigad (Maharashtra)

6. Area of plant 263 Hectares (Cement Plant Area)7. Toposheet No. 57/I/68. Altitude 260 m above msl9. Max. Temp. 45.6 °C10. Min. Temp. 16 °C11. Relative Humidity 25-77%12. Avg. Annual Rainfall 725.9 mm13. Latitude

LongitudeLatitude: 15° 40’ 15”N to 15° 41’ 24”NLongitude: 78° 27’21”E to 78°27’54”E

14. Capacity 36 MW electric power generation15. Cost of Project Rs. 240 Crore16. Capital and recurring cost of

Environment Management PlanRs. 60 Crore (Capital)Rs 2.50 Crore/annum (Recurring)

17. Manpower Requirement 80 persons18. Power Requirement The auxiliary power requirement for the

project will be 13.5%19. Water Requirement 3300 M3/day and the same will be sourced

from bore wells for which due authorizationhas been obtained from the State GW deptt.

20. Nearest Railway Station/Airportalongwith distance in kms.

Nandyal – 24 km SHyderabad (Shamshabad) – 172 km SE

21. Nearest town, City, District HeadQuarters along with distance inkms.

Nandyal – 24 Km, SKurnool – 48 km, NWDistrict Head quarter: Kurnool - 48 km, NW

21. Nearest National Highway NH-18 connecting Nandyal – Kurnool, 22.4km, SW

22. Nearest Port Krishnapatanam Port – 237.6 km, SE23. Village Panchayats, ZillaParishad,

Municipal corporation, Localtelephone nos. to be given) body(complete postal addresses withtelephone nos to be given)

Bilakalagudur village, GadivemulaMandal,Kurnool Dist. of Andhra Pradesh518 508

2.0 NEED FOR USE OF PET COKE

JSW Cement Limited has received Environment Clearance for thecoal-based Captive Power Plant (CPP) of 36 MW within the cementplant premises located at village Bilakalagudur, Gadivemula Mandal,Kurnool Distt., A.P. The objective of setting up of this coal based CPPwas to meet the power requirements of Cement Plant in an economicand effective way. Due to uncertainty in the availability of coal linkageand rising prices of imported coal, it is proposed to change the fuelfrom coal to pet coke for which approval from MoEF&CC is beingsought. The proposed fuel, i.e. Pet Coke is readily available in Indianmarket. For the above CPP, the conversion to pet coke as analternative fuel is envisaged due to the following reasons:

1) Petroleum coke (Pet coke) is a carbonaceous solid derived from oilrefinery coker units or other cracking processes. The chemicalcomposition of petroleum coke is mostly elementary Carbon (usuallyover the 85% C dry with sulphur content of about 8.5 % (max)) withhigh heating value and very little ash content (usually less than 1-2%).

2) Petroleum coke is a fuel that has long been considered an ideal fuelfor the circulating fluidized bed combustion (CFBC) technology.

3) Despite the low volatile content of pet coke, combustion efficiency isquite good in a circulating fluidized bed (CFBC) boiler, (at least 2.5%higher than that of Coal fired CFB).

4) Lower temperatures improve the emissions performance as well asreduce the potential for agglomeration and deposition. Therecommended furnace design temperature should be typically in therange of 850 - 900°C. This will in-turn reduce the NOx emissions aswell.

5) Compared to other low ash coals, pet coke has advantage in terms ofbed material inventory. In spite of having low ash content, the bedmaterial requirement is minimum, since limestone and its reactedproducts (gypsum) act as the bed material.

6) Use of Pet Coke in cement Kiln will facilitate use of sub-gradelimestone to the optimum extent resulting in production of highquality clinker which, in turn, will facilitate addition of more slag inPortland Slag Cement (PSC). This will result in natural resourceconservation.

3.0 JUSTIFICATION OF PROPOSAL

The pet coke based captive power plant will ensure supply of power ata competitive cost, providing greater flexibility and viability to theJSWCL Manufacturing operations in an environmentally responsivemanner.

The project will result in following environmental and economicbenefits:

1) Generation of power at a competitive cost compared to powergenerated by using imported coal.

2) Utilization of industrial waste thus resulting in fossil fuelconservation.

3) Installation of FGD will greatly minimize SO2 emission from thestack (>99% reduction and to meet new environmental norms of<100 mg/Nm3).

4) With the installation of Air Cooled Condenser, fresh waterconsumption will be reduced by 67% with corresponding equivalentreduction in waste water generation.

5) Solid wastes viz. Fly Ash and Bottom Ash generated from the CPPwill be reused/ recycled in the cement plant located within thepremises.• Gypsum produced as a result of desulphurization of flue gases

with limestone will be fully utilized in cement manufacturingprocess. This will help to conserve natural Gypsum.

• Fly ash will be used for manufacturing of PPC.• Bottom ash will be used in cement raw mix.

6) Entire treated waste water will be used in dust suppression.

4.0 LOCATION OF THE PLANT

The JSWCL Cement Plant is located at Bilakalagudur village,Gadivemula mandal, Kurnool District, Andhra Pradesh. Averagealtitude of plant site is about 260 m above mean sea level and islocated between 15°40'15" - 15°41'24"North Latitude and 78°27'21" -78°27'54" East Longitude. The plant is part of Survey of India Toposheet No. 57/I/6 (Scale: 1:50000).Fig – 1 shows the location map ofthe Plant Site.

ANDHRA PRADESH

LOCATION MAP

Chittoor

SPSR Nellore

Prakasam

GunturKrishna

Kurnool

Anantapur

YSR Kadapa

West Godavari

East Godavari

Vishakhapatnam

Vizianagaram

Srikakulam

FIG - 1

INDIA

KURNOOL DISTRICT

PLANT SITE

HalviKosigi

Kuppagallu

Adoni

Gudikallu

Emmiganuru

NendavaramNagaladinne

MantralayamMadhavaram

UlindakondaKodumuru

Kuruva

Varakallu

Uyyalavada

Ramallakota

Kalava

GanjNamuru

Gandigargevula

Bandi Atmakuru

Santajuturu

NandyalMahanandi

Chelima

SirvelYalluruLliuruKottapeta

Koilkuntla

Sanjamula

Uyyalavada

Nandipadu

Kolimigundla

Neraducharla Owk

Garladinne

JonnagiriPyapaliMaddikeraChintakunta

Alur

Molagavalli

Hosuru

TuggaliPattikonda Chanugondla

Dhone

Devanakonda

KarivemulaVeldurti

Hebbeli

Holalagondi

Guduru

Gonegandla

Polukollu

GargeyapuramMiduturu

Kambalapalle

VelugoduRegadiguduru

Rollapenta

Peddacheruvu

Srisailam

PratakotaPagidyala

Nandikotkur

Betamcherla

Rangapuram

Banganapalle

Chagalamarri

Mutyalapadu

AllagaddaAhobilam

Rudravaram

Timmanayanipeta

Aspari

Kurnool

Nagarpatnam

Atmakuru7

18

7

LEGEND

RAILWAY TRACK

RIVER & CANAL

ROAD

DISTRICT BOUNDARY

STATE HIGHWAY

TALUK HEADQUARTER

DISTRICT HEADQUARTER

TOWN

STREAMS

NATIONAL HIGHWAY

PLANT SITE

18

Note:- Not to Scale

N

Nearest railway line connecting Kurnool – Nandyal of South CentralRailway line is located at a distance of 24.0 km to Southern directionfrom the site. Kurnool is major town located at a distance of 48.0 km

in WNW. Key map showing the location of various features around thePlant site is shown in Fig – 2.

B.S.ENVI-TECH (P) LTD.,

CLIECT :

TITLE :

SECUNDERABAD

PREPARED BY

KEYMAP

SCALE2km10

FIG - 2

LOCATION :

M/s. JSW CEMENT LIMITED

N

1.4km

2.0km

3.4km

3.0km

3.6km

Pesaravayi

Regadaguduru

Bujanuru

BilakalaguduruGadivemula

Korrapoluru

Allagadda

Grandhivemula

Somapuram

GANI R F

KU

NDERU

R

Chindu

kuru

Cha

nnel

Paramaturu Channel

Sub

ibra

nch

Cha

nnel

Reg

adag

udur

u

branch Channel

Bilakalaguauru

bran

ch C

hann

el

Korra

polu

ru

261

146

LEGEND

SETTLEMENTS

SPOT HEIGHT

RIVER

FOREST

CANALS

STREAMS/ TANKS

ROADS

PLANT SITE

PLANT SITE

Kurnool District, Andhra Pradesh.Bilakalaguduru Village, Gadivemula Mandal,

The National Highway (NH-18) connecting Kurnool – Nandyal islocated at a distance of about 22.4 km in SW direction.

The State Highway (SH-27) connecting Atmakur – Velugodu is locatedat a distance of about 10.5 km in Eastern direction, The nearestrailway station is located at Nandyal RS which 24.0km in Southerndirection.

There are no wild life sanctuaries, national parks, elephant/tigerreserves within 10km radius of the study area.

Nearest Settlements to the Plant Site are: Bilakalaguduru – 1.4 km – W Regadaguduru –3.0 km – NE Pesaravayi – 3.6 km – SE Bujanuru – 2.0 km – WSW Gadivemula – 3.4 km - W

Nearest Forest to Plant Site is Gani RF located at 3.1 km in SWdirection

No industries are located within 10 km radius. The site is not fallingin Critically Polluted Areas listed by MoEF.

Co-ordinates of the plant site on topo sheet are shown in Fig – 3

Salient features of Plant Site are given in Table – 2 and Fig-4 showsthe study area of 10 km radius around the Plant Site.

5.0 PROJECT DESCRIPTION:

Integrated Cement Manufacturing unit of JSW Cement is located atvillage Bilakalagudur, Gadivemula Mandal, Kurnool Distt., A.P. It is afully integrated cement plant with captive mining of limestone. Due touncertainty in uninterrupted power availability, a 36 MW coal basedCPP was planned to be set up within the cement plant premises tomeet the power requirement of the process plant for whichenvironmental clearance has been granted by MoEF vide letter no. J-11011/889/2007-IA.II (I) Dated 25.08.2008with subsequent extensionvide letter no. J-11011/889/2007-IA.II (I) Dated 06.01.2014 valid till23.08.2018 andat par CFE extension from APPCB vide Letter No. Gen-5/PCB/RO/KNL/2013/336, dated 23.07.2013 valid till 05.01.2019.

03

SC

ALE

36

km

PREP

ARED

BY

SEC

UN

DER

ABAD

SH

OW

ING

10

km R

AD

IUS

TO

PO

GR

AP

HIC

AL

MA

P

FIG

- 4

Sur

vey

of I

ndia

Top

oshe

ets

Inde

x to

11I10I9I

I 3I 2

57I 1

57 57575757

REF

ER T

O T

HIS

MAP

AS:-

1:5

0,00

0

Publ

ishe

d un

der

the

dire

ctio

n of

SH

EET

57/I

/6 F

IRST

EDIT

ION

the

Sur

veyo

r G

ener

al o

f In

dia

- 19

82

6I57

7I5757

I 5

78°

30'

15°

45'

78°

25'

15°

45'

15°

40'

15°

40'

To Vel

ugod

u2.

3km

To Kal

va18

.0km

To Mid

turu

9.6k

m

To Nan

dyal

16.7

km

PLA

NT

SIT

E

146

100

LEG

END

SET

TLEM

ENTS

SPO

T H

EIG

HT

RIV

ER

CO

NTO

URS

FOR

EST

CAN

ALS

STR

EAM

S/

TAN

KS

RO

AD

S

Tudi

cher

la

Vid

yana

gar

Kri

shna

pura

m

Mad

duru

Mar

iyap

uram

Kot

tala

Gun

taka

ndal

a

Penc

hika

lapa

lli

Abd

ulla

hpur

am

Vel

panu

ru

Ayy

avar

ipal

le

Mad

hava

ram

Boj

anam

u

Pora

mot

uru

Kar

imad

dula

Sat

ajut

uru

Pesa

rava

yi

Reg

adag

udur

u

Jiru

padu

Gad

igar

evul

a

Chi

nduk

uru

Buj

anur

u

Bila

kala

gudu

ruG

adiv

emul

a

Kor

rapo

luru

Alla

gadd

a

Jam

mim

anu

Kot

tala

Van

ala

Sun

kala

mm

a Kot

tala

Ala

ganu

ru

Tala

mud

ipi

Bol

lava

ram

Bho

gesh

war

am G

udi

Gra

ndhi

vem

ula

Bug

gani

palli

Mam

idon

ipal

li

Pedd

a D

eval

apur

am

Som

apur

am26

0

250

250

230

250

310

300

350

GA

NI

R F

KUNDERU R

Chind

ukur

u Cha

nnelPa

ram

atur

u C

hann

el

Subibranch Channel

Regadaguduru

bran

ch C

hann

el

Bila

kala

guau

ru

branch C

hannel

Korrapoluru

Ippu

Vag

u

KURNOOL CUDDAPA

H CANAL

Mogili Vagu

Salla Vagu

Mad

di E

ruGal

Eru

PLAN

T SIT

E

261

328

370

280

270

260

M/s

. JS

W C

EM

EN

T L

IMIT

ED

CLI

ENT

:

TITL

E :

LOC

ATI

ON

:

Kur

nool

Dis

tric

t, A

ndhr

a P

rade

sh.

Iruk

u Se

la

Bila

kala

gudu

ru V

illag

e, G

adiv

emul

a M

anda

l,

Installation of CPP was kept on hold due to non-availability of coallinkage till yet. Moreover, operating a CPP with imported coal is noteconomic. Thus, it is now proposed to use pet coke as a fuel for theCPP. The pet coke is proposed to be brought to site by rail/ road. Incase of road transport, pet coke will be brought in high capacitycovered trucks to avoid spillage.

Circulating Fluidized Bed Combustion (CFBC) technology to be usedin the upcoming CPP is capable of using wide variety of solid fuels andhence change of fuel to pet coke will not require any specialconstruction or modification in the plant design. Pet coke requirementfor the project will be about 0.12 million TPA, while the correspondinglimestone requirement to control SO2 emission will also be about 0.12million TPA. Pet coke storage of 15 days and limestone storage of 3days has been considered by providing covered storage yard. The CPPis coming up in 10 Ha of land within the cement plant complex. Noalternate site is considered due to the availability of land and requiredinfrastructure within cement plant complex. Also, the power to beproduced is meant for captive use at JSWCL.

5.1 CEMENT PLANT

JSW proposes to use pet coke due to uncertainty in the availability aswell as rising prices of coal. Use of pet coke in InLine calciners (ILC) isviable as the kiln is already equipped with InLine Calciner (ILC). In-line calciners generally have lower NOx emissions than separate-linecalciners (SLC), since all of the kiln exhaust gases must pass throughthe calciner. In an ILC, the fuel is injected into the kiln riser belowwhere the tertiary air enters at the base of the calciner. This so-calledreduction zone, designed for a particular gas retention time, has anoxygen deficient atmosphere that promotes NOx reduction.

The process of clinker production in kiln systems creates favourableconditions for use of pet coke due to high temperatures, longresidence times, an oxidising atmosphere, alkaline environment, ashretention in clinker, and high thermal inertia which ensure that thefuel’s organic part is destroyed and the inorganic part, includingheavy metals is trapped and combined in the product.

No additional machinery is required for firing of Petcoke in kiln. Noadditional pollution control equipment will be required for control ofParticulate matter, SO2 and NOx.

6.2 CAPTIVE POWER PLANT

Process Description

CFBC Technology:

The depleting trend of coal quality and environmental considerationsdue to high sulphur and high ash content fuels, the technology ofcirculating fluidized bed combustion (CFBC) invented in 1980s hasbecome popular over the time. CFBC boiler consists of a boiler and ahigh-temperature cyclone as a solid separation device. A coarsefluidizing medium and char in the flue gas are collected by the hightemperature cyclone and recycled to the boiler. Recycling maintainsthe bed height and increases the denigration efficiency. To increasethe thermal efficiency, a pre-heater for the fluidizing air andcombustion air, and a boiler feed water heater, are installed. In CFBCboilers, combustion takes place at temperatures in the range of 800-900°C resulting in reduced NOx emissions compared with pulverizedcoal fired units or any other coal fired technologies. SO2 emission isreduced by injection of limestone in the combustion chamber.Circulating beds use a higher fluidizing velocity, so the particles areconstantly held in the flue gases, and pass through the maincombustion chamber and enter into a cyclone, from where the largerparticles are extracted and returned to the combustion chamber.Combustion conditions are relatively uniform through the combustor,although the bed is somewhat denser near the bottom of thecombustion chamber. There is a great deal of mixing, and residencetime during one pass is very short. The bed material is preferred eitheras crushed refractory or from the fuel ash or as sand in some cases.Due to the large heat capacity of the bed, combustion is stable and nosupporting fuels are required, provided the fuel heating value issufficient to raise the combustion air and the fuel itself above itsignition temperature. The intense turbulence ensures good mixing andcombustion of the fuel. The schematic of a CFBC boiler is shown atFig – 5.

Fig – 5 SCHEMATIC OF A CFBC BOILER

Limestone Feed and Control Mechanism

Sulphur capture in CFBC boilers happens by injecting Limestonealong with fuel. The fuel and Lime mixture enters into combustionchamber through multiple feed points located in furnace front close tothe bottom primary zone. Limestone undergoes decomposition bytaking heat from the hot bed material (endothermic) and converts intoCalcium Oxide (CaO).This process is called Calcination. The calcinedLimestone being porous in nature gets entrained in flue gas andenters the top section of furnace where the mixture of Oxygen andSulphur Dioxide reacts with Calcium Oxide and converts into CalciumSulfate (CaSO4).This Process is called Sulfation. This process is anexothermic reaction. Thus, the Limestone converts gaseous SO2emission to solid Calcium Sulfate and gets removed from the system.Attributing higher particle residence time and recirculation, theSulphur capture efficiency in CFBC boilers can be achieved to almost95%. Limestone injection control consists of Limestone variable speedrotary feeder. The amount of limestone that is required for a givenamount of fuel depends on the sulphur content of coal. An increase insulphur dioxide emissions will necessitate an increase in the amount

of limestone that is required for a given fuel flow to the furnace. Thelimestone demand is a function of the main fuel flow. An increase infuel flow demand will result in a corresponding increase in thelimestone demand to provide the demand signal to the LimestoneVariable Rotary Feeder.

Flue Gas Desulfurisation unit

Wet limestone type flue gas desulphurization system (FGD) will beprovided to capture the remaining SOx emissions afterdesulphurization in the CFBC Bed by limestone injection. Relativelyclean flue gas from the ESP is quenched using spray at the flue gasinlet to the scrubber. The wet limestone slurry is sprayed countercurrent to the flow of flue gas from the top surface to achieve effectiveSO2 mass transfer and chemical absorption in to the liquid phase.

Schematic view of Flue Gas Desulphurization Concept is shown at Fig– 6

Fig – 6 SCHEMATIC VIEW OF FLUE GAS DESULPHURIZATION

The brief chemical reactions taking place in the scrubber to captureSO2 are as below:

(1) Gaseous SO2 reacts with waterSO2 + H2O ↔ H2SO3 ↔ HSO3- + H+ SO3 -2

(2) Neutralisation reaction:CaCO3 + HSO3 + H+ ↔ CaSO3 + CO2 ↔ + H2O

(3) Oxidation reactionCaSO3 + ½ O2 = CaSO4

Thus, the SO2 in the flue gas is absorbed and converted to sulphite.Sulphite is further oxidised to sulphate. The gypsum produced in theFGD will be utilized in the cement plant. Gypsum solids are removedfrom the system by the bleed system. The quantity of gypsumproduced from the FGD is around 400 kg/hr.

Technical Features of Main Plant & Equipment

The Coal/Pet coke based power plant consists of the following majorequipment:

a) Three (2 operating +1 standby) steam generators, along with allancillaries and auxiliaries, stack and duct work, damper, suction airfilters along with controls and instrumentation, suitable for base loadoperation with Coal/ Pet coke as fuel.

b) 2 nos. steam turbine generators set (2 x 18 MW) with deaerator & feedheating equipment, steam condenser, CEP and feed water pumps withall piping systems.

c) Other auxiliary systems and major equipment needed, while operatingon pet coke as fuel:• Flue Gas Desulphurization unit• Limestone handling system• Fly Ash, bottom ash and Gypsum handling systems

The power plant will be provided with the state-of-the-art DistributedDigital Control System (DCS), which will integrate various closed loopsub-systems, open loop sub-systems, monitoring and informationsub-system covering the entire plant. The system will integrate thevarious proprietary control packages supplied by the main equipmentsuppliers for harmonious plant operation.

6.0 PLANNING IN BRIEF

The cement manufacturing facility of JSW Cement located at villageBilakalagudur, Kurnool Distt. requires uninterrupted power supplyfor its continuous manufacturing operations which is currently beingsupplied from the state Grid. But due to uncertainty in availability ofuninterrupted power that too at relatively higher cost, it is envisagedto generate captive power by utilizing coal based generation in CCP,which has been kept on hold due to non-availability of linkage coal.The present proposal is to convert fuel firing from Coal to Pet Coke.

7.0 PROPOSED INFRASTRUCTURE:

Approx. 10 ha of land within JSWCL complex will be utilized forsetting up the CPP. This includes plants and utilities, storage andgreenbelt. Conversion to pet coke as fuel will not require anyadditional construction redesigning of utilities than those planned forthe coal based plant. The JSWCL complex has a robust green beltcovering approx. 36% of the total plant area and the same will bestrengthened further in the CPP area by planting native and tolerantspecies.

8.0 FUEL-REQUIREMENT, QUALITY AVAILABILITY &TRANSPORTATION:

It is envisaged that pet coke required for the project will betransported through rail/ road. If imported, the same will be unloadedat Krishnapatanam port from where it will be transferred to the site incovered trucks.During road transport pet coke will be brought inclosed trucks. Limestone will be transported from captive mine (max.distance 1 km) to CPP in dumpers covered from 3 sides.

PET COKE QUANTITY:

Considering pet coke with gross calorific value (GCV) of 7670 kCal/kgand plant load factor of 100%, the annual pet coke requirement forCPP works out to be about 0.12Million Tonnes. The daily pet cokerequirement with 100% PLF works out to be about 314 Tons/day forgeneration of 36 MW power.

Other infrastructure facilities like access roads, housing facility for theconstruction staff with supply of water and electricity, communityfacilities viz. market, housing, construction power, health care etc. arealready set up at JSWCL complex for other on-going operations.

FUEL QUALITY (PET COKE):

Pet coke for the project will be available either from Indian refineriesor can be imported through Krishnapatnam port, as required. Duringroad transport, pet coke will be brought in high capacity coveredtrucks. Pet coke requirement for the project will be about 0.229 MTPAfor Cement Plant and 0.12 MTPA for Captive power plant, while thecorresponding limestone requirement to reduce SO2 emission will alsobe about 0.12 million TPA. The proximate and ultimate analysis of petcoke to be used for the captive power plant, are as follows:

Heating ValuesLHV 7670 kcal/kgHHV 7895 kcal/kgUltimate Analysis (weight %)Moisture 4%Ash 1.50%Carbon 79.07%Hydrogen 3.21%Nitrogen 1.37%Chlorine 0.63%Sulphur 8.50%Oxygen 1.69%Total 100%Proximate Analysis (weight %)Moisture 4%Ash 1.50%Volatile Matter 14.22%Fixed Carbon 80.30%Total 100%

Source : JSW

Because of the extremely low ash (<2%) and high sulphur contents ofpet coke (8.5%), limestone is used in the majority of bed materials ofthe CFBC boilers using pet coke. Limestone sizing is critical not onlyfor efficient sulphur capture but also for effective fluidization and fuelmixing thereby uniform temperatures and heat transfer is attained.Limestone will be sourced from the captive mine situated adjacent tothe cement plant. Limestone of approx. 45% CaO content will be usedfor CPP.

PET COKE HANDLING PLANT:

The pet coke handling will be done in the same system designed forcoal. In order to limit spread of dust, water sprinkling arrangements

will be in place in the covered stockyard. Adequate dust extractionequipment will be installed at specific locations of high dustgeneration at transfer points.

9.0 ENVIRONMENTAL IMPACTS

Environmental impacts due to use of pet coke in the Cement plantand power plant has been worked out and presented below undereach environmental component.

9.1.1 AIR ENVIRONMENT

The emission details along with emission parameters for Coal andPetcoke are given below.

EMISSION DETAILS (EC OBTAINED)Location Height Temp- Dia- Velocity

of fluegas

Flowrate

Nm3/hr

Emissions from stacks(gm/sec) (Max.)

M OC M M/sec PM SO2 NOxCEMENT PLANT

*RawMill/Kiln

140 146 5.6 7.4 476841 3.97 13.25 105.97

CAPTIVE POWER PLANT+CPPBoilerstack

95 120 3.2 20 75263 1.06 12.56 6.28

*emissions are based on PM = 30 mg/Nm3, SO2 = 100 mg/Nm3 and NOx 800 mg/Nm3

in case of kiln+ emissions are based on PM=50 mg/Nm3 , SO2 = 600 mg/Nm3 and NOx 300 mg/Nm3

in case of power plant

EMISSION DETAILS (EC REQUESTED)Location Height Temp- Dia- Velocity

of fluegas

Flowrate

Nm3/hr

emissions fromstacks (gm/sec)erature meter

M OC M M/sec PM SO2 NOxCEMENT PLANT

*RawMill/Kiln

140 146 5.6 8.1 488762 4.07 13.57 108.6

CAPTIVE POWER PLANT+CPPBoilerstack –firedwith 100%petcoke

30 120 1.75 25 81441 0.67 2.25 2.25

#petcoke or coal will be fired at any given time. Control of SO2 will be by desulphurization forboth the fuels*emissions are based on PM = 30 mg/Nm3, SO2 = 100 mg/Nm3 and NOx 800 mg/Nm3 in caseof kiln+ emissions are based on PM=30 mg/Nm3 , SO2 = 100 mg/Nm3 and NOx 100 mg/Nm3 in caseof CPP

The emission load in terms of Kg/hr (both from cement plant kiln andpower plant is given below :

Kg/Hr EC granted EC requestedCoal Coal Petcoke

Particulate Matter 18.10 16.54 17.06Sulphur Dioxide 92.91 *55.22 *56.9Oxides of Nitrogen 404.1 389.01 399.06

9.1.2 GROUNDLEVEL CONCENTRATION

The incremental ground level concentration due use of petcoke incement plant and kiln computed using AERMOD model (EPArecommended model) is given below :

EC granted EC requestedIncrementalGround LevelConcentrations(ug/m3)

Particulate Matter 0.335 0.543Sulphur Dioxide 2.11 1.10Oxides of Nitrogen 7.77 7.89

Predicted incremental ground level concentration of PM10, SO2 andNOx due to use of petcoke in kiln of cement plant and boiler of powerplant are shown in Fig - 7 to Fig – 9. 50 High 24-hourly averageground level concentrations of PM10, SO2 and NOx are given in Table –3 to Table – 5.

TABLE - 3

PREDICTED HIGH 50 24-HOURLY AVERAGE CUMULATIVE GROUNDLEVEL CONCENTRATIONSOF PARTICULATE MATTER (PM10)


KILN OF CEMENT PLANT AND BOILER OF CAPTIVE POWER PLANT

RANK CONC ON AT RECEPTOR (XR,YR) OF TYPE RANK CONCON

AT RECEPTOR (XR,YR) OF TYPE

g/m3 (m,m) g/m3 (m,m)

1 0.30756c 16033124 AT ( 250.00, 433.01) GP 26 0.20801c 16033124 AT ( 492.40, 86.82) GP2 0.29023c 16033124 AT ( 171.01, 469.85) GP 27 0.20276 16030524 AT ( -0.00, 1000.00) GP3 0.28369c 16030924 AT ( 173.65, 984.81) GP 28 0.20257c 16033124 AT ( 500.00, 0.00) GP4 0.28234c 16033124 AT ( 321.39, 383.02) GP 29 0.19883c 16033124 AT ( 492.40, -86.82) GP5 0.27575c 16033124 AT ( 173.65, 984.81) GP 30 0.19861c 16031624 AT ( 171.01, 469.85) GP6 0.2719 16032024 AT ( 250.00, 433.01) GP 31 0.19845 16032024 AT ( 383.02, 321.39) GP7 0.26899 16031224 AT ( 173.65, 984.81) GP 32 0.19614 16030524 AT ( 173.65, 984.81) GP8 0.25555 16032024 AT ( 171.01, 469.85) GP 33 0.19589c 16033124 AT ( 250.00, -433.01) GP9 0.25405 16031224 AT ( 342.02, 939.69) GP 34 0.19553c 16033124 AT ( 469.85, -171.01) GP10 0.25324c 16030924 AT ( 342.02, 939.69) GP 35 0.19494c 16033124 AT ( 321.39, -383.02) GP11 0.25188c 16033124 AT ( 383.02, 321.39) GP 36 0.19267c 16033124 AT ( 433.01, -250.00) GP12 0.24425c 16033124 AT ( -0.00, 1000.00) GP 37 0.19248c 16033124 AT ( 383.02, -321.39) GP13 0.23362 16032024 AT ( 321.39, 383.02) GP 38 0.19220c 16033124 AT ( 171.01, -469.85) GP14 0.23003c 16033124 AT ( 433.01, 250.00) GP 39 0.18913c 16031624 AT ( 250.00, 433.01) GP15 0.22742 16031224 AT ( -0.00, 1000.00) GP 40 0.18870b 16031024 AT ( 342.02, 939.69) GP16 0.22606 16030524 AT ( 86.82, 492.40) GP 41 0.18756c 16033124 AT ( -0.00, 500.00) GP17 0.22530c 16033124 AT ( 86.82, 492.40) GP 42 0.18725 16031324 AT ( 173.65, 984.81) GP18 0.22352 16030524 AT ( 171.01, 469.85) GP 43 0.18649 16031824 AT ( -0.00, 500.00) GP19 0.22151c 16030924 AT ( -0.00, 1000.00) GP 44 0.18553c 16030924 AT ( 171.01, 469.85) GP20 0.21689 16031224 AT ( 500.00, 866.03) GP 45 0.18447 16030524 AT ( 250.00, 433.01) GP21 0.21641c 16033124 AT ( 469.85, 171.01) GP 46 0.18263 16030524 AT ( -0.00, 500.00) GP22 0.21599c 16030624 AT ( 342.02, 939.69) GP 47 0.18209c 16033124 AT ( 86.82, -492.40) GP23 0.21435c 16030624 AT ( 500.00, 866.03) GP 48 0.18191c 16030924 AT ( 250.00, 433.01) GP24 0.21167c 16033124 AT ( 342.02, 939.69) GP 49 0.18087c 16030924 AT ( 86.82, 492.40) GP25 0.21119 16032324 AT ( 342.02, 939.69) GP 50 0.17965 16031824 AT ( -86.82, 492.40) GP

TABLE - 4

PREDICTED HIGH 50 24-HOURLY AVERAGE CUMULATIVE GROUNDLEVEL CONCENTRATIONSOF SULPHUR DIOXIDE (SO2)





g/m3 (m,m) g/m3 (m,m)

1 1.28572c 16033124 AT ( 173.65, 984.81) GP 26 0.95468c 16030924 AT ( -173.65, 984.81) GP2 1.27287 16031224 AT ( 173.65, 984.81) GP 27 0.95333c 16030624 AT ( 642.79, 766.04) GP3 1.27248c 16033124 AT ( -0.00, 1000.00) GP 28 0.95177c 16030624 AT ( 984.81, -173.65) GP4 1.23196 16031224 AT ( -0.00, 1000.00) GP 29 0.94444 16032024 AT ( 260.47, -1477.21) GP5 1.22400c 16033124 AT ( 342.02, 939.69) GP 30 0.94412 16031224 AT ( -173.65, 984.81) GP6 1.19433c 16030924 AT ( 342.02, 939.69) GP 31 0.93935c 16030924 AT ( 964.18, 1149.07) GP7 1.19217c 16030924 AT ( 173.65, 984.81) GP 32 0.92495c 16030924 AT ( 939.69, 342.02) GP8 1.17849 16032024 AT ( 342.02, -939.69) GP 33 0.92256c 16030624 AT ( 1000.00, 0.00) GP9 1.17442 16031224 AT ( 342.02, 939.69) GP 34 0.91928c 16030924 AT ( 1149.07, 964.18) GP10 1.16598 16031224 AT ( 500.00, 866.03) GP 35 0.91817c 16033124 AT ( 642.79, -766.04) GP11 1.15422c 16030924 AT ( -0.00, 1000.00) GP 36 0.90900c 16033124 AT ( 513.03, -1409.54) GP12 1.1376 16032024 AT ( 173.65, -984.81) GP 37 0.89010c 16030924 AT ( 750.00, 1299.04) GP13 1.05416c 16033124 AT ( 342.02, -939.69) GP 38 0.87399c 16030624 AT ( 939.69, -342.02) GP14 1.05243c 16030924 AT ( 500.00, 866.03) GP 39 0.86778 16031224 AT ( 766.04, 642.79) GP15 1.04209c 16033124 AT ( -173.65, 984.81) GP 40 0.86181c 16033124 AT ( 766.04, -642.79) GP16 1.04008 16031224 AT ( 642.79, 766.04) GP 41 0.85523c 16030924 AT ( 1299.04, 750.00) GP17 1.02968 16032024 AT ( 500.00, -866.03) GP 42 0.85273 16032024 AT ( 642.79, -766.04) GP18 0.99478c 16030624 AT ( 500.00, 866.03) GP 43 0.85238 16032724 AT ( 766.04, -642.79) GP19 0.98817c 16033124 AT ( 500.00, -866.03) GP 44 0.84986 16030524 AT ( -0.00, 1000.00) GP20 0.98224c 16033124 AT ( 500.00, 866.03) GP 45 0.84469c 16030624 AT ( 766.04, 642.79) GP21 0.98125c 16030924 AT ( 642.79, 766.04) GP 46 0.83791c 16030924 AT ( 984.81, 173.65) GP22 0.97719c 16030924 AT ( 766.04, 642.79) GP 47 0.83785 16032724 AT ( 866.03, 500.00) GP23 0.97371c 16033124 AT ( 173.65, -984.81) GP 48 0.83747c 16030624 AT ( 984.81, 173.65) GP24 0.97315 16032024 AT ( 513.03, -1409.54) GP 49 0.83721c 16033124 AT ( 642.79, 766.04) GP25 0.97278c 16030924 AT ( 866.03, 500.00) GP 50 0.83071 16032724 AT ( 642.79, -766.04) GP

TABLE - 5

PREDICTED HIGH 50 24-HOURLY AVERAGE CUMULATIVE GROUNDLEVEL CONCENTRATIONSOF OXIDES OF NITROGEN





g/m3 (m,m) g/m3 (m,m)

1 7.67176 16032024 AT ( 173.65, -984.81) GP 26 5.28249 16031824 AT ( -500.00, -866.03) GP2 7.44952 16032024 AT ( 342.02, -939.69) GP 27 5.27666c 16030624 AT ( 984.81, 173.65) GP3 6.72652c 16030624 AT ( 984.81, -173.65) GP 28 5.27238c 16033124 AT ( 0.00, -1000.00) GP4 6.55586c 16033124 AT ( 342.02, -939.69) GP 29 5.23389c 16033124 AT ( 260.47, -1477.21) GP5 6.41243 16032024 AT ( 260.47, -1477.21) GP 30 5.21578c 16030924 AT ( 1149.07, 964.18) GP6 6.41164c 16033124 AT ( 173.65, -984.81) GP 31 5.20821 16032024 AT ( 347.30, -1969.62) GP7 6.30157c 16030624 AT ( 1000.00, 0.00) GP 32 5.15838 16032724 AT ( 866.03, -500.00) GP8 6.21385c 16030624 AT ( 939.69, -342.02) GP 33 5.11290c 16031724 AT ( 500.00, -866.03) GP9 6.18763 16032024 AT ( 513.03, -1409.54) GP 34 5.10776 16031224 AT ( 939.69, -342.02) GP10 6.11058c 16030924 AT ( 866.03, 500.00) GP 35 5.09441c 16030624 AT ( 1409.54, -513.03) GP11 5.90593c 16030924 AT ( 939.69, 342.02) GP 36 5.09298c 16030924 AT ( 642.79, 766.04) GP12 5.84488 16032024 AT ( 500.00, -866.03) GP 37 5.0687 16031824 AT ( -642.79, -766.04) GP13 5.81069 16032724 AT ( 766.04, -642.79) GP 38 5.04114 16030424 AT ( -939.69, -342.02) GP14 5.80672c 16030924 AT ( 766.04, 642.79) GP 39 5.03186c 16030624 AT ( 866.03, -500.00) GP15 5.75379c 16030624 AT ( 1477.21, -260.47) GP 40 5.02989 16032024 AT ( 684.04, -1879.39) GP16 5.74058c 16033124 AT ( 500.00, -866.03) GP 41 5.01486c 16030924 AT ( 1409.54, 513.03) GP17 5.6905 16032724 AT ( 642.79, -766.04) GP 42 4.97768c 16033124 AT ( 642.79, -766.04) GP18 5.63218c 16033124 AT ( 513.03, -1409.54) GP 43 4.96828 16030524 AT ( 173.65, -984.81) GP19 5.55178 16031224 AT ( 984.81, -173.65) GP 44 4.96129 16032724 AT ( 500.00, -866.03) GP20 5.51317 16032024 AT ( 0.00, -1000.00) GP 45 4.93933c 16033124 AT ( 684.04, -1879.39) GP21 5.44683 16031224 AT ( 1000.00, 0.00) GP 46 4.92669 16030424 AT ( -984.81, -173.65) GP22 5.44423 16030524 AT ( 0.00, -1000.00) GP 47 4.92283 16030524 AT ( -173.65, -984.81) GP23 5.42475c 16030924 AT ( 1299.04, 750.00) GP 48 4.87819c 16030624 AT ( 1969.62, -347.30) GP24 5.38249c 16030624 AT ( 1500.00, 0.00) GP 49 4.87731 16031824 AT ( -342.02, -939.69) GP25 5.33634c 16030924 AT ( 984.81, 173.65) GP 50 4.82047c 16031724 AT ( -500.00, -866.03) GP

9.1.3 AIR POLLUTION CONTROL MEASURES

The change in pollution control equipment due to use of pet coke inkiln and power plant are given below :

POLLUTION CONTROL EQUIPMENTEC Granted EC Requested Remarks

Sl.No.

Location / Unit Type ofEquipment

Type of Equipment

Control of Particulate Emissions1 Kiln/Rawmill Bag house Bag house No change2 Boiler – CPP

(proposed)ESP ESP No change

Control of SO21 Kiln/Raw mill Absorption

in KilnAbsorption in kiln Optimization

of raw mixand processparameterswill be donefor efficientabsorptionof SO2 in

kilnatmosphere.

2 Boiler – CPP - Limestone injection atCFBC boiler and Fluegasdesulphurization(FGD)

Control of NOx emissions1 Kiln/raw mill Low NOx

burner andLow NOxCalciners

Low NOx burner andLow NOx Calciner

No Change

2 Boiler – CPP AFBC withlow NOXburner

CFBC – increasing theretention time of fuelin combustion zone

and maintainingtemperature at 800-900oC to minimize

NOx emissions

Note: Results of Pet Coke Trial Run conducted in Aug’15 in our kiln asper CPCB & APPCB protocol show that there is no increase in SO2,NOx and PM in kiln while the Pet Coke was used. Also, no increasewas observed in other emission parameters as well.

Control of Particulate Matter

Cement plant: Pollution control equipment for control of particulateemission specified above are designed for meeting outlet emissionsbelow 30 mg/Nm3.

Power plant: Due to the very low ash content in Petcoke, there will below particulate matter emission in power plant.

Control of sulphur dioxide

Cement Plant

The combustion zone of the kiln with the presence of high lime dustacts as a scrubber combining to form calcium sulfate preventingmuch of the potential SO2 from the emission gas stream.

The combustion of Sulfur: S + O2 → SO2The formation of Calcium Sulfate: CaO + SO2 + ½ O2 → CaSO4

There are also minute amounts of sodium and potassium that enterthe kiln through the clay content of raw mix. Thus, Sodium andPotassium also combine with SO2 forming Sodium Sulfate (NaSO4)and Potassium Sulphate (K2SO4).

Power Plant

CFBC technology is ideal for pet coke firing because its long burningprocess ensures complete combustion of the lowly volatile pet coke.The technology also captures a large amount of Pet Coke's sulphurduring the combustion process - typically 6-8.5 percent. The vigorousmixing of the fuel, limestone and ash particles during the low-temperature fluidized process allows the CFBC to cleanly andefficiently burn almost any combustible material, while minimizing theformation of NOx and optimising the capture of SOx as the fuel burns.The combustion temperature is well below the melting point of thefuel's ash, which allows the CFBC to minimize the corrosion andfouling issues experienced in conventional boilers.

Flue Gas Desulphurization (FGD) unit with limestone injection isproposed to be installed to capture SO2 content in the flue gases tothe extent of 99.36%. The limestone requirement to reduce SO2emission will be about 0.12 million TPA.

Control of oxides of nitrogen

Cement Plant: The kiln is equipped with InLine Calciner (ILC). In-linecalciners generally have lower NOx emissions than separate-linecalciners, since all of the kiln exhaust gases must pass through thecalciner. In an ILC, the fuel is injected into the kiln riser below wherethe tertiary air enters at the base of the calciner. This so-calledreduction zone, designed for a particular gas retention time, has anoxygen deficient atmosphere that promotes NOx reduction.

Power Plant: Installation of CFBC Boiler and low NOx burners willhelp to reduce the NOx concentration at the outlet to meet regulatorystandards of 100 mg/Nm3 in power plant

9.2 WATER ENVIRONMENT

9.2.1 WATER CONSUMPTION

The water requirement of the plant is 4500 m3/day. The plant wisewater requirement for which EC is granted and EC is requested isgiven below:

WATER REQUIREMENT (M3/DAY)Requirements Remarks

ECGranted

ECRequested

Cement Plant& colony

2700 2700 Reduction in water consumptiondue to switch over from watercooled condensate system to Aircooled system

Captivepower Plant

1800 600

Total 4500 3300

The unit wise water consumption of plant alongwith water balance isgiven below:

WATER BALANCE (m3/day)EC Granted EC Requested Remarks

REQUIREMENT

LOSS/

USAGE

WASTEWATER

REQUIREMENT

LOSS/USAG

E

WASTEWATER

CEMENT PLANT 1300 1300 0 1300 1300 0 No ChangePOWERPLANT

AuxiliaryCooling Water 1435.5 1230.5 205 139.5 120 19.5

Reduction inwater

consumptionand

wastewatergeneration

by 90 %

FGD 0 0 0 96 48 48

AdditionalConsumptio

n for FGDBOILER 115 0 115 115 0 115

No change

Service/Portable/Ac &Ventiliation 240 240 0 240 240 0Deaerator ventloss 9.5 9.5 0 9.5 9.5 0

Greenbelt 600 600 0 600 600 0Mines 100 100 0 100 100 0Colony 700 80 620 700 80 620Total 4500 3560 940 3300 2497.5 802.5

9.2.2 WASTEWATER GENERATION, TREATMENT AND UTILISATION

The wastewater generation from the above water consumption is givenbelow

WASTEWATER GENERATION, M3/DAYWaste-water

generationTreatment Utilisation

POWERPLANT

AuxiliaryCoolingWater 19.5

Full fledgedETP will beprovided

Dustsuppression at

plant andminesBOILER 115

FGD 48DOMESTICWASTEWATER –PLANT AND COLONY

620 Full fledgedsewage

treatment*

Use inGreenbelt

Total 802.5*STP in plant is already installed. Residential colony yet not constructed.

9.3 LAND ENVIRONMENT

9.3.1 SOLID WASTE GENERATION

The solid waste generation is mainly ash from the power plant. Theash generation from the plant with use of coal and petcoke is givenbelow.

The maximum expected quantities of Fly Ash and bottom ash to begenerated as a result of combustion of Pet Coke will be 7.5 & 273 TPDrespectively. Only dry ash handling system will be adoptedand the ashwill be stored in silos. Transportation of Ash in dry form from thehoppers to storage silos will be done through pneumatic conveying.100% fly ash will be utilized for manufacturing of Portland PozzolanaCement (PPC). The bottom ash of CFBC boilers will have minimumunburnt carbon and thus will be used in cement raw mix. Ashdisposal will be carried out in closed type top loading bulkers.

SOLID WASTE GENERATION (T/DAY)ExistingEnvironmentalClearance (EC)


utilization

FROM BOILERFuel Coal PetcokeTotal ash 120 280.5 Total ash will be

utilized in cementmanufacturing process

Fly ash(80%)

96 7.5

Bottomash, (20%)

24 273 (includeslimestoneinjected

FROM FLUE GAS DESULPHURISATIONGypsumgeneration

- 10

10.0 BUDGET FOR ENVIRONMENTAL MANAGEMENT PLAN

An amount of Rs. 60 Crore (Capital expenditure, about 25% of theproject cost) will be incurred for implementation of EMP. Rs 2.50Crore/annum is Recurring Cost for the captive power plant.

No additional capital and recurring cost envisaged for cement plant.

11.0 PROJECT SCHEDULE & COST ESTIMATE:

Project schedule: 29 MonthsCost estimate: Rs. 240 Cr

12.0 CONCLUSION

JSW proposes to obtain amendment in EC for use of petcoke inaddition to coal as alternative fuel in Kiln of cement plant and Boilerof power plant.

Use of Pet coke will not result in increase of SO2 due to completeabsorption by the limestone.

JSW proposes to adopt CFBC technology for boilers and air cooledcondensate system for condensate cooling. Use of CFBC technologyenables use of pet coke in the boiler and injection of limestone whichcontrols the sulphur dioxide emission by 95 %. Balance 5 % ofsulphur dioxide will be controlled by adopting Flue gasDesulphurisation.

In CFBC boilers, combustion takes place at temperatures in the rangeof 800-900°C resulting in reduced NOx emissions compared withpulverized coal fired units or any other coal fired technologies. Infact,a CFBC boiler, due to low temp combustion, doesn’t allow formation ofthermal NOx which is the largest contributor of overall NOx emissions.Additionally, low NOx burners will also be provided in the boilerswhich use less excess air (3 to 5%) and use staged combustion (fueland air are combusted in multiple stages) thus low NOx in each stageof combustion.

Amendment in EC proposal will facilitate use of pet coke in Kiln andBoiler. Use of Pet Coke in cement Kiln will facilitate use of sub-gradelimestone to the optimum extent resulting in production of highquality clinker which, in turn, will facilitate addition of more slag inPortland Slag Cement (PSC). This will result in natural resourceconservation.

Due to proposed change in boiler technology from AFBC to CFBC andwater cooled condenser to Air Cooled Condenser, non-requirement ofraw water reservoir and less space requirement for fuel storage, theland area required for the Power Plant will be reduced to 10 Ha from20.24 Ha within Cement Plant area of 263.05 Ha owned by JSWCL.

In view of the above, JSW requests MOEF&CC to consider the aboveaspects and issue the following amendments in Environmentalclearance :

a. Use of Pet coke as alternative fuel in addition to coal in kiln ofcement plant and boiler of power plant

b. Change of Boiler technology from AFBC to CFBC

c. Change of Condensate Cooling System from water cooled to aircooled

d. Addition of PPC as finished product.

* * *

Documents

JSW Cement Ltd