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PRE FEASIBILITY REPORT
APPLICATION UNDER THE PROVISIONS OF MOEF&CC NOTIFICATION
S.O.804 (E) DATED 14TH MARCH, 2017
FOR
2X60 MW COAL BASED CAPTIVE THERMAL POWER PLANT AT
VILLAGE KARIAJHAR/MAJHGAWAN, RAMPUR NAIKIN TALUK,
SIDHI DISTRICT, MADHYA PRADESH
Submitted by:
UltraTech Cement Limited.
September, 2017
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Executive Summary
Project Name : 2x60 MW Coal Based Captive Thermal Power Plant at village
Kariajhar/Majhgawan, Rampur Naikin Taluk, Sidhi District, Madhya
Pradesh by Jaiprakash Associates Ltd.
Plant Location : Village Kariajhar/Majhgawan, Rampur Naikin Taluk, Sidhi District,
Madhya Pradesh
Geographical
Coordinates :
Latitude–24°19’41”–24°19’54”N
Longitude- 81°19' 45’’ – 81°19’59” E
Land Area : CPP is installed in an area of 25 ha, available within the existing
premises of cement plant. Project area is already in industrial use.
Water Requirement :
The total water requirement of entire project is around 1566
m³/day which is being met from Bansagar Canal.
Permission for withdrawal of 1600 m³/day of water from Bansagar
Canal by Water Resources Deptt., GoMP vide letter no:
94/2010/31/903 dated 19.08.2011.
Coal Requirement 1.0 MTPA
Man Power Requirement : During operation phase-54 persons
Nearest Railway Station : Rewa (24 km, NW)
Nearest Airport Khajuraho (150 km)
Nearest town : Rewa (24 km, NW)
Reserved Forests :
Govindgarh Reserved forest (0.2 km, NW)
Shikarganj Reserved forest (8.8 km (ESE)
Bardaila (Reserved forest (9.0 km, ESE)
Nearest River : Son River (9.0 km, SE)
Nearest Lake/Ponds : Govindgarh Lake (6.0 km, NW)
Bansagar Lake (7.6 km, SSW)
Ecological Sensitive
Areas
(Wildlife Sanctuaries)
: The Son-Gharial sanctuary is located at a distance of 9.0 km, SE
direction
1.0 BACKGROUND OF THE PROJECT
2x60 MW Imported Coal based Captive Thermal Power Plant of M/s Jaiprakash Associates
Limited at village Kariajhar/Majhgawan, Rampur Naikin Taluk, Sidhi District, Madhya
Pradesh was taken over by M/s UltraTech Cement Limited with effect from 29th June 2017 as
per the scheme of arrangement approved by National Company Law Tribunal Bench-
Mumbai on 15th February, 2017 in case of UltraTech and National Company Law Tribunal
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Bench-Allahabad on 2nd March, 2017 in case of Sellers (JAL/JCCL) for the transfer of “JAL
Business” and “JCCL Business to UltraTech on a going concern basis.
Jaiprakash Associates Ltd. (JAL) had set up an integrated Cement Plant (Unit-I) to
produce Cement - 2.00 MTPA, Clinker -1.5 MTPA along with Captive Power Plant (35
MW) at Majhigawan, Tehsil Rampur Naikin, Sidhi (M.P.) after obtaining
Environmental Clearance from MoEF vide its ref. No. J-110011/51/2007-IA II (I)
dated 09.08.2007. Subsequently, cement production capacity was expanded, by
setting up an additional production line (Unit-II), from 2.0 MTPA to 3.50 MTPA upon
receiving Environmental Clearance from MoEF&CC vide its ref. No. J-
110011/546/2010-IA II (I) dated 08.11.2011.
Further, to meet the uninterrupted power for above mentioned integrated cement
plant and other units of the company at different locations, subject project was
implemented, within the existing premises of integrated cement plant, upon
receiving environmental clearance from MoEF&CC, Govt. of India vide its reference
No. F.No. J-13012/94/2009-IA-II-(T) dated 30th January, 2012.
The Consent to Establish (CTE) was obtained from MPPCB vide its letter ref. No.
1611/TS/MPPCB/2012 dated 09.03.2012 to establish 2X60 Coal Based Captive
Thermal Power Plant and Consent to Operate from MPPCB vide its letter ref. No.
3037/TS/MPPCB/2012 dated 04.05.2012 under Air Act, 1981 & vide its letter ref. No.
3035/TS/MPPCB/2012 dated 04.05.2012 under Water Act, 1974.
2. 0 PURPOSE OF RESUBMISSION
The project was considered for Environmental Clearance before the EAC (Thermal) in
its 30th meeting held on 8-9, August, 2011. The Committee recommended the
project for Environmental Clearance. Subsequently, it was brought to the notice of
the ministry that JAL had gone ahead with the construction activities at site without
mandatory environmental clearance. This was brought to the notice of the EAC
(Thermal) in its 32nd meeting held during 12th - 13th September, 2011. The
committee decided that ministry may take the matter in accordance with the
procedures and policy decision taken in such matters.
As per the directions of MoEF, JAL had submitted the copy of resolution passed by
the Board of Directors of JAL during its meeting held on 11th January, 2012 and
Corporate Environment & Energy Policy. Further, as per the O.M. of MoEF dated
16.11.2010 for consideration of cases of violation, the Madhya Pradesh Pollution
Control Board had filed a petition with the Chief Judicial Magistrate of Sidhi, M.P.
on 14.12.2011 under Section 15 of the Environment Protection Act, 1986. Based on
the information and clarifications submitted to MoEF&CC, the Hon’ble committee
recommended environmental clearance to the project. Environmental Clearance was
issued by MoEF&CC vide its letter Ref. No. J-13012/94/2009- IA.II (T) dated
30.01.2012.
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Now, present application is submitted under the provision of MoEF&CC Gazette
Notification S.O.804 ( E) dated 14th March, 2017 as it is a violation case due to start
of construction and installation work without requisite prior Environmental Clearance
as per the provision of the EIA Notification, 2006 notified under Environment
(Protection) Act, 1986.
(i) Brief description of nature of the project
Jaiprakash Associates Limited had installed coal based Captive Thermal Power Plant
of 2 x 60 MW capacity adjacent to its existing cement plant at Kariajhar village, Sidhi
district, Madhya Pradesh.
(ii) Need for the project and its importance to the country and region
There is constant shortfall of power, and MPSEB resorts to frequent power
curtailment. In view of shortage of the power from the utility grid, JAL intends to
meet the continuous power requirement of cement plant and its auxiliaries.
In view of the above, JAL is constructed an alternative, sustainable and economic
power source for operation of the group units.
(iii) Demand- Supply Gap
Captive Power Plant was established to cater the need of exiting integrated cement
plant and company’s other units at different locations.
(iv) Imports vs. Indigenous production
Not applicable
(V) Employment Generation (Direct and Indirect) due to the project
The total manpower of power plant at present in the operating unit is about 54
persons.
3. 0 VIOLATION DETAILS
Jaiprakash Associates Ltd. had started partial construction activities in terms of
carrying out pre-project activities and construction/installation of certain Plant
structures. However, all construction activities were suspended in December, 2011
and restarted after obtaining Environmental Clearance from MoEF&CC dated
30.01.2012 followed by Consent to Establish from MPPCB dated 09.03.2012.
4.0 PROPOSED LOCATION
(i) Types of project including interlinked and interdependent project, if any.
In view of its captive requirement, Jaiprakash Associates Limited had set-up a coal
based Captive Thermal Power Plant of 2 x 60 MW capacity adjacent to its existing
cement plant at Kariajhar village, Sidhi district, Madhya Pradesh. The CPP have two
Circulating Fluidized Bed Combustion (CFBC) boilers having capacity of 60 MW each.
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ii) Location (map showing general location, specific location, and project
boundary & project site layout with coordinates.
The project is located at Kariajhar/Majhgawan village of Sidhi district of Madhya
Pradesh.The index map of the site is given in Figure-1. The study area map is shown
in Figure-2. The project area falls in Survey of India (SOI) Toposheet No.63 H/4, H/7
and 63 H/8.
(iii) Details of alternate sites considered and the basis of selecting the
proposed site, particularly the environmental considerations gone into
should be highlighted.
The alternative sites were not considered, since the location of CPP was within the
boundary of the existing Cement Plant, which is in industrial use.
iv) Size or magnitude of operation
The land requirement for captive power plant ultimate capacity of 2 x 60 MW and its
facilities is approximately 61.77 acres (25 hectares). The cost of the total project is
about Rs.519 Crores.
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FIGURE 1-INDEX MAP
Project Site
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FIGURE 2-STUDY AREA MAP
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6.0 DETAILS OF CAPTIVE POWER PLANT
The capacity of captive power plant is 120-MW, two (2) Circulating Fluidized Bed
Combustion (CFBC) boilers had installed for power generation. The details of captive
power plant are presented in Table-1.
TABLE-1
DETAILS OF PROPOSED CAPTIVE POWER PLANT
Sr. No. Features Description
1 Capacity 120 MW
2 Configuration 2x60 MW
3 Type of boilers Circulating Fluidized Bed Combustion (CFBC)
Boilers
4 Power evacuation Through SEB/PGL transmission line
7 Coal Requirement 1.0 MTPA
11 ESP efficiency >99.98%
13 Water
Requirement
1566 m3/day
14 Source of water Bansagar Canal (Permission for withdrawal of
1600 m³/day of water from Bansagar Canal by
Water Resources Deptt., GoMP vide letter no:
94/2010/31/903 dated 19.08.2011)
7.0 PROCESS DESCRIPTION
Capacity
The power plant with 2 x 60 MW has installed with a production capacity of 120 MW.
Process Technology
Conventional steam cycle operating in Rankine cycle, consisting of 2 nos of CFBC
boilers of 250 TPH and 2 nos Turbines 535 ºC at 110 ata pressure.
Process Description
Coal is fired in a high pressure boiler to produce steam which is fed to steam turbine
which drive the generator connected rigidly to it. The power output from the
generator through appropriate electrical system is fed to the grid for distribution to
consumers.
Exhaust steam from the turbine is cooled in the water cooled surface condenser and
the condensate water is recycled in the power cycle involving boiler, turbine and
condenser as mentioned. Water for cooling purposes is required in the condenser,
heat exchanger of auxiliary systems of boiler, turbine and generator etc. In addition,
water is required for bottom ash handling system, dust suppression system of coal
handling, fire fighting systems, drinking (in plant and colony), make up for the power
cycle etc. Hot water outlet of condenser and other heat exchangers is cooled in
suitable cooling tower and reused in the system. Similarly, water used in other
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systems mentioned above is recycled to the extent possible after suitable treatment.
However, make-up is required to be added for replenishing the loss due to
evaporation, blow down and other consumptive use. However, make up is required
to be added for replenishing loss due to evaporation, blow down and other
consumptive use. To minimize the make up, effluent water from different process in
the power station is chemically treated so as to make it suitable for use in the
development of greenbelt, sanitation, dust suppression etc.
The fly ash from the bottom of the ESP hoppers is collected in dry form and
pneumatically conveyed to fly ash silos. From these silos, fly ash is used in the
existing cement plant to manufacture PPC.
Effluent treatment plant along with guard pond system and sewage treatment plant
is provided for wastewater treatment.
Plant layout and process flow sheet is given in Figure-3 and Figure-4.
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FIGURE-3
PLANT LAYOUT
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FIGURE-4
PROCESS FLOW SHEET
12
Power Generating Equipment
Thermodynamic Cycle
The thermodynamic cycle consists of the boiler, the steam turbine, the condenser,
the condensate extraction and boiler feed systems, the condensate and feed water
heaters along with all other necessary equipment for single reheat regenerative feed
heating.
Turbine Generator Unit
The steam turbine with standard multi-stage, multi-cylinder, tandem compound,
single reheat, condensing type machine operating at 3000 rpm with minimum of six
(6) uncontrolled extractions for regenerative feed heating.
Details of Air Cooled Condenser (ACC)
Air cooled surface condenser is a direct system using ambient air for rejecting the
heat to the atmosphere without cooling water as the mean of heat transport. The
turbine back pressure is a function of the ambient dry bulbs temperature. To reject
the heat to the atmosphere an adequate fin tube surface is necessary. To create and
maintain the necessary vacuum inside the condenser, air ejector is provided.
Details of Steam Generators and Accessories
The selection covers selection of mechanical equipment and system for efficient
operation of the Captive power plant.
The captive power plant consists of 2 numbers of 60 MW MCR capacity steam
Turbine generator and 2 numbers of CFBC boiler of 250 TPH capacity.
Steam Generator
The steam generating system for each unit of 2x60 MW the power plant consists of
two numbers of boilers of 250 TPH capacities with all the auxiliaries.
The boilers has circulating fluidized bed type, natural circulation, balanced draft, and
water cooled membrane wall radiant furnace design with three (3) stage super-
heaters and inter-stage desuperheater.
The steam generator is provided with a steam drum and the drum is of fusion-
welded type. The steam drum with necessary nozzle connections for the steam
outlets, safety valves, feed water inlets, down-comers, continuous blow down, level
indicators, chemical dosing, sampling connection, drains and vents to assure the
required steam purity.
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Furnace
The furnace envelope is constructed of fully water-cooled membrane/fin welded walls
and the construction is gas pressure tight
Super Heater
Super-heater system is of three (3) stage design with inter-stage desuperheating to
achieve the rated steam temperature over 60% to 100% MCR load. The super-
heater is combination of convection and radiation type.
Economiser
The economiser is located downstream of the super-heaters and evaporator sections.
The economiser is of bare tube construction, inline arrangement, counter flow type
and the economiser is designed for inlet temperature of 235C.
Air Heater
Air heater is arranged as the last heat recovery section downstream of economiser.
Air heater is recuperative type with flue gas flowing inside the tubes and the
combustion air flowing over the tubes.
Draft System
The draft system for the steam generator is suitable of producing a balanced draft
with sub-atmospheric pressure condition in the furnace.
HP & LP Dosing System
Steam generator with High Pressure (HP) dosing and Low Pressure (LP) dosing
system. The HP dosing system is based on ‘tri-sodium phosphate’ dosing and this is
dosed in boiler water to take care of the ingress of the hardness salts and to increase
the boiler water pH. The LP dosing system is based on ‘hydrazine’ dosing and this is
dosed in the feed water to scavenge the last traces of oxygen and to increase the
feed water pH.
Blow Down Tank
One Continuous Blow Down tank (CBD) and one Intermittent Blow Down tank (IBD)
is provided for each of the boiler. The flash steam from the CBD tank is piped to the
de-aerator and outlet of the IBD tank is vented to the atmosphere.
De-aerator
One De-aerator of de-aerating capacity equal to twenty percent (20%) higher than
the gross MCR steam generation capacity of boiler with a de-aerated water storage
tank of minimum 20 minutes operation.
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Boiler feed Water Pump
Two working and one standby boiled feed water pumps are installed. The one of
three boiler feed pump motor with soft starter for one set.
9.0 Site Analysis
(I) Connectivity
The project is well connected with NH-75 at a distance of 2.3 km, E and NH-7 at a
distance of 24 km, NW.
(II) Land form, land use and land ownership
The land requirement for captive power plant ultimate capacity of 2 x 60 MW and its
facilities is approximately 61.77 acres (25 hectares). The required land is available
within the existing cement plant that is spread over 120.62 ha
(III) Existing Infrastructure
The infrastructural facilities are common for cement plant and power plant.
10.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
No R&R issues involved
11.0 Greenbelt Development
Thick greenbelt have been provided with trees planted in rows. 33% of the total
project area developed as greenbelt and green cover as per CPCB/ MoEF, New Delhi
guidelines.
12.0 Socio-Economic Benefits
The industrial activity of the project coupled with the ancillary industries, contributed
to the overall socio-economic development of the region.
Direct Benefits to the National and state Exchequer
Power tarrif;
Excise duty
State sales tax or VAT
Income by way of registration of trucks, payment of road tax and payment of
tax for interstate movements
Income tax from individual as well as corporate taxes by the cement company
and ancillary units.
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Direct Employment
Unskilled/semi-skilled labor for the plant is drawn locally or from nearby places. The
employment of local personnel in skilled and executive staff category depend on
availability and sustainability of individuals.
Indirect Employment
Apart from direct employment, a lot of persons employed indirectly in truck transport
operation, repair garages, other ancillary units, market/shops etc.