Form 1 Annexures

Annexure – I

Water Balance - m3/day

S. No. Utility Water Requirement (m3/day) Wastewater

generation (m3/day)

Remarks

Fresh Treated Total

1. Power Plant

DM Plant 70 70 70 Recycle / reuse for greenbelt, domestic

needs

Boiler 605 605 106 Recycle / reuse for ash quenching, dust

suppression

Cooling Tower 750 750 262 Recycle / reuse for greenbelt, domestic

needs

Sub Total 1425

2. Domestic 70 30 100 90 Treated in STP /Septic tank followed by

soak pit

3. Floor washing 10 10 6 Recycle / reuse

4. Vehicle Work Shop, Fire

water makeup, etc.

20 20 18 Recycle / reuse

5. Compost Plant 350 350

6. RDF Plant 25 25

7. Recycling complex 10 10

8. Greenbelt 1080 80 1160

Total 2575 525 3100 552

Source: HMWSSB /borewells within site

Annexure – II Topographical Map – 15 km Radius

Detailed Project Report of

Waste to Energy Power Plant

Detailed Project Report

Of

Waste to Energy based 2 x 24 MW Power Plant

at

Integrated Municipal Solid Waste Management

Project,

Jawaharnagar (V), Kapra (M),

Medchal (D), Telangana

By

Greater Hyderabad Municipal Corporation

(GHMC), Hyderabad, Telangana

Foreword

The percentage of India’s population living in cities and urban areas has increased over

the years since independence, showing the rapid pace of urbanization. This will

accelerate even further, and by the year 2021 over 40% of Indians are expected to

reside in the urban area. This has been fuelled by rapid growth in industrialization,

commercialization, development of secondary and tertiary sectors of economy and

mass migration. The progressively improving standards of living, rapid urbanization and

the wasteful consumer attitudes have resulted in the increase of quantities of municipal

wastes to be handled.

The problem of municipal solid waste management has acquired alarming dimensions in

India, like any other developing country, is fraught with many inadequacies. In addition,

it is a major economic burden on local Government & furthermore, open burning of

MSW adversely affects the environment by emitting pollutants to the atmosphere.

Thus, it is increasingly felt that the first step towards sustainable waste management

programme is to quantify factors affecting environmental quality factors affecting

environmental quality pertaining to MSW. The report of high power committee on

urban solid waste management in India stated that urban solid waste management

continues to remain one of the most neglected areas of urban development in India.

Furthermore, the disposal of the waste is by unplanned and uncontrolled open dumping

at the landfill sites.

Many initiatives are being taken up by the central government, state and local / city

governments, for addressing the challenges and providing improved infrastructure

service and facilities. The “Ministry of Environment, Forests and Climate Change”

(MoEFCC) along with the apex body “Central Pollution Control Board” (CPCB) has issued

guidelines for municipal solid waste management and handling, viz., “Municipal Solid

Waste” (management and handling) Rules, Amendment, 2016. The 74th constitutional

Amendment by MoEFCC is a very important milestone in introducing the decentralized

local urban governance in India. It provides good opportunity and ways for efficient

working of the municipal bodies. However, in spite of enactment of 74th Constitutional

amendment, the urban local bodies are not able to implement adequately various facts

of the amendment.

Municipal Solid Waste (MSW) is defined as refuse from households, waste from

commercial establishments, and refuse from institutions, market waste, yard waste and

street sweeping. The quantity of MSW generated by a city depends upon a number of

factors such as good habits, standard of living and degree of commercial and industrial

activity in the city. Municipal solid waste is a heterogeneous mixture of paper, plastic,

cloth, metal, glass, organic matter, etc., generated from households, commercial

establishments and markets. Packaging materials are becoming an increasingly

important component of municipal waste in developed countries. Through waste from

hospitals and nursing homes are required to be collected and treated separately, in

most cities and towns, such wastes continue to form a part of MSW.

The quantity of MSW is usually expressed on a per capita basis. MSW generated in

gram / day is transformed in per capita terms, using population of the corresponding

states. A new indicator “collection efficiency” has been also incorporated which relates

to the efficiency of service provision for waste management. The total urban municipal

waste generation per year has increased to more than three folds in the last few

decades. This tremendous increase in waste generation led to the problem of local

governments, responsible for managing it.

The urban areas of India produce about 30 million tons of solid waste from household

and commercial activities every year. It is estimated that there is a potential for

generating about 1,000 MW of power from MSW in India. If this potential is to be

effectively used, it will not only contribute substantially to the overall power generation

capacity but will also give a good return on investment, apart from improving the

environment.

Generation of energy from MSW has certain distinct advantages, such as:

• The total quality of waste gets reduced substantially.

• The quality of leftover waste, from the point of review of causing environmental

degradation is improved.

• Demand for land for disposal of wastes is reduced.

• Proceeds from the sale of energy / products improve the commercial viability of a

waste disposal project.

Fully aware of the advantages of MSW based power plants, the management of M/s.

HiMSW Limited have decided to install a MSW based power plant in a phased manner at

Jawahar Nagar dump site in Hyderabad, using the MSW generated from the city, to

produce environmental friendly renewable power. HiMSW Limited intends to set up

MSW power plant (also referred to as Waste to Energy) in a phased manner. There will

be two blocks of Waste to Energy plants – each comprising of 2 units of 600 TPD MSW

Combustors with 24 MW capacity and totally to 48 MW.

Contents

S. No. Description Pg. No.

1. Project at Glance 01

2. Introduction 03

3. Fuel its properties and Technology selection 06

4. The Power Plant Scheme 08

5. Operations and Maintenance Requirements 19

6. Manpower and Training 26

7. Environment Protection and Waste Management 30

8. Project Cost Estimate 35

1

1. Project at a Glance

1.1 Power plant Detail

1.1.1 MSW Power Plant capacity : 4 x 600 TPD Municipal Waste

Combustors with an aggregate

capacity of 48 MW in phase manner

Phase I : 2 x 600 TPD Combustor with 24 MW

installed capacity

Phase II : 2 x 600 TPD Combustor with 24 MW

installed capacity

1.1.2 Power output : 48000 kW

1.1.3 PLF : 65% in the 1st year and 80% from 2nd

year onwards

1.1.4 Auxiliary power consumption

(15%)

: 7200 kW

1.1.5 Saleable Power to Grid : 40800 kW

1.1.6 Main Fuel used in the power

plant

: Presorted MSW

1.1.7 Auxiliary fuel used in the plant : Diesel in the start-ups. No. auxiliary

fuel will be used in the normal plant

operations

1.1.8 Export grid voltage : 132 kV

1.1.9 Grid Interconnection : In Parallel with TSTRANSCO substation

at Malkaram

1.1.10 Total water consumption : 1425 Cum/day

1.2 Capacity and detail of major power plant equipment

1.2.1 Boiler & Auxiliaries

Design Capacity of Combustor

(600 TPD)

: 56000 kg/h

No. of Boilers/MSW Combustors : Four (4)

Boiler Outlet Steam Parameters : 45 kg/cm2(a)

: 400 5 °C

Feed water temperature at

boiler inlet

: 150°C

Type of firing grate : Reciprocating Step grate

2

Quantity of MSW used : 4 x 600 TPD

Particulate emission at chimney

outlet

: 30 mg/Nm³

Dioxins and Furans emission : < 0.1ng/Nm³

1.2.2 Turbo-generator & Auxiliaries

Each Turbogenerator capacity : 24000 kW

No. of turbogenerators to be

installed

: TWO (2)

Turbogenerator type : Double bleed cum condensing

Turbine inlet Steam Parameters : 42 kg/cm2(a)

: 395 5 °C

Turbine exhaust steam pressure : 0.2 ata

Type of condensing equipment : ACC

De-aerator operating

temperature (ºC)

: 150 °C

Generation voltage : 11 kV

1.2.3 Other BOP equipment (will be independent for each block of WTE of 24 MW)

Aux. Cooling tower capacity : 600 m³/h/each

Cooling tower type : FRP

Air compressor capacity : 4 x 450 Nm³/hr each

Type of chimney : RCC

Chimney height : 80 m Each

TG hall Crane for maintenance : EOT

Crane capacity : 25 ton

Auxiliary transformer capacity : 3 x 2.5MVA

Generator transformer capacity : 1 X 30 MVA

Start-up DG set capacity : 1x 1010 kVA

1.3 1.3 Project cost

The estimated cost of the project is Rs. 720 crore for 48 MW

1.4 Project Financials

1.4.1 Interest on term loan Indicative : 12%

1.4.2 Interest on working capital : 12%

3

2. Introduction

Modern metropolitan cities and urban areas have grown large and wide with population

in millions. Rapid urbanization, increasing population and Industrial diversification has

led to the generation of enormous volumes of municipal and Industrial waste. This

necessitates management of solid waste at generation, storage, collection, transfer and

transport, processing, and disposal stages in accordance with the best principles of

public health, economics, engineering, conservation, aesthetics and environmental

considerations.

Large population calls for the proper maintenance of the city in terms of infrastructure,

traffic management, cleanliness, sanitation and waste management. Under such

circumstances, the twin problems to be addressed are efficient and effective

management as well as a scientific approach to it.

Cities are considered as the growth engines, but growth benefit of environmental

concern is self-defeating. Despite the fact that the urban local bodies utilize major part

of its staff and resource for collection and disposal of solid waste, most of the waste

generated from households and commercial establishments is not collected and only a

fraction of what is collected receives proper treatment / disposal. It is due to the fact

that these local bodies lack financial and administrative resources apart from

inadequate institutional mechanisms. Furthermore, in all metropolitan cities and most

large cities in India, about 50 to 60% of the municipal waste collected is dumped in open

dumpsites. The rest keeps lying around in municipal bins and roadsides for several

weeks to months, becoming an environmental/health hazard.

It is reported that, bigger urban local bodies spent around Rs. 1600 to Rs. 2000 / ton on

garbage for its collection, transportation & disposal.

Waste management in any region includes the following four aspects. They include:

• Proper mechanisms for collection of waste regularly from residential as well as

industrial areas.

• A scientific and eco-friendly system of segregation of waste into organic,

inorganic, plastic and metal etc.

• Transportation of waste from the place of collection to the destination of

disposal.

• A method of disposal of waste in appropriate places following a clean procedure.

4

Nowadays municipalities are forced to find new methods for waste disposal due to

critical environmental problems from old landfills and a lack of land availability caused

by a fast growing population and a higher rate of waste production.

Most of the developed countries have been successful in addressing this problem by

evolving efficient MSW management system and also by providing technological

solutions to garbage disposal/treatment. With the ever increasing generation of

garbage, it is time for immediate and concerted action. The proper disposal of urban

waste is not only absolutely necessary for the preservation and improvement of public

health but it has an immense potential for resource recovery.

Waste to Energy (WTE) is the sum of processes that produce electric energy from waste.

Nowadays it has also become a safe and favorable form of energy recovery from the

environmental point of view. As such, it is currently regarded as an essential element in

the mechanism of integrated waste management, in all industrialized countries. Waste-

to-energy provides the fourth “R” in a comprehensive solid waste management

program: Reduction, Reuse, Recycling, and energy Recovery.

HiMSW Limited is a subsidiary of the “Ramky Enviro Engineers Limited” based at

Hyderabad. The group which has emerged as India’s largest in the environmental sector

has pioneered the art and engineering of Solid Waste Management (SWM) in India. It

has established itself in the Leadership position in the country in the field of

environment and infrastructure.

HiMSW Limited is establishing an integrated MSW project for Greater Hyderabad

Municipal Corporation (GHMC) at Jawahar Nagar to handle MSW in compliance with

MSW rules 2016. The main objective of the proposed Integrated Municipal solid waste

processing is 100% processing of MSW generated in the city limits through a

combination of processes such as Compost, pre-sorted waste and also Waste to Energy

and to dispose-off the same through a most scientific, and productive disposal. The

installed capacity of the WTE plant will be 48 MW in a phased manner.

The following pictures illustrate the site location of the proposed plant.

5

6

3 Fuel its Properties and Technology Selection

MSW is highly heterogeneous and percentage of its constituents varies widely

depending on the source. Further seasonal changes also contribute to the higher level of

heterogeneity in MSW. To assess the suitability of any technology for processing MSW,

it is very important to broadly analyse the composition and the weight fraction of each

of the constituents with reference to different sources of its generation.

Some of the municipal corporations make separate arrangement to collect, transport

and dispose off the building construction / demolition waste mainly as land filling /

levelling purpose. The waste generated in hospitals, nursing homes and clinics are

generally referred to as Biomedical waste and are incinerated separately and hence not

part of MSW. Industrial waste also does not become part of MSW as it is separately

collected, treated and disposed off. It is, therefore understood (for the purpose of

finding technological solutions) that MSW consists generally of the waste generated

from residential, commercial and from market places, bulk generators like hotels &

restaurants as well as educational institutions etc.

The MSW includes, garbage-organic material discarded or waste generated as a result of

the storage, preparation and consumption of food, rubbish, paper, wood, glass, metal,

leaves, and debris-construction and demolition of structures mainly generated from

vegetable markets, hotels, community halls, street sweepings and residential areas.

Composition of MSW differs widely from place to place.

The difference in organic content in MSW which is much higher in the low income areas

than the high income, while the paper and plastic content is much higher in high income

areas than low income areas. This reflects the difference in consumption pattern,

cultural and educational differences.

During the last 10 years, life and consumption styles have remarkably modified the

composition of MSW. The quantity of organic waste has decreased, while packaging-

related waste has increased (as of now it is about 40% of the total). Such a massive

presence of packaging material, like plastic, paper, cardboard – all of which have high

energy contents – has progressively raised the overall Heating Value of MSW.

MSW collected from different sources has different Gross Calorific Values (GCV). The

GCV varies from 1500 to 2200 kcal/kg (The corresponding Lower Calorific Value (LCV)

7

varies from 1200 to 1700 kcal/kg). However, after mixing in the MSW pit, the MSW

possesses an average lower calorific value of 1724 kcal/kg.

Incineration:

Incineration technology is the controlled combustion of waste with the recovery of heat

to produce steam that in turn produces power through steam turbines.

Incineration process needs sufficient quantity of air for complete combustion of the

incoming MSW to generate heat energy.

Incineration of MSW allows huge savings at the landfill as the volume of MSW is

reduced almost to 20% in the form of ashes and slag as compared to the original waste

volume.

In WTE plants based on incineration, the entire energy contents of waste is recovered,

except the unavoidable fraction that is lost through the flue gas, cooling devices, boiler

walls and ash. The direct combustion of MSW releases more available energy compared

to pyrolysis and gasification. In view of world wide experience of WTE plants, European

Union (EU) has 400 units, Japan has 100 units, USA has 87 units and china has around 60

units. From the above it is evident that the energy recovery from MSW through

incineration is a proven technology. Most importantly, MSW combustors have to be

designed for a higher value than present in order to achieve the objective of disposal of

MSW.

Considering all the above, incineration of MSW to produce power will be the option for

this project.

Typical view of a MSW fired boiler & Auxiliaries

8

4 The Power Plant Scheme

Steam Cycle for the Power Plant and selection of Boiler

The steam cycle defines the transformation of the heat energy to the mechanical energy

at the turbine shaft, through the various thermodynamic processes that is capable of

producing the net heat flow or work when placed between the energy source and

energy sink. The heat energy is derived from burning of some fuels or using heat energy

already available in the hot waste gases. The cycle needs a working fluid and steam is

considered for the same. Steam is viewed as the most favoured working fluid mainly

because of its unique combination of high thermal capacity, high critical temperature,

high latent heat, excellent heat transfer characteristics, and wide availability at cheaper

cost, non toxic and non corrosive nature.

All the steam based power plants operate under the Rankine Cycle. In simple terms the

Rankine Cycle is described as the combination of the various processes like the

isentropic compression of water in the boiler feed water pumps (1 to 2), reversible heat

addition to the working fluid (2 to 3) through the liquid, two phase and super heat

states, isentropic expansion of the working medium in the turbine (3 to 4) and the

constant pressure heat rejection to the atmosphere (4 to 1) through the condenser.

Simple Rankine Cycle

9

The cycle to be adopted for this project will be a modified Rankine Cycle with the

addition of a Regenerative feed water heating. Reciprocating step grate is widely used in

various countries and is a proven technology for burning pre-sorted MSW.

Reciprocating Step Grate assembly

The proposed MSW based power plant shall be designed to burn the pre-sorted MSW in

the boiler. Bulky objects present in the MSW are removed during the pre-sorting

process.

Selection of Turbo-generator for the Power plant

Steam turbines are broadly classified in to condensing steam turbines and non

condensing steam turbines. The non-condensing steam turbines are also called as back

pressure turbines. In the power generation application, generally condensing steam

turbines are widely used. The condensing steam turbine is designed to operate with the

exhaust pressure below the atmospheric pressure (Vacuum pressure).

The high pressure condensing steam turbines for power generation application are

broadly classified as Regenerative type steam turbine and Reheat type steam turbines.

Regenerative turbines are widely used and well proven in the power and process

Fuel travel direction

Reciprocating step grate

Furnace

Bottom ash

Fuel in

10

industries for the capacity ranging from 10 MW to 100 MW. Reheat turbines are

generally used for a capacity more than 100 MW range.

For the capacity under consideration, and the experience of the turbine vendors in the

Indian market, Regenerative type steam turbine is selected for this project. The turbine

selected will be double bleed cum condensing machine. The steam required for the de-

aerator and SCAP will be taken from the bleed of the turbine.

Typical arrangement of steam turbine

Selection of Pollution control equipment to control the emission (Flue Gas cleaning

system).

Combustion of waste in grate furnace results in the formation of exhaust gases that

contain various pollutants. These pollutants include particulate fly ashes and gaseous

flue gas constituents.

Substances found in the flue gas of WTE plants (before treatment) can be classified into

three groups:

11

Macro-pollutants:

Substances present in gaseous form, inorganic gases, such as CO, HCl, SO2, HF,

and nitrogen oxides (NOx).

Micro-pollutants:

Substances present in very low concentrations, such as heavy metals (lead,

cadmium, copper & zinc, etc.), organic chlorinated compounds like

chlorophenols, polychlorobiphenils, dioxins, furans and aromatic polycyclic

hydrocarbons (PAH).

Dust

Solid-state particles upon which dioxins and other condensable micro-pollutants

tend to fix.

Prior to the emission of flue gases into the atmosphere, concentrations of the pollutants

mentioned must be reduced by technical measures.

Reduction of acid gases (HCl, HF & SO2)

Semi dry flue gas cleaning system is envisaged for reduction of acid gases.

In semi-dry processes, the adsorption agent added to the flue-gas flow is aqueous lime

solution or lime slurry. An aqueous suspension of calcium hydrate is used to neutralize

the acid potential in the flue gas. Calcium hydrate is effective on all gases but nitrogen

oxides. The water solution evaporates and the reaction products are dry.

The residue may be re-circulated to improve reagent utilisation.

12

Semi dry Flue gas cleaning system

Reduction of Nitrogen oxides

Nitrogen oxides in the flue gas of a waste incineration plant are formed largely from the

nitrogen contained in the fuel.

NOx production can be reduced using furnace control measures such as Prevent over

supply of air (i.e. prevention of the supply of additional nitrogen)

Although sufficient oxygen is required to ensure that organic materials are oxidised

(giving low CO and VOC emissions), the oversupply of air can result in additional

oxidation of atmospheric nitrogen, and the production of additional NOx.

Staged combustion in the furnace also envisaged by over fire air nozzles at various

location along the height of the boiler. This involves reducing the oxygen supply in the

primary reaction zones and then increasing the air (and hence oxygen) supply at later

combustion zones to oxidise the gases formed.

NOx can be reduced by the prevention of unnecessarily high furnace temperatures

(including local hot spots).

The use of a well distributed primary and secondary air supply to avoid the uneven

temperature gradients that result in high temperature zones and, hence, increased NOx

13

production is a widely adopted and important primary measure for the reduction of NOx

production

Provisions shall be made in the furnace for Ammonia injection system which shall be

installed later considering the pollution control requirements.

Reduction of Dioxins/Heavy metal

Dioxins are usually the principal contaminants due to the presence of plastics in the

waste. Heavy metals may also be present as a secondary contaminant. The temperature

at the point of injection has been reduced to 130°C to minimize the volatility of the

contaminants, which consequently optimises the adsorption efficiency.

Activated carbon is injected into the gas flow. The carbon is filtered from the gas flow

using bag filters. The activated carbon shows a high absorption efficiency for heavy

metals as well as for PCDD/F. Different types of activated carbon have different

adsorption efficiencies.

The adsorption of dioxins by activated carbon is controlled by the properties of both the

carbon and the adsorbate, and by the conditions under which they are contacted. This

phenomenon is generally believed to result from the diffusion of vapor-phase molecules

into the pore structure of carbon particles. These molecules are retained at the surface

in the liquid state because of intermolecular or Van der Waals forces.

As the temperature falls, or as the partial pressure of the vapour above the carbon rises,

the average time that a molecule resides on the surface increases. So does the fraction

of the available surface covered by the adsorbate. However, the carbon surface is not

uniform and consists of sites whose activities vary. More active sites will become

occupied first and, as the activity of the remaining available sites decreases, the

adsorption energy will change.

The physical structure of activated carbon contain randomly distributed pores in the

carbon, between which lies a complex network of irregular interconnected passages.

Pores range in diameter down to a few angstroms and provide an internal surface area

from 300 to 1,000 m2/gram of carbon. The volume of pores at each diameter is an

important variable that directly affects carbon performance.

Since adsorption takes place at the carbon-gas interface, the surface area of the carbon

and pore radius is the important factors to consider.

14

The performance of activated carbon systems depends primarily on the carbon injection

rate, carbon injection method, carbon properties, flue gas temperature, and PM control

method.

Dust removal:

To separate dust particles from the flue gas, cyclones or electrostatic precipitators or

bag filters are installed.

The selection of gas cleaning equipment for particulates from the flue-gas is mainly

determined by:

- particle load in the gas stream

- the average particle size

- particle size distribution

- flow rate of gas

- flue-gas temperature

- compatibility with other components of the entire FGT system

- Required outlet concentrations.

Bag Filter:

Filtration efficiencies of bag filters are very high across a wide range of particle sizes.

Compatibility of the filter medium with the characteristics of the flue-gas and the dust,

and the process temperature of the filter are important for effective performance. The

filter medium should have suitable properties for thermal, physical and chemical

resistance (e.g. hydrolysis, acid, alkali and oxidation). The gas flow rate determines the

appropriate filtering surface i.e. filtering velocity.

15

Typical arrangement of a bag filter

Bag filters are filtering separators operating as surface filters. Separation of the particles

takes place mainly on the surface of the filter medium, which is passed by the gas flow.

On the surface of the filter medium, the particles retained form a layer, the dust cake,

which causes an increasing pressure loss with increasing layer thickness. For this reason,

the dust cake has to be removed regularly. By the construction of the filters and

selection of filter media, these separators may be adapted optimally to the operation

conditions and properties of the dusts, such that they can be used in various industrial

sectors. Materials serving as filter media are fiber layers, membrane like materials,

sintered metals or ceramics. For dedusting flue gas in waste incineration plants, for

instance, PTFE membrane filter hoses are applied.

The filter areas can be cleaned by shaking or compressed air. In case of compressed-air

cleaning, the filter elements are usually passed by an air flow from outside to inside and

cleaned by a jet pulse (0.1 to 1 second) that is blown into the filter element. The setup

and functioning of a fabric filter with jet-pulse cleaning are shown schematically in the

following figure.

Clean gas out

Flue gas in

Ash discharge

16

Bag filter with pulse jet cleaning

Operation temperature of a fabric filter is limited decisively by the filter materials used.

In large-scale waste incineration plants, fabric filters are operated at temperatures

ranging from 170 to 200C.

Fabric filters reach a very high separation efficiency of more than 99%. In particular for

fine particles, i.e. at particle sizes in the range of 10 µm, fabric filters represent a very

efficient separation system. However, fabric filters are associated with the drawback of

a relatively high pressure loss which ranges between 500 and 2000 Pa. This pressure loss

must be compensated by an increased fan power. When coated with adsorptive or

reactive substances, fabric filters may also be applied for further gas cleaning.

The flue gas cleaning system envisaged for this project consists of Semi dry process with

bag filters.

Semi dry flue gas cleaning system includes reaction tower, lime slurry making system &

high speed atomiser. The acid gas is reacted with lime slurry and heavy metal and

dioxins are absorbed by active carbon.

Selection of Condenser for the Power plant

The heat sink selection should be initiated in the early stages of the project

development. The elements that significantly affect the selection of the heat sink option

in a power plant include the following:

17

- Availability and quality of water throughout the year.

- Change in water characteristics, due to change in ambient conditions and

seasonal variations

- Disposal of water

- Site location

Once the heat sink has been selected, its performance is optimized based on historical

weather data for the wet bulb and dry bulb temperatures at site. Equipment design

parameters such as approaches are then determined in order to achieve maximum cycle

efficiency at the optimum cost.

If sufficient water is not available at the site, throughout the year, the only option is to

go in for an Air Cooled Condenser system (ACC). Hence for this project ACC option is

selected. The advantage of this system is, minimal or no issues associated with

blowdown, disposal of water and plume formation.

Air cooled Condenser must be placed close to the turbine building to minimise the

pressure drop between the steam turbine and the Condenser, reducing the steam duct

cost and improving the cycle efficiency.

Description of power plant scheme

The proposed MSW based power plant scheme for the HMSWL, consists of Four (4)

number of steam generators capable to burn 600 TPD of Segregated MSW in each

boiler, with super heater steam outlet parameters of 45 kg/cm2(a), 400°C and Two (2)

24 MW extraction cum condensing turbogenerator.

The Turbo generator capacity is arrived based on the actual steam quantity available to

generate power, with required margins to take care of the VWO conditions of the TG

and to meet various operating and upset conditions of the power plant.

The steam generator is equipped with complete required system like air and flue gas

system, fuel and ash system, feed water and steam system, Dust collection system, soot

blower system, Steam and water analysis system, Boiler draft system, Instrument air

system, Electrical system, instrumentation and control system, etc.

18

Each turbine will be double (2) bleed cum condensing machine. The steam required for

the de-aerator is taken from the bleed of the turbine. ACC is identified as the

condensing equipment. Steam required for the ejector and gland sealing is about 350

kg/h at 10.0 kg/cm2 (a), is taken from live steam line through PRDS station.

The Power plant cycle will be provided with a de-aerator serving the dual purpose of de-

aerating the feed water as well as heating the feed water with the bleed steam drawn

through the turbine. The de-aerator considered is a floating pressure type.

The feed water management program shall ensure the supply of good quality make up

water to the system. In the proposed power cycle, from the steam supplied to the

turbine, about 98% will come back as the condensate from the ACC to the steam

generator, through the feed water heating system (De-aerator). The complete make up

required for the plant operation will be treated ground water.

Make up of required quality is considered from the water treatment plant. The make up

for the cycle will be added in the condensate hot well and the quantity of makeup will

be controlled by the hot well level control system.

Well engineered Fuel feeding and ash handling system is considered for this project.

The power generation will be at 11 kV level. After meeting the power plant internal

consumption, the remaining power will be stepped up by a step-up transformer and

exported to the TSTRANSCO grid

The complete plant instrumentation and control system for power plant shall be based

on DCS philosophy, covering the total functioning requirements of measuring,

monitoring, alarming and controlling, logging, sequence interlocks and equipment

protection etc.

19

5 Operation and Maintenance Requirements

General

This section of the report outlines the operation and maintenance philosophy to be

adopted for the proposed MSW based power plant. This broad outline given here will

provide useful guidelines for the basic and detailed engineering of the plant, so that all

the requirements of the operation and maintenance of power plant are met and

provided for the engineering stage itself.

The production of power from steam involves the interaction between several major

components and subsystems. The steam supply system includes feed water, water

treatment, fuel handling and preparation equipment, boiler system, emission control

equipments, etc. The turbo generator generates power and part of the power is fed to

the power plant, the surplus being exported to the state electricity grid. Since the power

is exported to the grid, the power plant should operate in parallel with the TSTRANSCO

grid.

Efficient and competent operation and maintenance is the key to applying WTE

technology successfully and securing the optimum benefit of the investments made.

MSW based power plants require highly skilled personnel and careful maintenance.

MSW plants are capital-intensive and require high maintenance costs and comparatively

higher technically trained operators.

The boiler maintenance plays a vital role in the MSW power plant and thus the power

plant operator should develop a dedicated team with the training from the boiler

manufacturer.

The operation and maintenance of the MSW based plants broadly divided into the

following areas

- Waste receiving and storage

- Combustion system

- Energy recovery

- Flue gas cleaning system

20

The MSW power plant availability will be lower than the conventional fuel fired power

plants as the boiler operation requires frequent cleaning of tubes and grates. The

cleaning cycle shall be once in a month or two months. The boiler manufacturer shall

provide the proper schedule for cooling, cleaning and start up considering the

properties of refractories and boiler construction materials.

The boiler maintenance team should also be conversant with the operation and

maintenance of flue gas cleaning system.

System Design Philosophy

The main O&M objective is the high availability and reliability of the plant. In order to

achieve the main objective, the following principles would be adopted.

Optimum margin on the operating parameters of all important equipment and

auxiliaries and systems to ensure operation of the plant at rated capacity under

all modes of operation.

Providing redundant and standby capacity for all critical equipment.

Use of equipment and systems with proven design, performance and have a high

availability track record under similar service conditions.

Selection of the equipment and adoption of a plant layout to ensure ease of

maintenance.

Strict compliance with the approved and proven quality assurance norms and

procedures during the different phases of the project.

The basic and detailed engineering of the plant will aim at achieving high standards of

operational performance especially with respect to the following key parameters.

Optimum efficiency of the equipment.

Low auxiliary power consumption.

Low make up water consumption.

The plant instrumentation and control system should be designed to ensure high

availability and reliability of the plant to assist the operators in the safe and efficient

operation of the plant. It should also provide historical data for the analysis and help in

the plant maintenance people to take up the plant and equipment on preventive

maintenance.

21

Operation Requirements

The operation of the plant starts with the Commissioning. In broad terms commissioning

can be defined as setting up of the plant to work safely. It is necessary to ensure that all

equipments are completely erected before operations begin. The commissioning

procedures should never compromise personnel and the system safety.

As the success of the MSW energy recovery depends on the incoming fuel, the

operators shall take care of the following, regarding fuel input

- Regular visual inspection of MSW pit

- Checking of fuel deliveries from the trucks

- Keeping records/documents of weighment data from weighbridge

- Homogenisation of MSW by Grab operators

The Grab crane operators shall have a good view of waste storage pit and loading areas

and their mechanisms to monitor them by positioning the control room with a view of

the MSW pit and feed hopper areas.

A proper checklist procedure must be drawn up, which shall include all the sections of

the plant and shall take into account, the contractual responsibilities, the technological

relationship between the various sections, pre-commissioning, Cleaning requirements,

etc. The checklists procedure helps in the following:

a) To ensure that the necessary checks are carried out on each item of the

plant before it is put into commercial service.

b) To indicate a contractor's commissioning requirements from the client or

from other contractors.

c) To ensure that energy is supplied to equipment or a plant when it is safe to

do so.

d) To facilitate the recording of the progress on the various commissioning

activities.

e) To provide a basis for the plant history.

The operation of the power plant interconnected to grid, is an activity that must be

properly coordinated, with in the plant as well as with the state electricity grid

substation to which the power plant will feed power. The MSW based power plant

operating in parallel with the grid eventually makes this power plant a part of state

utility system and hence the power plant must assume some of the same

responsibilities of state utility. With this, the local dispatch centre will need to monitor

22

the incoming power from the power plant on a continuous basis. Hence, the plant

operation should follow the grid disciplines / conditions.

The operation of unit demands closely controlled operating conditions. The unit start-

ups, shut-downs and even, load variations must strictly follow the carefully laid down

procedures given in the operational manuals. Generally, the plant shall be sufficiently

instrumented to permit close checks on such operating parameters as boiler tube and

drum metal temperatures, Gas temperatures, turbine expansions, casing metal

temperatures, condenser vacuum, etc.

The MSW being stored in the pit will release gases like methane, H2S etc., hence the

maintenance personnel shall be provided with the safety equipments such as oxygen

cylinders, masks, etc., during maintenance in the pit to avoid suffocation and odour

nuisance.

An important feature of the modern power generating plant is the automatic safety

lock-out devices. While sufficient thought goes into it at the design stage, it remains the

responsibility of the operating staff to ensure that the safety devices are set correctly

and kept in operation.

While safety of the plant and personnel is the foremost importance in the operation, the

efficient operation of the plant cannot be ignored. While operating, it is important to

check the essential parameters of the plant and equipment to ensure that the plant

performance is at the optimum level. Any variations in the operating parameters or any

deviations from normal performance of the equipment or plant shall have to be

analyzed immediately to diagnose the problem and to take remedial measures to bring

back the plant and equipment to its original parameters.

Water Chemistry

With the increase in the steam temperatures and pressures of the modern boilers,

ensuring good quality of water has assumed greater importance. The boiler to be

installed at the power plant will generate steam at a pressure of 45ata and warrants

strict maintenance of water quality; both feed water and boiler water within limits for

proper operation of the boiler and avoiding scale or deposit formation in turbo-

generators. A routine check-up of the feed water quality during the start-up of the plant

and also periodic check-ups during operation, will result in the elimination of any serious

problem due to the water quality. Similarly, the monitoring of water treatment plant

23

and the water quality at RO plant outlet, the water quality at the inlet of the RO plant

and cooling tower is of utmost importance.

Instrumentation

The modern day power generating system like the one envisaged for the specific power

plant cannot be effectively operated without proper instrumentation and control

system. An effectively designed instrumentation and control system performs the

following functions:

Provides operators with the indication or record of the instantaneous, averaged

or integrated value or condition of the various operating parameters such as

temperatures, pressures, flows, levels, position of valves, switches, current,

voltage, power, etc.

It also provides at convenient locations either local, remote or automatic control

system to control the above operating parameters and gives alarms and even

ensures automatic trip outs, when operating parameters reach beyond the

normal range to the unsafe or undesirable range.

Instrumentation is increasingly taking over many functions of the operator. Its response

to changing and transient conditions, its ability to anticipate, detect and discriminate

faulty conditions and act accordingly is quicker and for more accurate if well designed.

With the ability of the microprocessor based systems to include data acquisition and

processing capabilities, the system’s ability, to log and process periodically the plant

data, is also far superior and permits more timely corrective actions.

Presently, some of the responsibilities of the operation section are taken over by good

instrumentation. The most difficult thing to be encountered in the initial stages of plant

operation is the necessity to develop in the operation staff a faith in the

instrumentation. Many times the operator’s first response to a meter reading too high

or too low is to disbelieve it on the ground that it may be reading incorrectly. If

instruments are not checked and calibrated frequently, the operator will delay taking

corrective actions.

24

The plant operator should follow the guidelines given below:

Frequent checking and calibration of instruments

Developing a habit of cross checking instrument indications with each other to

determine whether the instrument is faulty or there is an abnormal operating

condition; and

Developing a habit of analyzing indicated data to determine accurately what

could be wrong.

Export of power to grid:

The sale of surplus power and supply to the grid from the power plant introduces

responsibility on the plant operator as given below. It is important to recognise that:

Generation voltage 11 kV at the power plant has to be stepped up to 132 kV to the

grid voltage at the point of interconnection.

The power plant has to operate in parallel with the grid system which is a very vast

power carrier. The power plant has to protect its equipment against possible faults

or other disturbances from the grid.

The power export and connection to the TSTRANSCO grid should be properly

metered and documents maintained.

Maintenance Requirements

The main objectives of the maintenance section are to keep the plant running reliably

and efficiently as long as possible. Reliability is impaired when a plant is thrown to

forced and unforeseen outages.

Efficient operation implies close control not only over the cost of production but also

over the cost of maintenance. There are two components in maintenance cost, one is

the direct cost of maintenance i.e., the material and labour and the other is the cost of

production loss.

There are two categories of maintenance work. One is the irksome breakdown

maintenance, which is expensive. Much as it is desirable to avoid or minimize this, its

existence must be accepted. Secondly, it is the preventive maintenance with proper

planning and execution of plant and equipment overhauls. This maintenance activity

should be clearly planned with regard to the availability of material and labour. It is also

essential to develop proper inspection procedures with non-destructive testing

25

methods. Such inspections, by trained personnel reveal defects not necessarily

detected by mere visual inspection.

The following help in reducing the breakdown maintenance and also help in planning for

preventive maintenance.

- Careful logging of operation data / historical information from the DCS and

periodically processing it to determine abnormal or slowly deteriorating conditions.

Walk down checks of the plant.

- Careful control and supervision of operating conditions. Wide and rapid variations

in load and frequency conditions do contribute to increased maintenance

particularly on the high temperature and high pressure units. The turbine throttle

steam pressure and temperature conditions must also be kept steady at the rated

value.

- Regulate routine maintenance work such as keeping equipment clean, cleaning heat

exchangers, filters, effectively executed lubrication program, effective operating

supervision over bearings, commutator or slip ring brushes, gland and flange

leakage, etc.

- Correct operating procedures.

- Frequent testing of plant equipment to determine internal condition of equipment

such as plant cycle efficiency tests, heat exchanger and pump performance tests,

generator and turbine shaft vibration tests, turbine lube oil testing, etc.

- Close coordination with the manufacturers to effect improvements in plant layouts

and design, use of better material, introduction of such facilities as cathodic

protection, use of better protective paints, etc.

- Multi task load management systems that have recently been developed and

marketed also enable continuous monitoring of different electrical parameters

enabling timely corrective measures to be undertaken.

It is extremely important that proper records are maintained not merely for the

maintenance work done but also of the material used and actual man hours spent, etc.

Some sort of a card system shall have to be introduced to keep records that are most

useful in future planning of outages and providing for effective control.

Another important requirement of a good maintenance program is to ensure that

spares are ordered in time and good stocks of the frequently required spares are

maintained.

26

6 Man Power and Training

Rapid growth of industrial activity in the country, has brought, an acute shortage of man

power availability. Requirement for the plant personnel shall be well planned and a

proper program of recruitment and training shall be thought of.

The power plant operation and maintenance personnel must be trained and available

before the plant commissioning commences and therefore it is essential that,

appointments are made well before the programmed plant commissioning date. The

staffing and the organisational structure should be decided based on considering the

specific requirements of the man power preferably, with a power plant background.

The level of competence and skills required for personnel of a waste to energy plant has

to be higher than those required for a conventional power plant. This is because of the

processing needs, changing composition, seasonal fluctuations and unstable combustion

possibilities. The O&M personnel in the MSW power plant (Especially the boiler

operators and the shift engineers), requires appropriate training as the MSW mass firing

technology is in developing stage in Indian context. The proper training shall be

provided by the equipment supplier at manufacturer’s works and at project site.

The requirement of the personnel required must be based on the rational assessment of

the following factors:

a) The nature of the fuel, plant and machinery i.e. Logistics, storage and feeding of

MSW, Grate fired MSW boiler, Flue gas cleaning system, etc., Extraction cum

condensing turbo generator with associated air cooled condenser system,

paralleling with grid and working in conjunction with the grid, ash handling plant,

cooling water system, RO plant, etc.,

b) Socio economic conditions

c) Availability of personnel with right background and exposure.

d) Company policy regarding recruiting permanent labour and contract labour.

Once staffing is finalised and agreed, a suitable scheme for training shall be

programmed and implemented. The main objective of the training program is to equip

each personnel to carry out his particular function with skill and confidence. Training

programme shall be based on classification of discipline, designed to cater engineers,

supervisors, skilled workers etc.

The power plant should be considered under various functional heads as given below:

27

a) Administration

b) Time office & security

c) Purchase & Stores

d) First aid / Occupational health centre

e) Accounts

f) Reception / Stenographer / Telephone operator

g) Transport department

h) Industrial safety cell and fire fighting department

i) Plant operations

The organisation proposed, assumes that the power plant will be headed by plant

manager, holding the full charge of the power plant, reporting directly to the head

office. The staffing recommended here takes care of the operation, maintenance and

record keeping for the plant.

The plant manager should be a graduate with a minimum of 10 to 15 years experience,

out of which at least 5 to 8 years in a power plant. The shift engineers could be diploma

holders with minimum 6 years experience. The supervisors and maintenance personal

should be having adequate experience. The titles against various positions are only

indicative and can be altered to suit the company’s practices and to meet the individual

recruits’ aspirations.

The plant operation team will work in three shifts per day. Each shift will be controlled

by a shift charge engineer. There will be the additional shift charge engineer who will

function as a reliever. The shift charge engineer will be located at the control room and

will be in full charge of the plant operation during the shift.

The maintenance organization of the plant is divided as Electrical Maintenance and

Mechanical Maintenance.

The shift electrical supervisor report to the shift charge engineer during the plant

operation, but they are administratively responsible to the service engineer

maintenance.

The service engineer maintenance is responsible for functioning of the maintenance

group and will be assisted by a mechanical supervisor, electrical supervisor and

instrumentation technician. In addition, there will be mechanical and electrical

28

technicians for attending to maintenance works of the plant & machinery.

The documentation of the engineering office is in the charge of a service engineer

maintenance reporting to the Plant Manager. He is responsible for maintaining the

master copies of all the technical documentation of the power plant. Industrial safety

cell and fire fighting department will also be under the service maintenance engineer.

A few labour contractors shall be registered with the Company for meeting the

requirements of plant cleaning & surge load requirements of the operating and

maintenance group to handle major break down / maintenance work.

In addition to the above, sufficient number of contract labourers will be required for

assistance in receipt of MSW, feeding of MSW, rejects disposal, etc.

The security and other plant assistance requirements like drivers, gardening, etc., shall

be left on contract to external agencies.

The major objectives of the operational training shall be to acquaint the operators with

the following:

a) The nature, purpose and limitations of all plant and equipment

b) The detailed operating instructions on each section and equipment of the plant.

c) Normal start up and shutdown program for the unit.

d) The emergency procedures.

The basis for the training shall be the Plant’s operating and Maintenance Manual

Particulars Book, which is compiled from the manufacturer’s instructions, the contract

documents and the drawings. In addition, the information gathered from the visits to

the other operating plants and to the manufacturers works shall also be included in the

training. Supervision and coordination of the training program requires full time

attention of a senior executive of the plant, and also the consultant’s assistance may be

taken. The training program shall include lectures, expositions by experienced plant

operators and maintenance personnel, informal discussions and visits to operating

plants and manufacturer’s works. Exposure to the courses conducted by instructions like

Power Plant Training Institute should be given to the operating & maintenance staff.

29

The maintenance training program should be based on the requirements of the

individual maintenance functions, like mechanical, electrical, instrumentation etc. The

engineers and the technicians should be sent to the manufacturer’s works to witness

the production and be associated with the erection of plant and equipment.

The power plant should be equipped with proper measuring / testing instrument for

periodic cross checking of parameters shown in the control room and power plant area

local gauges. Logging of data and periodic review of the plant operation, review of

failures, break downs, etc., should be done to improve the availability of the plant.

The power plant manager will be helped by one administrative officer, two accounts /

procurement assistants, one purchase assistant and a MSW logistics supervisor.

It is proposed to explore to outsource the O&M to technology provider. Hitachi Zosen

India (P) Ltd is also being considered for this project and O&M in their view of their and

expertize.

30

7 Environment Protection and Waste Management

General

Environmental protection and the control of solid, liquid and gaseous effluents or

emissions are key elements in the design of all steam and power generating systems.

The pollution control board has fixed the regulations on the emissions according to suit

various industrial sector. The pollution norms for combustion systems are regulated by

State and Central Governments and these specific rules and requirements are constantly

changing from time to time. The most significant of these emissions in any power plant

are sulphur dioxide (SO2), oxides of nitrogen (NOx) and fine airborne particulate. In,

MSW fired power projects, another important pollutant is Dioxins and Furans. All of

these require specialized equipment for control.

Environmental control is primarily driven by Government legislation and the resulting

regulations at the local and National levels. These have evolved out of a public

consensus that the real costs of environmental protection are worth the tangible and

intangible benefits now and in the future. To address this growing awareness, the

design philosophy of energy conversion systems such as steam generators has evolved

from providing the lowest cost energy into providing low cost energy with an acceptable

impact on the environment. However, minimizing aqueous discharges and safe

disposing of solid by-products are also key issues for power plant systems.

MSW is burnt effectively in the boiler otherwise which would be burnt in heaps. The

MSW incinerators burn the wastes in a controlled, engineered environment and

disperse the flue gas into the atmosphere through the chimney. The MSW power

project will reduce the undesirable emissions from the open burning of MSW and as

power is generated the considerable amount of emissions which would have generated

from burning the fossil fuel for generating the same power is avoided. Thus the emission

factor about MSW power plants is that, the dust or the green house gases released into

the atmosphere are no more than what would have been produced by alternative

method of disposal. The MSW power plants thus are environmentally friendly, deserves

for encouragement.

Atmospheric emissions arise primarily from the by-products of the combustion process

SO2, NOx, particulate fly ash, volatile organic compounds (VOC) and some trace

quantities of other materials and are exhausted from the stack. The MSW fired power

plants are prone to produce PCDD and PCDF, which is very harmful to living organisms

and ecosystem. The other source of air emissions is the cooling tower and the

31

associated thermal rise plume which contains heat and some trace materials along with

the water vapour.

Aqueous discharges arise from a number of sources. These include cooling tower blow

down, sluice water from the bottom ash handling system (if wet ash handling system

used), boiler chemical cleaning solutions, as well as a variety of low volume wastes

including ion exchange regeneration solutions from the Reverse Osmosis (RO) Plant,

boiler blowdown, leachate from the storage pit, sewerage system discharges from

buildings and plant floor drains.

Particulate matter and gaseous pollutants

The elements polluting the air that are discharged from the proposed MSW power unit

are,

- Dust particulate from fly ash in flue gas (SPM)

- Nitrogen oxide in flue gas (NOx)

- Sulfur-di-oxide in flue gas (SO2)

- Di-oxins and Furans in flue gas

The chimney is selected considering Sulphur-di-oxide emission to meet central pollution

control norms. The height of chimney has been selected as 80 m for the power plant.

Provision is also made by way of over fire air system in the furnace to contain NOx

emission from the power plant boiler. Semi dry type gas cleaning system is envisaged for

this plant. The acid gas emissions are controlled by dozing lime slurry into the gas

stream. The furnace and the flue gas residence time (minimum 2 seconds with a

minimum flue gas temperature of 850°C) in the furnace are designed such that, the

Dioxins and Furans emissions are reduced. The flue gas is further treated with activated

carbon which ensures the PCDD/ PCDF are limited to less than 0.1 ng/m³ of flue gas.

Semi-dry type gas cleaning system with lime dozing is envisaged for reduction of acid

gases and activated carbon injection is envisaged for reducing the dioxins/ furans and

heavy metal emissions.

The MSW storage has been envisaged in a completely closed shed in the tipping /

storage area. This measure will reduce the dust nuisance in the power plant area. Also

the forced draught fan takes suction from the storage pit there by maintaining slightly

negative pressure in the MSW storage pit. This will eliminate odour in the MSW storage

32

pit area.

As MSW will be stored in a covered shed, no bird menace is expected. Arrangement will

be made for suitable spray on the MSW to overcome the nuisance of bird menace,

mosquito and fly nuisance and odour.

Dry fly Ash and Furnace Bottom Ash

Dry fly ash collected from the bag filter hoppers and the economiser hoppers and the

ash collected from the furnace bottom, Evaporator / superheater bottom hoppers can

be used for land filling, cement or brick manufacturing.

The total ash generated in this MSW power plant will be maximum of about 244550

tonnes per annum {for both blocks of 24 MW WTE put together}

The reuse potential of MSW incinerated ash in the light of toxicity and compressive

strength is prone to huge variation due to the heterogeneous composition and higher

moisture content of the solid waste.

Higher concentration of heavy metals and some hazardous chemicals are observed in

the fly ash of existing MSW fired WTE facilities. The bottom ash collected from the

furnace bottom is observed with relatively less concentration of hazardous material.

The MSW ash contains non-combustibles such as metals, glass, concrete, brick, etc. The

ash is not preferred for any other use and is disposed in landfills.

Water Pollution

Effluent from water treatment plant

Hydrochloric acid and sodium hydroxide will be used as regenerants in the proposed

Demineralisation plant of water treatment plant. The acid and alkali effluents

generated during the regeneration process of the ion-exchangers would be drained into

an acid/alkali proof lined underground neutralizing pit. Generally these effluents are self

neutralizing. However, provisions will be made such that the effluents will be

neutralized by addition of either acid or alkali to achieve the required pH of about 7.0.

33

The neutralizing pit will be sized approximately for 50 m3 capacity. The rejects from RO

plant will have high TDS which could be diluted and used for cleaning purposes in the

project. This water also could be used for Ash Quenching / Dust suppression.

Chlorine in cooling water

In auxiliary cooling tower water, residual chlorine of about 0.2 ppm is maintained at the

outlet. This chlorine dosing is done to prevent biological growth in the cooling tower

system. This value would not result in any chemical pollution of water and also meets

the national standards for the liquid effluent.

Steam generator blow down for each block

The salient characteristics of blow down water from the point of view of pollution are,

the pH and temperature of water since suspended solids are negligible. The pH would

be in the range of 9.8 to 10.3 and the temperature of blow down water will be about

100C The quantity of about 1.2 TPH (approx) of blow down from the each boilers are

very small and hence, it is proposed to put the blow down into the trench and leave it in

the neutralizing pits.

Sewage from various buildings in the plant

Sewage from various buildings in the power plant area will be conveyed through

separate drains to the septic tank. The effluent from the septic tank will be disposed in

soil by providing disposing trenches. There will be no ground pollution because of

leaching due to this. Sludge will be removed occasionally and disposed off as land fill at

suitable places.

Thermal Pollution

The power plant is equipped with an air cooled condenser and hence, there is much less

water pollution which otherwise would have emanated from water cooling system.

There is only an auxiliary cooling tower which is used for cooling the plant auxiliaries

and the capacity of the cooling tower is much less and will be let into the effluent

treatment pit.

This eliminates the letting out of high temperature water into the canals and prevents

thermal pollution. Blow down from the cooling tower will be trenched out and

ultimately conveyed to the effluent pit. Hence, there is no separate pollution on account

of blow down from cooling water system.

34

Noise Pollution

The rotating equipment in the power plant will be designed to operate with a total noise

level of not exceeding 85 to 90 db (A) as per the requirement of Occupational Safety and

Health Administration (OSHA) Standards. The TG & DG will be provided with acoustic

enclosure to meet the standards.

Monitoring of Effluents

The characteristics of the effluents from the proposed plant will be maintained so as to

meet the requirements of State Pollution Control Board and the minimum national

standards for effluent from thermal power plants. Air quality monitoring will also be

undertaken to ensure that the dust pollution level is within limits.

Air Quality Monitoring Program

The purpose of air quality monitoring is the acquisition of data for comparison against

the prescribed minimum standards and thereby assures that the air quality is

maintained within the prescribed levels.

Impact of the Pollution on the Environment

As all the necessary pollution control measures to maintain the emission levels of dust is

taken and other effluents will be treated in the effluent treatment plant, there will be

no adverse impact on either the air or water quality in around the Power plant site on

account of the installation of the plant.

35

8 Project Cost Estimate

A. Civil Works

S. No. Description Cost in

Rs. Lakhs

1. Land & Site Development

Soil Investigation, levelling, internal roads etc

350.00

2. Power Plant building & other equipment foundations

a) Technical building (TG & Boiler Area).

b) Foundations for boilers, TG, ACC and other BOP packages.

c) Chimney

4950.00

3. Building and Civil Works

MSW Storage pit , Ramp, Raw water reservoir, WTP & Fire water

pump house, DG shed etc

3874.00

Sub Total of Civil Works : 9174.00

B. Mechanical Works

S. No. Description Cost in

Rs. Lakhs

1. 4 x 600 TPD , MSW boilers including instrumentation and control

systems , steel structures & supports, Flue Gas cleaning system

including LDO system

39400.00

2. 2 x 24 MW bleed cum condensing Turbo Generator units, control

and instrumentation, Alternator, Relay panels, LAVT, NGT etc

3500.00

3. Two Units of Air Cooled Condensers and Auxiliaries for 2 x 24 MW

project

2500.00

4. Ash Handling system & Ash Silo for two 2 x 24 MW project 780.00

5. Aux. steam piping, cooling water piping, compressed air piping

and other miscellaneous piping

600.00

6. Water Treatment Plant 375.00

7. Air Conditioning & ventilation 150.00

8. Air compressors & Compressed Air system 150.00

9. Fire fighting and protection system 240.00

10. Miscellaneous Pumps 170.00

11. EOT Crane for TG hall, Traction lift and wire rope hoist 185.00

Sub Total of Mechanical works : 48050.00

36

C. Electrical works

S. No. Description Cost in

Rs. Lakhs

1. 11/132 kV substation at Plant site 874.00

2. Bay extension switch yard at substation end 414.00

3. Generator Transformers 360.00

4. Distribution & Converter transformers 230.00

5. L T Package 370.00

6. Variable Frequency Drive (VFD) package 415.00

7. Cables package 410.00

8. Electrical Contract package includes Cable trays, LT Bus Duct,

Lighting & Fixtures and other miscellaneous items like earthing etc.

585.00

9. DG set 170.00

10. Transmission line for Grid Connectivity 800.00

Sub Total of Electrical Works : 4628.00

D. Instrumentation & Control System

S. No. Description Cost in

Rs. Lakhs

1. Plant Instrumentation requirements 521.50

2. Distributed Control Systems for the whole plant integration

through control room

360.00

3. Flue Gas Analyzers for All combustors 250.00

Sub Total of Instrumentation and Control Systems : 1131.50

E. Miscellaneous Fixed Assets

S. No. Description Cost in

Rs. Lakhs

1. Technical Handling vehicles for internal use 100.00

2. Work shop equipment, laboratory equipment and measuring

instruments

81.00

3. EB power facility at the plant 20.00

4. Office equipment, monitoring systems, communication systems etc 60.00

5. Safety equipment, First Aid etc 50.00

Sub Total of Miscellaneous fixed assets : 311.00

37

F. Pre-operatives, Consultancy

S. No. Description Cost in

Rs. Lakhs

1. Detailed Engineering services 400.00

2. Pre-operative expenses for 24 Months 250.00

3. PMC, III Party Inspection and other engineering consultancy &

insurance for E&C period

318.5.00

Sub Total of Pre-operatives, Consultancy : 968.50

Summary of the Project Cost

S. No. Description Cost in

Rs. Lakhs

A. Civil Works 9174.00

B. Mechanical Works 48050.00

C. Electrical works 4628.00

D. Instrumentation & Control Systems 1131.50

E. Miscellaneous Fixed Assets 311.00

F. Pre Operatives , PMC & Consultancy 968.50

G. Contingencies 3211.00

H. Interest During Construction 4526.00

Total Project Cost : 72000.00