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FORM – 1
(I) BASIC INFORMATION.
Name of the Project. :
WASTE MANAGEMENT AND RESOURCE
RECOVERY PROJECT using 30 T/Day hazardous
solid waste and 15 T/day aqueous liquid waste
destruction using Plasma thermal Destruction and
recovery (PTDR) technology
Location / site
alternatives under
consideration.
:
M/S. PLASMA ENERGY APPLIED
TECHNOLOGIES ANKLESHWAR PVT.LTD
Plot No. 9206 , Gidc Estate,
Ankleshwar – 393 002
Dist: Bharuch,
Gujarat.
Size of the project * :
30 T/Day hazardous solid waste and 15 Tons /day
aqueous liquid waste destruction using PEAT
proprietary Plasma thermal Destruction and
recovery (PTDR) technology
Expected cost of the
project. : Apprx. Rs. 46.2 Crores
Contact Information. :
DR.C.B.UPASANI, DIRECTOR
M/S. PLASMA ENERGY APPLIED TECHNOLOGIES
ANKLESHWAR PVT.LTD
SHED NO. K1 7705/2,3,4, GIDC,
Phone No.: +91.2646 220293
E. Mail ID : [email protected]
Screening category. : 7 (d)
* capacity corresponding to sectorial activity ( such as production capacity for
manufacturing, mining lease area and production capacity for mineral production,
area for mineral exploration, length for linear transport, infrastructure, generation
capacity for power generation etc.,)
(II) ACTIVITY.
1.
Construction, operation or decommissioning of the Project involving actions,
which will cause physical changes in the locality (topography, land use,
changes in water bodies, etc)
Sr.
No.
Information / checklist
conformation.
Yes /
No.
Details thereof (with approximate
quantities/ rates, wherever
possible) with source of
information data.
1.1
Permanent or temporary change in
land use, land cover or topography
including increase in intensity of
land use (with respect to local land
use plan.)
Yes
Presently the proposed project site
is barren land. The site is located in
GIDC estate, Ankleshwar, Dist.
Bharuch.
1.2 Clearance of existing land,
vegetation and buildings? No
Plots already marked by GIDC as
service plot.
1.3 Creation of new land uses. Yes
Reserved service plot of GIDC will
be used for waste management and
resource recovery activity.
1.4 Pre-construction investigations e.g.
bore house, soil testing? Yes
Soil testing will be carried out by
unit.
1.5 Construction works? Yes
The present open plot will be
changed in to PTDR (Plasma
Thermal Destruction and Recovery
plant.)
1.6 Demolition works? No Not Required.
1.7
Temporary sites used for
construction works or housing of
construction workers? No
Local workers will be employed for
construction work.
1.8
Above ground buildings, structures
or earthworks including linear
structures, cut and fill or
excavations.
Yes Tentative Plant Layout is attached
as ANNEXURE – I
1.9 Underground works including
mining or tunneling? No
No such underground work is
required.
1.10 Reclamation works? No Not Required.
1.11 Dredging? No Not Required.
1.12 Offshore structures? No Not Required.
1.13 Production and manufacturing
processes? Yes
This is common infrastructure
facility for destruction of hazardous
waste and energy recovery. Detailed
process description is attached as
ANNEXURE-II
1.14 Facilities for storage of goods or
materials? Yes
Proper storage of hazardous waste
will be done. Detailed is attached as
ANNEXURE-II: Refer para 2.3.4
1.15 Facilities for treatment or disposal
of solid waste or liquid effluents? Yes
Only slag as a bio-product will
come out.
Liquid effluent expected discharge:
25KL/day will be disposed off in
CETP of BEAIL /ETL upon
confirmation from them. Till then
the proposed facility will observe
zero effluent discharge.
Please refer EMP attached vide
ANNEXURE-VI
1.16 Facilities for long term housing of
operational workers? No
Skilled operational manpower is
available in Ankleshwar region.
1.17 New road, rail or sea traffic during
construction or operation? No
The notified area has well
developed road facilities.
1.18
New road, rail, air waterborne or
other transport infrastructure
including new or altered routes and
stations, ports, airports etc?
No The notified area has well
developed road facilities.
1.19
Closure or diversion of existing
transport routes or infrastructure
leading to changes in traffic
movements?
No The proposed site is located in
GIDC notified area.
1.20 New or diverted transmission lines
or Pipelines? Yes Source: GEB
1.21
Impoundment, damming,
culverting, realignment or other
changes to the hydrology of
watercourses or aquifers?
No The proposed site is located in
GIDC notified area.
1.22 Stream crossing? No Not applicable
1.23 Abstraction or transfers of water
form ground or surface waters? No Source of water supply :GIDC
1.24
Changes in water bodies or the land
surface affecting drainage or run-
off? No
The proposed site is located in
GIDC notified area.
1.25
Transport of personnel or materials
for construction, operation or
decommissioning? Yes
The transportation of construction
material, man power, raw materials
& finished goods will be done by
road trucks.
1.26
Long-term dismantling or
decommissioning or restoration
works? No
No such activities will be involved
in proposed project.
1.27
Ongoing activity during
decommissioning which could
have an impact on the
environment?
No There will be no decommissioning
activities in the proposed project.
1.28 Influx of people to an area in either
Temporarily or permanently? No Local man power will be employed.
1.29 Introduction of alien species? No No such activity is associated with
proposed project.
1.30 Loss of native species or genetic
diversity? No
No such activity will be carried out
which will lead to loss of native
species or genetic diversity.
1.31 Any other actions? No Not required.
2
Use of Natural resources for construction or operation of the project (such as
land, water, materials or energy, especially any resources which are non-
renewable or in short supply):
Sr.
No.
Information / Checklist
conformation.
Yes /
No.
Details thereof (with approximate
quantities / rates, wherever
possible) with source of
information data.
2.1 Land especially undeveloped or
agricultural land (ha) No
Proposed project site is located in
GIDC notified area.
2.2 Water (expected source & competing
users) unit: KLD Yes
Expected water requirement:
250KL/day which shall be sourced
through the water supply network of
GIDC.
Attached as Annexure – III
2.3 Minerals (MT) No No such type of activity is
associated with proposed project.
2.4 Construction material – stone,
aggregates, sand / soil (expected
source – MT) Yes
All construction materials shall be
sourced from local source with legal
authorization for supply.
2.5 Forests and timber (source - MT) No No forest and timber products will
be used.
2.6 Energy including electricity and fuels
(source, competing users) Unit: fuel
(MT),energy (MW) Yes
Connected Load will be 1500 KVA.
This power shall be utilized during
the start up of the plant only from
GEB Grid. During the regular
operation phase power will be
generated as a recovery from
resources in the tune of apprx. 0.2
MW. This surplus power shall be
used within the proposed facility or
rolled over to the GEB Grid.
CNG will be used as an auxiliary
fuel in the steam boiler during the
plant start up and heat up period.
During the regular operations phase
CNG shall be use as pilot flame fuel
only which shall be approximately
30 Kg./ Hr.
For Details please refer Energy
Balance attached vide
Annexure –IV
2.7 Any other natural resources (use
appropriate standard units) No No other natural resources are used.
3 Use, storage, transport, handling or production of substances or materials, which
could be harmful to human health or the environment or raise concerns about
actual or perceived risks to human health.
Sr.
No.
Information / Checklist
conformation.
Yes /
No.
Details thereof (with approximate
quantities / rates, wherever
possible) with source of
information data.
3.1
Use of substances or materials, which
are hazardous (as per MSIHC rules)
to human health or the environment
(flora, fauna, and water supplies)
Yes
The proposed facility will handle
waste capacity of 30 T/Day
hazardous solid waste and 15
Tons/day aqueous liquid waste
Refer Annexure II para 2.3.2 &
Annexure V
3.2 Changes in occurrence of disease or
affect disease vectors (e.g. insect or
water borne diseases) No
No change in occurrence of disease
due to proposed project.
3.3 Affect the welfare of people e.g. by
changing living conditions? No
The area is already well developed
and industrialized.
3.4
Vulnerable groups of people who
could be affected by the project e.g.
hospital patients, children, the elderly
etc.,
No
There will be no such effects due to
proposed project. The proposed site
is located in GIDC Estate.
3.5 Any other causes. No No other cause.
4 Production of solid wastes during construction or operation or decommissioning
(MT/month).
Sr.
No.
Information / Checklist
conformation.
Yes /
No.
Details thereof (with approximate
quantities / rates, wherever
possible) with source of
information data.
4.1 Spoil, overburden or mine waste. No No such waste will be generated
from the proposed project.
4.2 Municipal waste (domestic and or
commercial wastes) No
Trash papers & food waste is
expected to be generated by the
proposed project
4.3 Hazardous wastes (as per Hazardous
Waste Management Rules) Yes
Generation of other wastes such as
used oil, contaminated
containers/barrels; waste packing
materials, is envisioned. For details
please refer EMP provided vide
ANNEXURE - VI
4.4 Other industrial process wastes No
Vitrified Slag and Na2S solution
will be generated from the proposed
project activity as recovered
resources. For details please refer
ANNEXURE - VI
4.5 Surplus product Yes
Vitrified Slag and Na2S solution
will be generated from the proposed
project activity as recovered
resources. For details please refer
ANNEXURE - VI
Surplus power in the tune of 0.2
MW will be generated which shall
be either utilized within proposed
facility or rolled over to GEB Grid.
4.6 Sewage sludge or other sludge from
effluent treatment. Yes
Sewage shall be disposed in soak
pit/ septic tank.
4.7 Construction or demolition wastes YES
Solid waste generated from
construction activity shall be
utilized as filling and levelling of
low lying area within the proposed
facility. No demolition work is
needed.
4.8 Redundant machinery or equipment. No No such waste will be generated.
4.9 Contaminated soils or other
materials. No No such waste will be generated.
4.10 Agricultural waste. No No such waste will be generated.
4.11 Other solid wastes. No No extra waste will be generated
from the project.
5 Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr):
Sr.
No.
Information / Checklist
conformation.
Yes /
No.
Details thereof (with approximate
quantities / rates, wherever
possible) with source of
information data.
5.1 Emissions from combustion of fossil
fuels from stationary or mobile
sources Yes
Through DG sets which operate
temporarily during power failure
/emergency.
5.2 Emissions from production
processes. Yes
Compliance with the emission
standards: Guidelines of CPCB-Flue
gas emission standards.
Refer Annexure II Project basis para
1.7 & ANNEXURE –V & EMP
Vide ANNEXURE - VI
5.3 Emissions from materials handling
including storage or transport. Yes
Adequate measures will be taken to
control emissions from the storage
of input hazardous waste. Please
refer EMP Vide ANNEXURE - VI
5.4 Emissions from construction
activities including plant and
equipment YES
Adequate measures will be taken to
control emissions from the proposed
project. Please refer EMP Vide
ANNEXURE - VI
5.5 Dust or odours from handling of
materials including construction
materials, sewage and waste.
YES Please refer EMP Vide
ANNEXURE - VI
5.6 Emissions from incineration of
waste. Yes
Compliance with the emission
standards: Guidelines of CPCB-Flue
gas emission standards.
Refer Annexure II Project basis para
1.7 & ANNEXURE –V & EMP
Vide ANNEXURE - VI
5.7 Emissions from burning of waste in
open air (e.g. slash materials,
construction debris)
No No burning activities will be carried
out in the proposed unit.
5.8 Emission from any other sources. No No other emission from any other
sources.
6 Generation of Noise & Vibration and Emissions of Light & Heat:
Sr.
No.
Information / Checklist
conformation.
Yes /
No.
Details thereof (with approximate
quantities / rates, wherever
possible) with source of
information data.
6.1 From operation of equipment e.g.
engines, Ventilation plant, crushers. YES
Appropriate measure will be taken
to abate Noise pollution at source.
The noise levels will be well within
the prescribe units. Please refer
EMP Vide ANNEXURE - VI
6.2 From industrial or similar processes. No
No significant noise, vibration or
emission of light and heat from the
unit. The noise levels will be well
within the prescribe units.
6.3 From construction or demolition. No
No significant noise, vibration or
emission of light and heat from the
unit. The noise levels will be well
within the prescribe units.
6.4 From blasting or piling. No No such activities are involved.
6.5 From construction or operational
traffic. No
No significant noise, vibration or
emission of light and heat from the
unit. The noise levels will be well
within the prescribe units.
6.6 From lighting or cooling systems. No
No significant noise, vibration or
emission of light and heat from the
unit. The noise levels will be well
within the prescribe units.
6.7 From any other sources. No No emissions from any other
sources.
7 Risks of contamination of land or water from releases of pollutants into the
ground or into sewers, surface waters, groundwater, coastal waters or the sea:
Sr.
No.
Information / Checklist
conformation.
Yes /
No.
Details thereof (with approximate
quantities / rates, wherever
possible) with source of
information data.
7.1 From handling, storage, use or
spillage of hazardous materials. No
Proper storage facilities for the
handling of chemicals and waste
will be provided in the unit.
7.2
From discharge of sewage or other
effluents to water or the land
(expected mode and place of
discharge)
No
Treated effluent confirming the
CETP inlet norm shall be disposed
in CETP of BEAIL/ETL.
7.3 By deposition of pollutants emitted to
air into the land or into water No
All the air emissions will be well
within the prescribed limits.
7.4 From any other sources. No No other sources will be there.
7.5 Is there a risk of long term build up
of pollutants in the environment from
these sources? No
There will not be any long term
build up of pollutants in the
environment from these sources.
8 Risk of accidents during construction or operation of the Project, which could
affect human health or the environment.
Sr.
No.
Information / Checklist
conformation.
Yes /
No.
Details thereof (with approximate
quantities / rates, wherever
possible) with source of
information data.
8.1 From explosions, spillages, fires etc.
from storage, handling, use or
production of hazardous substances.
Yes
Moderate risk is envisioned. Risk
minimisation through minimum
storage of of waste.
8.2 From any other causes. Yes. Moderate risk is envisioned by hot
equipment/exposure to power.
8.3
Could the project be affected by
natural disasters causing
environmental damage (e.g. floods,
earthquakes, landslides, cloudburst
etc)?
No. Earthquake proof structures will be
made.
9
Factors which should be considered (such as consequential development) which
could lead to environmental effects or the potential for cumulative impacts with
other existing or planned activities in the locality.
Sr.
No.
Information / Checklist
conformation.
Yes /
No.
Details thereof (with approximate
quantities / rates, wherever
possible) with source of
information data.
9.1
Lead to development of supporting
localities, ancillary development or
development stimulated by the
project which could have impact on
the environment e.g.:
• Supporting infrastructure (roads,
power supply, waste or waste water
treatment, etc.)
• housing development
• extractive industries
• supply industries
• other
No
The GIDC notified area is already
well developed and proposed
activity will not have significant
impact on the locality
9.2 Lead to after – use of the site, which
could have an impact on the
environment.
No There will not be any significant
impact on the environment.
9.3 Set a precedent for later
developments. YES
“ THIS PROJECT WILL SET
AN EXAPLE OF
HAZARDOUS WASTE
TREATMENT USING MOST
ENVIROMENTAL
FRIENDLY TECHNOLOGY
AND IT WILL CHART A
WAY FOR ALL FUTURE
PROJECTS PLANNED FOR
THE TREATMENT OF
HAZARDOUS WASTE”
9.4 Have cumulative effects due to
proximity to other existing or
planned projects with similar effects. Yes
THIS PROJECT WILL
SIGNIFICANTLY REDUCE
HAZARDOUS WASTE
STORAGE AT ANY POINT
OF TIME FACILITATING
DISPOSAL OF HAZARDOUS
WASTE & REDUCE
ACCUMULATION OF
HAZARDOUS WASTE IN
ANKLESHWAR AREA.
(III) ENVIRONMENTAL SENSITIVITY.
Sr.
No. Area.
Name /
Identity
Aerial distance (within 15 km.)
Proposed project location boundary.
1
Areas protected under international
conventions, national or local
legislation for their ecological,
landscape, cultural or other related
value.
No.
Not Applicable
2
Areas which are important or
sensitive for ecological reasons -
Wetlands, watercourses or other
water bodies, coastal zone,
biospheres, mountains, forests.
No.
Not Applicable
3
Areas used by protected, important
or sensitive species of flora or fauna
for breeding, nesting, foraging,
resting, over wintering, migration.
No.
Not Applicable
4 Inland, coastal, marine or
underground waters.
5 State, National boundaries. No. Not Applicable
6
Routes or facilities used by the
public for access to recreation or
other tourist, pilgrim areas.
No.
Not Applicable
7 Defense installations. No. Not Applicable
8 Densely populated or built – up area.
Anklesh
war &
Bharuch
city
Approximate distance – 9 kms &
14 kms respectively.
9
Areas occupied by sensitive man-
made land uses (hospitals, schools,
places of worship, community
facilities)
No.
Not Applicable
10
Areas containing important, high
quality or scare resources (ground
water, surface resources, forestry,
agriculture, fisheries, tourism,
minerals)
No.
Not Applicable
11
Areas already subjected to pollution
or environmental damage. (those
where existing legal environmental
standards are exceeded)
Anklesh
war.
The proposed project is located
within the GIDC estate,
Ankleshwar, which has been
declared as critical problem area by
CPCB
12
Areas susceptible to natural hazard
which could cause the project to
present environmental problems
(earthquakes, subsidence, landslides,
erosion, flooding or extreme or
adverse climatic conditions)
No. Not Applicable
ANNEXURE-I
PLANT LAYOUT
ANNEXURE-II
WASTE TREATMENT & RESOURCE
RECOVERY PROCESS
(Using PEAT Proprietary PTDR Technology)
1. Project Basis
2. Project Description
3. Process Flow Diagram
4. Material Balance
1. Project Basis
1.1 Waste Disposal Capacity: 45 Tons/Day
1.1.1 PTDR-1000 Plant:
Capacity 30 Tons/Day
Avg Feed Calorific Value of Waste: 4000 kcal/kg
Feed Rate of Waste: 1.5 Tons/hr
(Single Stream, at avg
CV of Waste)
Thermal Capacity: 6.0 Million
kcal/hr
Operating Hours: 7200 hrs/year
1.1.2 Multi Effect Evaporation Plant:
Capacity 15 Tons/Day
Avg Feed Calorific Value of Waste: < 500 kcal/kg
Waste Criteria: Non volatile, Toxic
compound, high TDS,
requires thermal
treatment for disposal.
Target Waste reduction: 75-80%
Residual Mass Treatment: to PTDR-1000 plant
for thermal
destruction
Operating Hours: 7200 hrs/year
1.2 Operation Range
Both plant will be designed to operate between 60% and 100% capacity with
respect to thermal capacity of the feed.
1.3 Waste Characteristics
Table 1.1: Waste Characteristics
Type of Waste Type 1
Packed
Waste(drums)
Type 2
Loose Solid
Waste
Type 3
Liquid Waste
High CV
Type 4
Liquid
Waste Low
CV
Type 5
Slurry and
Sludge
Waste
Distribution,
TPD
6 18 3 15 3
Mode of
Treatment Direct to
PTDR-1000
Direct to
PTDR-1000
Direct to
PTDR-1000
Volume
reduction in
MEE and
residues to
PTDR-1000
Direct to
PTDR-1000
Avg Calorific
Value
(Kcal/kg)
3094 3756 6670 <500 5566
Free Moisture
Content wt% 15 14 3 80 5
Inorganic
Content wt% 12 5 2 5 1
Halogens
Average in % 2
(F+Br+I < 1%)
2
(F+Br+I <
1%)
2
(F+Br+I <
1%)
2
(F+Br+I <
1%)
2
(F+Br+I <
1%)
Sulfur
Average in % 2 2 2 2 2
Consistence Powder, Solid,
Semi-solid,
Liquid
Solid
Powdery
Liquid with
impurities
Liquid with
impurities Viscous
Particle Size
Max size in
mm
500 500 <3 mm < 3 mm < 3 mm
Strips
Max size in
mm
<1000 <1000 - - -
Heavy Metals < 1%
Ultimate Analysis Considered for the process design of PTDR-1000 is tabulated as under
in table 1.2.
Combined
Waste
Packed
Solid
Waste
(Drums)
Loose
solid
Waste
(Bags)
Liquid
waste high
CV
Liquid
Waste
Low
CV
Slurry and
Sludge
Type 1 Type 2 Type 3
Type
4 Type 5
% DISTRIBUTION 100.00 20 55 10 5.00 10
QUANTITY Kg/hr 1500 300 825 150 75.00 150
COMPOSITION % by wt
CARBON C 47.50 42 47 66 7 63
HYDROGEN H 3.05 2 3 6 0 4
OXYGEN O 23.25 24 26 18 3 22
NITROGEN N 1.00 1 1 1 1 1
CHLORIDE Cl 2.00 2 2 2 2 2
SULFUR S 2.00 2 2 2 2 2
MOISTURE H20 15.50 15 14 3 80 5
INORGANIC/INERT 5.70 12 5 2 5 1
TOTAL 100.00 100.00 100.00 100.00 100.00 100.00
GCV KCAL/KG 3932.54 3094.00 3756.45 6670.05 481.38 5566.15
NCV KCAL/KG 3842.64 3007.00 3675.25 6652.65 17.38 5537.15
Table 1.2: Ultimate Analysis of Waste
Notes:
For design of PTDR-1000 design small fraction of Type 4 waste is considered to
directly inject into plasma furnace for accounting some waste categories which can
not be concentrated if those waste consists of volatile solvents and are not fit for
taking into Multi Effect Evaporator plant.
Maximum Limit of Hg+Cd+Th will be < 0.3 ppm by weight in combined waste.
Maximum Drum Size: Drum size of 500 mm diameter and 500 mm height can be
accepted in Plasma Reactor if drum is fed in horizontal position. Client to make sure
that when drum is kept in horizontal position waste does not spill out. Feeding of steel
drum will result in more energy consumption for melting of drum metal. If drum of
HDPE material is used it will save the energy cost to client and also reduce damage of
refractory lining.
1.4 Waste Heat Boiler
Steam Pressure: 40 kg/cm2 g
Steam Temperature: 400 deg C
Steam Flow Rate: 6.5 Tons/hr with Boiler Feed
Water at 100 deg C
1.5 Power Plant
Turbine: Condensing Type
Turbine Rating: 1.3 MW
Steam Rating: 5.2 Kg/Kwh
1.6 Utilities
1.6.1 GIDC water will be available as process water for use in plant. Specification of
GIDC water shall be as under.
pH: 6.5 to 7.5
Total Dissolved Salts: < 300 mg/lit
Total Hardness: < 120 mg/lit
Suspended Particles: < 25 mg/lit
1.6.2 Grid Electric Power from GEB will be available with following rating
Voltage: 11/ 22 / 33 KVA (Subject to confirmation from local GEB
authority), 3 Phase
Frequency: 50 Hz
1.7 Emission Standards
While operating at 100 % rated capacity, emission limit from the discharge of
stack shall be as under:
Parameter Emission Limit (mg/Nm3)
Particulates 50
HCl 50
SO2 200
CO 100
TOC 20
HF 4
NOX (NO and NO2 expressed 400
expressed as NO2)
Note: All values above shall be corrected to 10% oxygen on dry volume basis.
Hydrocarbon: 10 ppm, over an hourly rolling average on dry basis, measured as
propane.
Opacity: While operating properly at 100% rated capacity, the system shall have
visible emission rate of less than on equal to 10%, except for condensed water
vapour, from the discharge of stack (one hour rolling average ).
Dioxin / Furans: While operating at 100% rated capacity, the system shall have an
emission of dioxin and furans less than or equal to 0.1 ng TEQ / Nm3 corrected to
10% Oxygen. Sampling period shall be minimum 6 hours and maximum 8 hours.
Metals: While operating properly at rated capacity, the system shall have an
emission rate from the discharge of stack to atmosphere less than or equal to
Metals: Emission Limit (mg/NM3)
Cd+Th (& it’s compounds) 0.05
Hg (& it’s compounds) 0.05
Sb+As+Pb+Cr+Cu+Mn+Ni+V (& it’s compounds) 0.5
Note: All values above shall be corrected to 10% oxygen on dry volume basis.
1.8 Design Standard
ENPRO will follow good engineering practice for gas and liquids which either operates
at ambient conditions or near to ambient conditions and at less than 3.5 kg/cm2 g
operating pressure.
For design of pressure parts and vessels (especially boiler system) ENPRO will follow
ASME standards for design.
2. Project Basis
2.1 Project Objectives
The proposed project will be carried out under a project-specific Joint Venture that would
be established by a team led by PEAT International for the deployment of a proprietary
Plasma Thermal Destruction and Recovery (PTDR) system with a process capacity of 30
metric tons per day of industrial/hazardous solid, semi-solid and organic liquid (non-
aqueous) wastes. The system shall be designed to use the energy-rich syngas generated by
the PTDR system to generate electricity and dewater an expected total of 15,000 litres of
aqueous organic liquid wastes per day. The resulting solids generated by the dewatering
operations (approximately 20% moisture content) would then be processed in the PTDR
along with the other industrial/hazardous wastes.
The PTDR facility would be installed at a site within the Ankleshwar Industrial Estate in
Gujarat, India. The facility will have following objectives
To collect & receive the industrial hazardous wastes required to de destruct
through thermal treatment generated from the various industries situated in and
around Bharuch District.
To ensure safe and proper storage of the wastes receipt at site with respect to their
classification, characterization and compatibility. To ensure minimum storage
inventory at site limited to 30 days storage maximum.
To provide hazardous waste treatment using Plasma Thermal Destruction and
Recovery System (PTDR).
To educate and make the individual industry aware of storing the hazardous waste
in scientific manner and comply with the regulations.
To educate the industry to minimize the generation of hazardous waste at source
and manage the industrial growth in sustainable manner.
The project will provide the following benefits to the Ankleshwar Industries Association
(AIA) and vicinity:
Provide the ability to significantly expand the current treatment capacity for
industrial/hazardous wastes for AIA and other industrial facilities in the vicinity
Present an innovative and cost-effective use of the valuable alternative energy
produced by the syngas generated by the PTDR system that will allow for a
significant increase in the capacity of the plant to process aqueous organic wastes
(currently these wastes are typically incinerated, but due to their high water content
– approximately 92% - their calorific value is very low and thus require very high
consumption of fossil fuels during the incineration process).
In addition to the energy used in the processing of aqueous organic wastes, the
energy-rich syngas would be used in an onsite energy recovery system to produce
electric power that will supply the needs of the PTDR system with excess electric
power available to be supplied to the grid.
The Project is projected to result in a net reduction of CO2 emissions and should
therefore qualify for Clean Development Mechanism benefits.
Offer the above benefits while exhibiting the highest levels of safety and
environmental compliance. PTDR systems produce virtually no secondary wastes;
while generating valuable end-products with commercial value. Emissions from the
PTDR shall be far below regulatory limits (and significantly lower than current
regulatory standards). PTDR systems do not produce any harmful pollutants such
as dioxins and furans.
This project will utilize the proprietary and patented PTDR technology, PEAT's
environmentally benign process converts waste streams into three end-products:
a clean synthesis gas (“syngas”)
an inert glass silicate
a Na2S solution from scrubber as by product and
recovered metal alloys
Simply put, organic constituents of the feedstock is shifted into syngas to generate valuable
alternative energy (such as electric power, thermal energy or it can be used to create liquid
fuels such as ethanol) and inorganic constituents of the feedstock melt and are converted
into a hard, non-leachable glass product that can be used for a variety of commercial
purposes; sulfur content of feed stock is converted into Sodium Sulfide Solution which is
commercially saleble product; metal constituents in the feedstock are also recovered as a
pure metal or metal alloy. Essentially, all of the waste feedstock is converted into usable
end-products thus there is a 100% utilization of the waste, which totally eliminates the need
for a landfill.
The technology uses the ultra-high thermal energy from a plasma generation system (e.g.
torches) in an oxygen starved environment to first, pull apart the molecules that make-up
organic constituents of the waste, then, through the addition of controlled amounts of pure
oxygen and steam the dissociated molecules reform the base elements into the syngas,
consisting mainly of Carbon Monoxide (CO) and Hydrogen (H2) to be used as a fuel.
Inorganic waste, (e.g. batteries, printed circuit boards) is vitrified into an environmentally
safe glass silicate and recovered metal alloys.
The PTDR process provides a unique, cost-effective and virtually emissions-free
technology that is superior to other mainstream methods of waste treatment:
The PTDR process can utilize virtually any type of feedstock containing
combinations of organic, inorganic and heavy-metal constituents.
The PTDR process brings inherent synergies whereby the treatment of inorganic and
organic feedstock streams can be processed together, thus the pre-processing, staging
and management costs are minimized thereby reducing processing costs and
enhancing revenue streams.
Unlike incineration or metal-bearing waste stabilization, the PTDR process does not
create any secondary wastes that will require further treatment or landfilling. For
example, in addition to the excessive air pollution generated by the combusted flue
gases, incinerators produce large quantities of bottom and fly ash which are toxic in
nature, require further treatment (with stabilization agents) and the resulting post-
treated materials (whose disposal volume has been doubled by the addition of
stabilizing agents) will require final disposal, usually in specially designed hazardous
waste landfills.
The syngas end-product generated from processing the organic portions of the
feedstock is a valuable source of Alternative Energy (Approximate heat value: 9 to 11
MJ/Nm3, ~2,150 Kcal/Nm3 to 2,625 Kcal/Nm3). The synthesis gas end-product can
be used to generate thermal energy (that can offset the purchase of fossil fuels or
produce process steam), electricity and/or as a feedstock for the production of liquid
fuels such as ethanol. In addition, the hydrogen-rich composition of the syngas can
provide a valuable and in-expensive source of hydrogen for industrial, energy (e.g.
fuel cells), or transportation uses.
In February, 2008, PEAT successfully commissioned a demonstration PTDR-100
system at the Ankleshwar GIDC, adjacent to the Jayaben Modi Hospital. The
PTDR-100 is a fully self-contained waste processing platform with a design-basis
capacity of 60 kg/hr. During the demonstration phase, the PTDR-100 successfully
processed a wide range of waste streams generated by local Industries within the
Ankleshwar GIDC. The PTDR-100 system was designed and manufactured solely with
indigenous resources within India. PEAT therefore has the distinction of being the first
technology provider in India that can deploy a waste management solution that supports
the goals of sustainable development. The PTDR technology is NOT incineration and,
indeed, is far superior to incineration.
PTDR Incineration
• Mass-less heat created from
plasma torch at very high
temperatures– heat value of waste
is irrelevant to the process
• Molecular Dissociation of organic
wastes in an oxygen-starved
environment and vitrification of
inorganic constituents
• Uniform, reactor temperatures
above 1,500°C (plasma “plume”
temperature > 6,000 deg. C);
Controlled processing atmosphere
• Volume of gases generated by the
process are low, thus reducing the
complexity and size of the system
components
• Depending on waste composition
treated, PTDR generates 2 to 4
times the thermal energy that it
consumes
• No bottom or fly ashes generated
• Production of dioxins or furans is
impossible (due to factors such as,
high temperatures, oxygen starved
environment)
• No bottom or fly ashes generated;
no solid wastes requiring landfill
disposal
• Generates valuable end-products
• Combustion –excess air required
• Heat value of waste required to
maintain combustion reaction or
supplementary fossil fuels
required
• Operating temperatures around
1,000 °C (potential for “cold”
spots in the furnace
• Large volumes of off-gas
generated
• “Cold” spots, excess oxygen in
the furnace, unreacted carbon
due to incomplete combustion
can result in the formation of
unwanted pollutants, including
Dioxins and Furans
• Fly and bottom ash treatment
and landfill disposal needed
2.2 Site
PTDR project is proposed at Plot No 9602 in GIDC estate of Ankleshwar. The plot has
been allotted by GIDC. Plot size is 10000 M2. Key plan and Plot Plan of proposed site is
enclosed.
2.3 Project Component
Proposed PTDR project will have following major activities:
Collection and Transportation of Hazardous Waste to proposed facility
Storage of Hazardous Waste to Max 30 days of plant operation capacity.
Treatment of Hazardous Waste using PTDR System and conversion of waste into
resources.
The entire facility will be divided into the following components
1. Dedicated collection and transportation Vehicle for waste.
2. Weighing of incoming waste to site.
3. Laboratory for testing of incoming waste and for monitoring of plant
performance.
4. PTDR (Plasma Thermal Destruction and Recovery) System with Power Plant
using syn gas generated from the facility.
5. Multi Effect Evaporation (MEE) system for concentration of Aqueous waste.
6. Bleed Recycle Plant
7. Utilities: Cooling Tower, Water Treatment Plant, O2 & N2 Plant, Compresed Air
System, Power Distribution System
8. Administration Office
9. Maintenance Room
10. Emergency Exit Gate
11. Approach Roads
12. Wheel Washing Stations
13. Green Belt
2.3 Process Description
2.3.1 Pre Shipment Waste Analysis
Before a facility receives waste, waste profiling including a detailed chemical & physical
analysis of a representative sample of waste will be carried out. The purpose of the full
characterization before shipment is to satisfy the following requirements.
Determine if the waste is acceptable for receipt at the facility in terms of (a) the
facility’s permit and (b) the capability of the facility to treat or dispose of the waste.
Identify the inherent hazards of the waste so that appropriate precautions can be taken
during its handling and storage at the facility to prevent incidents.
Determine the physical characteristics and chemical constituents of the waste to allow
selection of effective waste processing and disposal methods.
Select the verification parameters to be tested upon arrival at the facility. These
parameters would ensure that each shipment of waste is the same type as the fully
characterized waste.
Select any treatability parameters to be tested that could vary so as to influence how
waste processing would be programmed.
Develop an estimate of the cost of treatment or disposal.
Finger print and bar code will be developed for each type of waste. Waste profile will be
recorded and documented.
2.3.2 Transportation of Hazardous Waste
Transportation is one of the most important areas of concern associated with handling
HW because the packaging and method of transporting HW will determine the
likelihood that an accident or spill with occur. Proper and rapid identification of a
spilled substance will determine how effectively and safely the situation can be
controlled.
Off-side transportation requirements involve proper:
Container: appropriate material, leak proof, mechanical stability...
Labeling of container: Identification, description…
Vehicles: equipment, labeling...
Collector/transporter: technical competence and relevant skills and other
requirements.
License/Manifest : application and documents,
Emergency procedures: spills, accidents...
Fees and fines : license, break of regulation
On site transportation typically involves smaller amounts of materials over shorter
distances. On-site transport does, however, pose significant risks from the frequency
of the activity and the lack of proper regulation. It is ensured that hazardous wastes
are packaged, based on the composition in a manner suitable of handling, storage and
transport. The labeling and packaging is required to be easily visible and be able to
withstand physical conditions and climatic factors.
The facility will meet following transportation requirement for hazardous waste:
Regulatory requirements of packaging, labeling and transportation of hazardous
wastes are given under Rule 7 of Hazardous Wastes (management & Handling )
Rules, 1989, as amended, notified under the Environment (Protection) Act, 1986
Shall possess requisite copies of the certificate (valid authorization obtained from the
concerned SPCB/PCC for transportation of wastes by the waste generator and
operator of a facility) for transportation of hazardous waste.
Shall have valid “Pollution Under Control Certificate” (PUCC) during the
transportation of HW and shall be properly displayed.
Vehicles shall be painted preferably in blue colour with white strip of 15 to 30 cm
width running centrally all over the body. This is to facilitate easy identification.
Vehicle shall be fitted with mechanical handling equipment as may be required for
safe handling and transportation of the wastes.
The words "HAZARDOUS WASTE" shall be displayed on all sides of the vehicle in
Vernacular Language, Hindi, English.
Hazardous waste shall be packaged in a manner suitable for safe handling, storage
and transportation. Labeling on packaging shall be readily visible & material used for
packaging shall withstand physical and climatic conditions
Information regarding characteristics of wastes particularly in terms of being
Corrosive, Reactive, Ignitable or Toxic will be is provided on the label.
All hazardous waste containers shall be provided with a general label as given in
Form 12 in Hazardous Waste (Management & Handling) Rules, 1989, as amended
Transporter shall not accept hazardous wastes from an occupier (generator) unless
six-copy (with colour codes) of the MANIFEST (Form 13) is provided by the
generator. The transporter shall give a copy of the manifest signed and dated to the
generator and retain the remaining four copies to be used for further necessary action
prescribed in the Hazardous Wastes (Management & Handling) Rules, 1989, as
under:
Copy 1 (White) Forwarded to the Pollution Control Board by the
occupier
Copy 2 (Light
Yellow)
Signed by the transporter and retained by the
occupier
Copy 3 (Pink) Retained by the operator of a facility
Copy 4 (Orange) Returned to the transporter by the operator of
facility after accepting waste
Copy 5 (Green) Forward to Pollution Control Board by the operator
of facility after disposal.
Copy 6 (Blue) Returned to the occupier by the operator of the
facility after disposal.
Generator shall provide the transporter with relevant information in Form 11 i.e.
Transport Emergency (TREM) Card regarding the hazardous nature of the waste and
measures to be taken in case of an emergency.
Name of the facility operator or the transporter, as the case may be, shall be
displayed.
Vehicle shall be fitted with roll-on / roll-off covers if the individual containers do not
possess the same.
Carrying of passengers is strictly prohibited and those associated with the waste
haulers shall be permitted only in the cabin.
Transporter shall carry documents of manifest for the wastes during transportation as
required under Rule 7 of the Hazardous Waste (M & H) Rules, 1989, as amended.
The trucks shall be dedicated for transportation of hazardous wastes and they shall
not be used for any other purpose.
Each vehicle shall carry first-aid kit, spill control equipment and fire extinguisher.
HW transport vehicle shall run only at a speed specified under Motor Vehicles Act in
order to avoid any eventuality during the transportation of HW.
Educational qualification for the driver shall be a minimum of 10thpass (SSC). The
driver of the transport vehicle shall have valid driving license for heavy vehicles from
the State Road Transport Authority and shall have experience in transporting the
chemicals. Driver(s) shall be properly trained for handling the emergency situations
and safety aspects involved in the transportation of hazardous wastes.
The design of the trucks shall be such that there is no spillage during transportation.
Packaging of Containers
The packing containers shall be able to withstand normal handling and retain integrity
for a minimum of six months. In general, packaging for hazardous substances shall
meet the following requirements:
Items shall be of such a strength; construction and type as not break open or become
defective during transportation.
Items shall be constructed and closed in a manner to prevent spillage of hazardous
substances.
Re-packaging materials including fastening shall not be affected by the contents or
form a dangerous combination with them.
Labelling
There are two types of labelling requirements:
Labelling of individual transport containers
Labelling of transport vehicles.
All hazardous wastes containers shall be clearly marked with current contents. The
marking shall be water proof and firmly attached so that they cannot be removed.
Previous content labels, when different, shall be obliterated. Proper marking of
containers is essential.
Containers that contain HW shall include the words "HAZARDOUS WASTE". The
information on the label shall include the code number of the waste, the waste type,
the origin (name, address, telephone number of the generator), hazardous property
(e.g. flammable) and the symbol for the hazardous property (e.g. the red square with
flame symbol).
The label shall withstand the effects of rain and sun. Labelling of containers is
important for tracking the wastes from the point of generation up to the final disposal.
The label shall contain the name and address of the waste management facility where
it is being sent for treatment and final disposal.
Emergency contact phone number shall be prominently displayed. For example
respective Regional Officer of the Station Pollution Control Board, Fire Station,
Police Station.
2.3.3 Waste Receipt at site
After arriving of the shipment at the gate following steps would be followed.
Check the pre shipment analysis has already completed and the shipment scheduled.
Weighing of truck.
Representative sample is collected for testing & verification of parameters.
Laboratory analysis for verification.
Truck is directed to designated storage space for the incoming waste.
After unloading truck is directed to wheel wash area.
The truck is then reweighed before it leaves the facility.
An Analysis Laboratory will have following min facility:
COD, BOD & TOC Apparatus
Spectrophotometer
Muffle Furnace & Laboratory oven
Atomic Absoprtion Spectorphotometer
Stirrer Magnetic & Electric
Water Bath & Hot Plate
pH Meter
Hardness, TDS Meter
2.3.4 Hazardous Waste Storage
For hazardous waste storage following will be implemented:
Storage Area (Storage Shed)
Flammable, ignitable, reactive and non-compatible wastes shall be stored separately
and never shall be stored in the same storage shed. There will be separate and
designated storage area for such waste.
In order to minimize risk of storage of hazardous waste the facility will not stored for
more than 30 days waste at site. In normal operating condition waste storage will be
limited to max 10 days only.
Storage area shall be designed to withstand the load of material stocked and any
damage from the material spillage.
Storage area shall be provided with the flameproof electrical fittings and it shall be
strictly adhered to.
Automatic smoke, heat / temp detection system and auto water sprinkler with alarm
shall be provided in the sheds.
Adequate fire fighting systems shall be provided for the storage area, along with the
areas in the facility.
Loading and unloading of wastes in storage sheds shall only be done under the
supervision of the well trained and experienced staff.
Fire break of at least 04 meter between two blocks of stacked drums shall be provided
in the storage shed. One block of drum shall not exceed 300 MT of waste.
Minimum of 1 meter clear space shall be left between two adjacent rows of drums in
pair for inspection.
The storage and handling shall have at least two routes to escape in the event of any
fire in the area.
Doors and approaches of the storage area shall be of suitable sizes for entry of fork
lift and fire fighting equipment;
The exhaust of the vehicles used for the purpose of handling, lifting and
Transportation within the facility such as forklifts or trucks shall be fitted with the
approved type of spark arrester.
In order to have appropriate measures to prevent percolation of spills, leaks etc. to the
soil and ground water, the storage area shall be provided with concrete floor
depending on the characteristics of waste handled and the floor must be structurally
sound and chemically compatible with wastes.
Measures shall be taken to prevent entry of runoff into the storage area.
The Storage area shall be designed in such a way that the floor level is at least 150
mm above the maximum flood level.
The storage area floor shall be provided with secondary containment such as proper
slopes as well as collection pit so as to collect wash water and the leakages/spills etc.
All the storage yards shall be provided with proper peripheral drainage system
connected with the sump so as to collect any accidental spills in roads or within the
storage yards as well as accidental flow due to fire fighting.
Storage Drums/Containers
The container shall be made or lined with the suitable material, which will not react
with, or in other words compatible with the hazardous wastes proposed to be stored.
The stacking of drums in the storage area shall be restricted to three high on pallets
(wooden frames). Necessary precautionary measures shall be taken so as to avoid
stack collapse. However, for waste having flash pointless than 65.5 O C, the drums
shall not be stacked more than one height
No drums shall be opened in the storage sheds for sampling etc. and such activity
shall be done in designated places out side the storage areas;
Drums containing wastes stored in the storage area shall be labelled properly
indicating mainly type, quantity, characteristics, source and date of storing etc.
Container shall be of mild steel with suitable corrosion and roll-on roll-off cover
which may either be handled by articulated crane or by a hook lift system works
comfortably for a large variety of wastes.
Other modes of packaging like collection in 200-L MS and plastic drums, card board
cartons, PP and HDPE/LDP containers also works for variety of waters. However, all
such containers shall be amenable to mechanical handling. It shall be leak proof.
In general, containers for liquid HW shall be completely closed (in fact: sealed).
There shall be no gas generation due to chemical reaction and therefore, no need for
air vents; expansion due to temperature increase/decrease normally does not need air
vents.
Container shall be covered with a solid lid or a canvas to avoid emissions, spillage,
and dust and to minimize odour generation both at the point of loading as well as
during transportation.
Container shall be easy to handle during transportation and emptying. As far as
possible manual handling of containers shall be minimized. Appropriate material
handling equipment is to be used to lad, transport and unload containers. This
equipment includes drum, dollies, forklifts, drum handling equipment, lift gates and
pallets. Drums shall not be rolled on or off vehicles.
Where 2-tier or 3-tier storage is envisaged the frames will have adequate strength to
hold the container.
The multi-use containers shall be re-usable. One-way containers (especially 160 I -
drums) are also allowed.
Loads are to be properly placed on vehicles. HW containers are not to overhang,
perch, lean or be placed in other unstable positions. Load shall be secured with straps,
clamps, braces or other measures to prevent movement and loss. Design of the
container shall be such that it can be safely accommodated on the transport vehicle.
Dissimilar wastes shall not be collected in the same container. Wastes shall be
segregated and packed separately. This is necessary to ensure that each waste finds its
way to the right disposal pathway.
Occupier/hazardous waste generator shall not resort to the dilution of wastes
(predominantly organic wastes).
Spillage/leakage control measures
The storage areas shall be inspected daily for detecting any signs of leaks or
deterioration if any. Leaking or deteriorated containers shall be removed and ensured
that such contents are transferred to a sound container.
Incase of spills / leaks dry adsorbents/cotton shall be used for cleaning instead of
water.
Proper slope with collection pits be provided in the storage area so as to collect the
spills/leakages.
Storage areas shall be provided with adequate number of spill kits at suitable
locations. The spill kits shall be provided with compatible sorbent material in
adequate quantity.
Record Keeping and Maintenance
Proper records with regard to the industry –wise type of waste received,
characteristics as well as the location of the wastes that have been stored in the
facility shall be maintained.
Miscellaneous
Smoking shall be prohibited in and around the storage areas.
Good house keeping shall be maintained around the storage areas
Signboards showing precautionary measures to be taken, in case of normal and
emergency situations shall be displayed at appropriate locations.
To the extent possible, manual operations with in storage area are to be avoided.
Incase of manual operation, proper precautions need to be taken, particularly during
loading / unloading of liquid hazardous waste in drums.
A system for inspection of storage area to check the conditions of the containers,
spillages, leakages etc. shall be established and proper records shall be maintained.
The wastes containing volatile solvents or other low vapor pressure chemicals shall
be adequately protected from direct exposure to sunlight and adequate ventilation
shall be provided.
Tanks for storage of liquids waste shall be properly dyked and shall be provided with
adequate transfer systems.
Storage sites shall have adequate & prompt emergency response equipment systems
for the hazardous waste stored on-site. This shall include fire fighting arrangement
based on the risk assessment, spill management, evacuation and first aid.
Immediately on receipt of the hazardous waste, it shall be analyzed and depending
upon its characteristics its storage shall be finalized.
Only persons authorized to enter and trained in hazardous waste handling procedures
shall have access to the storage site.
Mock drill for onsite emergency shall be conducted regularly and records maintained.
2.3.5 PTDR Process Description
Plasma Thermal Destruction and Recovery (PTDR) plant consists of following major
components
Waste Feed System: Solid and Liquid Waste Feed System, fork lift for drum amd
waste conveying, drum crusher, drum unloading and pumping system.
Plasma Reactor
Molten slag quenching and granulation system
Spray Dryer
Gas Conditioning and Cleaning System
Bag House
HCl Scrubbing System
Alkali Scrubbing System and Na2S recovery system
Solution preparation tanks.
ID Fan
PSA Plant for Nitrogen and Oxygen generation
Plasma Torch and Plasma Power Supply System
Syn Gas Utilization System: Syn Gas High Pressure Boiler, Auxiliary fuel supply and
burner, Condensing type Steam Turbine, Alternator and Power Panel
Exhaust Stack
PCC/MCC Panel, Substation, synchronizing panel, emergency DG Set.
Instrumentation and Control System
Raw water storage tank, elevated water storage tank, Water Treatment Plant, water
storage tank.
Cooling tower and cooling water circulation system
Air Compressor and compressed air network
Plant bleed water collection and recycling system
Fire water storage tank, fire water pumps and fire hydrant network and system. Fire
detection, alarm, auto sprinkler system, fire extinguisher.
Description of major sub system of PTDR plant and process is
described as under
2.3.5.1: Feed system
Solid Waste Feeding System:
1. Solid and semi-solid waste will be collected and received in various containers.
The maximum size of any waste material which can not be twisted / bent will not
be more than 400 mm. It means that any part will not have length more than 400
mm. The feed door to the system will have clear opening of 600 mm on both
sides:
2. Member Industries will be guided for packing of waste in drums and bags and
will be provided required dimensions of packing material so that waste which is
received at site will not be required to rehandle and repacked. However, till
member industries are not completely trained and till there is resistance in
adapting the packing material dimensions PEAT will follow following
methodology for handling of waste
3. Waste which is received in drums of 200 litres and if drum consists of material
which can be removed and repacked safely the contents repacked in smaller sized
containers and/or HDPE bags of acceptable size for charging into the reactor.
4. Drums whose contents cannot be removed for repacking would require pre-
treatment. While it is possible to charge the reactor with entire drums, the
contents of the drums must be such that the total quantity of organic material
contained in the drum is deemed to be within the ability of the reactor system to
accept the material without causing an overpressure condition in the furnace once
the material in the drum is exposed to the high temperature, reducing environment
of the plasma reactor. Given that the nature of wastes generated in the
Ankleshwar region is such that in all likelihood drummed wastes will have a high
calorific value, thus charging entire drums into the reactor would likely cause an
overpressure condition and the resulting “spike” in gas generation would
overwhelm the capacity of the Gas Conditioning and cleaning system.. Therefore,
for such types of wastes, the drums would be collected, sampled/evaluated and
prior to charging into the reactor, they would be processed in an on-site drum
crushing/shredding system. The drum crusher/shredding system would be
operated in an inert Nitrogen environment (Nitrogen to be supplied by an on-site
PSA system). The crushed/shredded contents would then be repacked into smaller
sized containers for charging into the plasma reactor.
5. Solid, Semi-solid/tarry wastes which are collected in HDPE bags or
drums/containers of acceptable size would be charged directly into the reactor at
the appropriate feeding interval, consistent with the design basis capacity of the
PTDR system, 1,500 kg/hr (25 kg/minute).
6. The solid Waste feed system will consist of two components: a solid waste feeder
outfitted with a hydraulically operated ram and gravity feed system, capable of
charging appropriately sized or shredded solid wastes into the reactor. The ram
feeding and gravity feeding systems will have double door systems. When waste
is charged to charging hopper(s), the hopper door will be kept open with plasma
reactor door in closed condition. After charging cycle is over hopper door will be
closed and plasma reactor door will be opened. For the case of the ram feeder,
after opening plasma reactor door Ram Pusher will push the waste inside the
plasma reactor at pre decided speed.
7. The hydraulic doors and ram operating mechanism sequences are interlocked
ensuring process safety and the continuity of feed. The section of the feeder
closest to the plasma reactor is refractory-lined to ensure the feeding chamber
remains within a prescribed temperature limit, also ensuring that any plastic bags
containing waste do not thermally degrade in the ram feeding chamber. A load
cell monitors the quantity of feedstock being introduced into the feeding
subsystem.
8. The total Capacity of the Solids Feeding System will be 1,500 kg/hr.
9. Liquid Waste Feeding System:
Liquid wastes are assumed to be “pumpable” and will be pumped from one or
more “Day Storage tank(s)” or directly from individual drums by an appropriately
sized pumping system, whose configuration and materials will be consistent and
compatible with the nature of the liquid wastes to be processed. The liquid wastes
will be pumped into the plasma reactor through one or more water-cooled spray
nozzles.
The capacity of the Liquids Feeding System will be in the range of 750 to
1,000 kg/hr
2.3.5.2 Plasma Reactor
The waste then enters the plasma reactor (with a design volume of approx 9.0 m3) made
of mild steel and lined with refractory and insulation, where the high temperature created
by the plasma torches will dissociate the molecules that make up the waste into their
elemental constituents. The dissociated constituents of the waste are then “re-formed”
(through the addition of stoichiometric amounts of oxidant: oxygen and/or steam) into a
synthesis gas, comprised mainly of Carbon Monoxide and Hydrogen gas. The plasma
reactor allows for a residence time of 2.0 seconds based on design basis gas flow. The
refractory and insulating materials are selected and designed to minimize heat losses,
ensure high levels of reliability in operations (including resistance to erosion and thermal
shock) and optimize the time required for pre-heating the system and natural cool down
and such that entire replacement should not be required for an average interval of two
years.
Due to nature of assumed design basis waste feedstock, it is required to inject oxidant to
meet the stoichiometric requirement of Oxygen to convert Carbon to Carbon Monoxide.
Oxygen of 90 to 93% purity shall be used as oxidant for the process. Oxygen shall be
generated from air using stand alone Pressure Swing Adsorption (PSA) plant. The use of
Oxygen instead of air will not only reduce the physical size of many system components
but also reduces the energy required to maintain Plasma Reactor Temperature up to
1200°C. In addition, and also due to the nature and variety of the potential waste streams,
it may also be necessary to inject steam or atomized water into the reactor. The steam or
water will also function as an oxidant and will provide additional temperature control as
well as reduce the amount of un-reacted carbon carried over into the syngas. The
addition of steam or water will also tend to enrich the calorific value of the syngas
through an increase in the amount of hydrogen gas produced.
Inorganic constituents in the waste will be vitrified (i.e. melted) in the plasma reactor and
then recovered, through a tapping process, as a product with valuable commercial
applications (such as a construction material). During non-tapping operations, the tapping
port is closed using tap plugs. When tapping is to be initiated, the tap plug is pulled out
of the plasma reactor allowing the molten vitrified matrix mixture to flow out of the
plasma reactor into the quench tanks. Quench tanks are continuously circulated with
water for maintaining quench water temp to less than 70 deg C. The heat of slag
solidification is removed by evaporation of water. Such water quenching will create small
granules of slag.
2.3.5.3 PSA Plant
Oxygen shall be used as oxidant for meeting the requirement of Oxygen to convert
Carbon to Carbon Monoxide. Oxygen was selected as the principal oxidant to be injected
(instead of Air) from the point of view of energy conservation, optimizing the energy
value of the synthesis gas and to minimize the plant foot print area. A PSA plant with a
nominal capacity of 250 Nm3/hr will be provided and shall consist of a screw air
compressor, molecular sieve columns, storage tanks and a local control panel.
Nitrogen will be used for a variety of purposes in the plant, including the pulsing of the
bag house filters. The nitrogen gas will be provided by an on-site PSA plant with a
nominal capacity of 150 Nm3/hr will be provided
2.3.5.3 Spray Dryer
The syngas leaving the Plasma Reactor at approximately 1,000 to 1,200°C will enter a
Spray Dryer where it will come into contact with a stream of scrubber bleed liquor which
will be an aqueous inorganic liquid waste. The waste water will cool the gas to a
temperature of approximately 220oC. Heavy solids will be collected at the bottom of the
Spray Dryer and will be taken out with double gate rotary air lock valve. Solids will be
collected in manual cart and will be fed to plasma reactor to convert it to vitrified slag.
2.3.5.4 Gas Conditioning and Cleaning System
The cooled syngas will be conveyed to the activated carbon injection and mixing system.
This system consists of storage hopper and a feeder for activated carbon. Accessories,
instrumentation, local control panel and terminal panels are provided for system
operation. A predetermined amount of material will be metered via a variable speed
screw conveyor into the ductwork before the bag-house. Activated carbon is injected into
the system to eliminate the potential for the reformation of any undesired compounds.
The cooled gas stream enters the Bag House (i.e. fabric filter) through the inlet damper
into the hopper. The syngas containing particulate and acid gas constituent’s strikes
baffle plates, which distribute the syngas uniformly through the housing and drop out
heavy particulate into the hopper. The hotter syngas flows upward into the bag module.
Particulate filtration is accomplished as the syngas flows from the outside (dirty side) of
the filter bag, across the filter bag media, to the inside (clean side) of the filter bag. The
clean gas exits the bag at the tube-sheet, flows through the clean gas plenum, and into the
outlet duct.
As the collector operates, the collected dust begins to form a dust cake, which increases
the resistance to flow (porosity of the filter). This is measured by a pressure sensor and is
defined as the system pressure drop or differential pressure. To maintain a moderate
pressure drop, the bags are cleaned using a pulsing nitrogen gas type system. The pulse
gas system delivers a momentary burst (or pulse) of high-pressure nitrogen gas down
through the inner bag surface. It expands the bag and dislodges the dust cake. The dust
cake falls directly into the hopper where it is removed by the dust conveying system.
The fabric filter cleaning is performed on-line whereby the cleaning procedure occurs on
a row-by-row basis. Therefore, only a fraction of the total filter gas is interrupted for
cleaning, allowing continuous filtration with no modules being taken off line. The
frequency and the duration of the nitrogen gas pulses and the time between pulses are
operator preset but can be adjusted.
Pulse gas for bag-house cleaning will be Nitrogen. The Nitrogen gas needed for the
operation of the following equipment will be provided by the on site nitrogen PSA plant:
The PSA plant will also provide process gas for the atomization of the liquid feed stream
at spray dryer and miscellaneous purges. The entire Gas Cleaning and Conditioning
System will be purged with nitrogen prior to start-up of the system. The bag house
“catch” will be collected at the bottom of the bag house and will be periodically recycled
back to the plasma reactor where they will be converted into vitrified slag.
The syngas, cleaned of particulate matter, is then conveyed to an HCl scrubbing system.
HCl scrubbing system is provided to cool down the gas and to capture HCl gas in
continuous circulating stream of HCl solution of 2-5% concentration. HCl scrubbing
system is provided with Acid Resistance Tile Lined low pressure drop ventury scrubber
followed by FRP (v) packed bed scrubber. Here gas is cooled down to it saturation temp
of approx 78 deg C. HCl is captured in circulating low concentration HCl stream. Due to
gas cooling and absorption of HCl gas heat will be generated. Heat generated in the
system will be removed in graphite tube heat exchanger using cooling water on other
side. Equivalent to HCl gas scrubbed a continuous bleed stream will be removed from the
system and will be collected in neutralization tank. There will be additional particulate
matter collection in the system which will be continuously removed in side stream filter
press. Filter cake generated from this filter press will be fed to plasma reactor. Cleaned
syngas from HCl scrubbing system is fed to Alkali scrubber for recovery of NA2S as by
product. HCl scrubber bleed will be neutralized with caustic solution to form NaCl
solution which will be fed to spray dryer as mentioned above.
Alkali scrubbing system will be two stages packed bed scrubber. Bottom part of scrubber
will be circulating 18-20% NA2S solution with 1-2% free caustic which will capture most
of H2S gas from the syn gas. Caustic will react with H2S gas under highly alkaline
condition to form NA2S
H2S + NaOH = NA2S + H2O
Upper part of alkali scrubber will have packed bed. Here gas is contacted with lean
solution of NA2S with more concentration of free NaOH (5-6%) to achieve almost
complete absorption of H2S here.
Depending on incoming H2S gas quantity; NA2S by product bleed stream will be
removed from the system from the bottom circulating stream of alkali scrubber. This
stream will be provided polishing filtration treatment to make it suitable for commercial
sale. Equivalent overflow will be received from the upper portion of alkali scrubber.
Make up caustic solution will be added to upper circulating stream of alkali scrubber.
Alkali scrubber is provided with Chevron type of mist eliminator at the top of scrubber to
entrap any entrained liquid droplets from the system. Heat of reaction and cooling of
gases will be removed from the system using indirect heat exchanger provided in the
scrubber liquor circulating circuit using cooling water.
Thus cleaned and conditioned syn gas from alkali scrubbing system is taken down stream
for syn gas utilization system.
2.3.5.5 ID Fan
An induced draft fan, constructed of SS304 impeller and casing in MSRL / MSFRP lined
to resist corrosion due to the presence of wet gases, is integrated within the system
downstream of the gas cleaning and conditioning system to create negative pressure
within the plasma reactor and the rest of the process train (-0.1 inches Water Column
(“W.C.”) to about -1/2 inches W.C.). The ID fan ensures a fast response by the Variable
Frequency Drive during pressure excursions that may occur in the Plasma Reactor during
operations.
2.3.5.6 Synthesis Gas Storage/Accumulation and Utilization Systems
A tank of approximate dimensions of 5.5 m3 will accumulate the syngas at a pressure of
+100 mmwcg. This system is designed to provide a uniform supply of syngas to the
syngas utilization and energy production systems. The synthesis gas will then be
conveyed to an on-site co-generation system consisting of a steam generator and a steam
turbine system that will produce approximately 1,100 KWe of electric power.
Co generation system will consists of steam boiler which will generate superheated steam
at 40 kg/cm2 G and 400 deg C. Steam boiler will consist of Syn gas combustion furnace,
syn gas burner, auxiliary fuel burner for start up and piloting, combustion air fan, steam
economizer, evaporator and super heater, steam drum, and boiler blow down system.
High pressure superheated steam is then fed to condensing type steam turbine which will
provide steam rating in the range of 5.0 to 5.2 kg/kwh. Steam turbine will drive alternator
which will generate power to the tune of 1000-1300 KWe depending on the syn gas
calorific value. Power generated from the power panel is fed to synchronizing electrical
panel which will synchronize power from o generation plant and power from grid and
will supply power to the PTDR facility.
From steam turbine extraction steam at 8 kg/cm2 g pressure will be obtained for
operation of multi effect evaporation system and to meet misc plant steam requirement.
Steam turbine is attached with steam condenser; vacuum system and condensate return
system. From condensing type turbine steam is taken to steam condenser from where
condensate obtained is recycled back to boiler feed water tank. Cooling water required
for steam condenser is obtained from cooling tower.
2.3.5.7 Multieffect Evaporation System for Aqueous Organic Liquid Waste
Dewatering System
The facility has proposed to install multi effect evaporation system for dewatering
aqueous in organic liquid waste having non volatile organic compounds. Such waste is
having water content as high as 90% and inorganic salts as high as 5 to 7% and organic
content as low as 1-2%. Still this type of waste is required to provide thermal treatment
due to toxic nature of organic and due to in ability of treating this waste conventionally.
For such specific waste facility will install multi effect evaporation system having alloy
tube (Cupro-Nickel / Zirconia) construction material. Such waste will be concentrated in
multiple effect evaporation system to achieve almost 80% volume reduction. For
concentrated mass it is proposed to use screw dryer to achieve min water content in the
bottom sludge. Evaporated and condensed water after polishing treatment (carbon
adsorption system) will be recycled back to water treatment make up water system.
Bottom sludge from the evaporation system will be repacked and fed to plasma reactor
for further treatment. Energy required evaporation will be met through extraction steam
available from the steam turbine as described above. Spent carbon from carbon polishing
treatment will be sent to plasma reactor for further destruction.
2.3.5.8 : 1,050 kWe Plasma graphite electrode Torch System with an Insulated Gate
Bipolar Transistor power supply
The plasma generation system utilized within the PTDR system is comprised of three
individual systems, each with a capacity of 350 KWe. The arc is transferred between the
bottom-mounted anodes and the vertically mounted cylindrical cathode electrodes for
each of the three torch assemblies.
The three torches, mounted at the top of the plasma reactor vessel, move up and down
within the plasma reactor. Due to this movement, the torches are housed within a sealing
and insulating assembly. This assembly insulates the torch body and ensures that its
structural elements are maintained within a prescribed temperature range. This avoids the
need for additional cooling, which would remove excess thermal energy from the torch
and thereby reduce the electrical-to-thermal efficiency. The process control system uses
an “inching” motor and guide column to position the electrodes into place.
The three bottom anodes are positioned at the bottom of the plasma reactor and are
elevated compared to the rest of the plasma reactor bottom which is lined with either 25
mm thick graphite plates (tiles) or, depending on the nature and composition of the
wastes being processed, a material with equal thermal properties that will enhance the
conduction of heat transferred from the plasma torch and prevent corrosion/erosion and
chemical attack from the inorganic constituents of the waste. These lining pates are
designed to quickly conduct the heat transferred by the arc throughout the entire plasma
reactor bottom. Plates are also provided on the sides of the plasma reactor bottom to an
elevation of approximately 250 to 300 mm above the plasma reactor bottom. These plates
also ensure the even and effective conduction of heat. The only portion of the graphite
that requires replacement are the anodes, which are cylindrical with an approximate
diameter of 225 mm and are inserted from the bottom of the reactor into an electrode
holding assembly that is elevated above the slag pool. Depending on the final
configuration chosen during the final design, the anodes will be manufactured in
replaceable sections of approximately 450 mm in length that are outfitted with threaded
connections at each end. The replacement sections are attached to each other by means
of these threaded connections. As the anodes are consumed, replacement sections of the
anode “rods” are inserted into the plasma reactor and a new replacement section is
attached to the end piece from the outside of the plasma reactor.
The configuration of the lining plates at the bottom of the plasma reactor is such that a
slope is created relative to the central portion of the plasma reactor. This slope is
designed to allow any solid residues to fall away from the centrally located plate, thus
preventing or limiting the ability of the arc to be formed.
The three cylindrical graphite electrode “cathodes” (mounted at the top of the plasma
reactor with an approximate diameter of 225 mm) are lowered to within 10 mm of the
corresponding bottom-mounted anode electrodes where the arcs are struck. Once the arc
is struck, the transferred-arc electrode assembly is raised to a height of approximately 25
mm to 75 mm above the bottom of the plasma reactor. Temperature in the plasma reactor
is measured from a minimum of two locations: one location in the upper section of the
plasma reactor; the other location measures the temperature of the lower sections of the
plasma reactor. The electrodes are operated without feeding commencing until the plasma
reactor bulk temperature reaches a minimum of 1,000°C to ensure proper
dissociation/pyrolysis/gasification of the organic constituents of the wastes. Once feeding
operations commence, the bulk temperature quickly increases to the desired operating
temperature range of 1,000 to 1,200°C (1,500oC when melting operations are conducted)
and above.
Any inorganic constituents in the waste are melted (vitrified) into an environmentally
safe, leach-resistant, vitrified matrix. The removal of the vitrified matrix presents no
hazards of any kind to personnel, requires no special tools and does not disrupt the
operating process. The vitrified matrix can be used in a variety of applications including
roadbed/fill construction, blast media and concrete aggregate. Depending on the nature of
the wastes to be processed, a continuous or intermittent tapping system would be
provided.
The replacement electrode sections for the plasma generation system can be continuously
attached to the back of the existing electrode from the outside of the reactor. There is no
need to remove system components during electrode replacement activities, thus there is
little down-time. Platforms and access ladders are provided to provide access to the top of
the plasma reactor and in between the two skids to allow for greater access to these areas,
particularly when adding electrodes.
The entire plasma generating system has an electrical-to-thermal efficiency greater than
75% and requires no pressurized external supply of carrier gas. The system supplies its
own gas flow - approximately 5 litres per minute of air per torch assembly. This small
flow of air enhances the thermal energy distribution within the reactor.
The torches are powered by an advanced Insulated Gate Bipolar Transistor (IGBT) power
supply that provides the following advantages over other plasma torch power supplies:
• Requires an input current that is approximately 30% less than silicon controlled rectifier
(SCR) systems
• Power factors around 0.97
• Low harmonic distortion (approximately 10 times less than SCR systems)
• High arc stability compared to SCR systems
• Control panel size is approximately 66% smaller than a comparable SCR system
2.3.5.9 Power Panel and Process Control System
The power/electrical panel houses the motor control center and the Process Logic
Controller (PLC) system and provides complete access to operate and monitor the
process. It is designed for continuous operation. The electrical panel houses the PLC
system which interfaces with the plant control system containing graphic interfaces (e.g.
flow diagrams and process indications of temperature, pressure, for example) of each
subsystem and major components critical for the safe operation and efficient monitoring
of the system.
Power generated in the PTDR plant at 11 KV shall be fed to a 11 KV swichgear which
feeds the in plant captive power demand. Accordingly two unit auxiliary transformers are
proposed. The various MCCs are the fed by the 415 V switchgear. The voltage levels in
the proposed plant will be 11 KV, 50 Hz generation, auxiliary utility voltage at 415 V, 50
Hz for 3 phase and 240 V for single phase and 110 V ac for control supply requirement.
There will be separate centralized MCC room from where power will be fed to all drives
of the plant. The MCC shall be fixed type cubicle, vermin proof with standard fuses,
relays and indication lamps. Weatherproof start – stop push button stations shall be
provided near each motor for local start stop control Necessary power and control cables
running from MCC to motors and back shall be provided. The cables shall confirm to
relevant Indian standards. All motors shall be of TEFC construction, and Class F
insulation. All drives above 50 HP shall be provided with VFDs as power saving option
and for better plant control.
The PTDR process is driven by proprietary, state-of-the-art instrumentation and a
computerized control system. A Supervisory Control And Data Acquisition (SCADA)
system which is a distributed measurement and control system that includes hardware and
software components is provided as the process control system providing a graphics-
based visualization of the control and monitoring system. The SCADA system
communicates with the PLC system. The control system obtains inputs from all of the
PTDR process subsystems to achieve total overall control of the system. Safety,
interlocking features and emergency shut-down aspects specific to each subsystem are
incorporated to assure safety features are not compromised.
Each subsystem has customized interface screens. The SCADA system monitors all input
and output parameters and prompts the operator to make appropriate adjustments (or
makes automatic adjustments for critical safety-related conditions) to the waste feed rate,
plasma reactor temperature, oxidant input (if required), and the gas cleaning and
conditioning system to ensure that the system operates to meet prescribed environmental
requirements. The SCADA system also records and logs all events onto a hard disk,
which can be printed for further assessment.
2.3.5.10: SAFETY MEASURES
Following overall safety measures is proposed for the facility -
Automated, PLC based control system for plant operation.
Safety interlocks for the plant normal start up and shut down (normal /
emergency) operation.
Standby emergency power supply for the system. Will include DG set as well as
battery back up for critical components such as waste feed system, emergency
venting system, nitrogen purging system.
Provision of Emergency Safety valve venting in case of power failure and
pressure built up in furnace.
Installation of smoke detectors, fire alarm, ambient/personal CO monitors fire
hydrant fighting system and fire extinguisher system.
Preparation of on- site emergency plan and risk assessment study.
Preventive maintenance.
Use of PPE’s
DO’s and DON’TS boards for workers at prominent place
Mock drills and training.
2.3.5.11 FIRE FIGHTING SYSTEM
The fire protection system shall comprise of
Hydrant system - For Haz waste storage, PTDR Plant, power plant block and
administration building area
Fixed Medium velocity water deluge spray system for cable spreader rooms.
Mobile foam system for liquid waste storage tanks
Fixed High velocity water spray system - For transformers and turbine lubrication
oil tank(s)
Wet pipe Sprinkler system for hazardous waste storage area operating based on
temperature indications and UV sensors feed back.
Fire detection and alarm system for haz waste storage area, PTDR plant, power
plant block and administration building area.
Fire Fighting system shall comprises of following major equipment and systems
Diesel driven main fire pumps for hydrant network serving of hydrants, water
spray, sprinkler and foam system.
Electric motor driven standby fire pumps for hydrant network serving hydrants
water spray, sprinkler and foam system.
Electric motor driven jockey pumps for hydrant network serving of hydrants,
water spray sprinkler and foam system.
All necessary pump controls complete with all accessories for the above-
mentioned pumps.
All buried piping and over-ground pipes, fitting ,valves, automatic actuators,
supports etc for fire water distribution networks
All necessary sign-posting for the water-hydrant ring system including brackets,
complete with accessories.
All necessary water spray rings, risers, pipes, valves, fittings, spray nozzles ,
sprinkler nozzles etc.
Complete Addressable analogue fire detection system with heat and smoke
detectors for various plant area including storages with necessary cabling,
interface panels, controllers, sounders, manual call points, sirens, response
indicators, and all necessary hardware and accessories.
All necessary electrical equipment like LV switch-gear, LV motors, LV power
and control cables, control panels with alarm, PBB and interlocks, necessary DC
systems, push button stations, cable trays and accessories, cabling, glands lugs,
earthing and lightning protection conforming to relevant electrical specifications.
PROCESS FLOW DIAGRAM (Block diagram)
ANNEXURE-III
WATER BALANCE
ANNEXURE-IV
ENERGY BALANCE
ANNEXURE-V
MASS BALANCE
ANNEXURE-VI
ENVIRONMENTAL MANAGEMENT PLAN
ENVIRONMENTAL MANAGEMENT PLAN
Environmental management plan is prepared for construction and operational stage to
mitigate negative impacts. This document describes the Environmental Management Plan
consisting of mitigation measures and monitoring plan.
Construction Stage
The construction activities of the project site will mainly comprise of civil foundation
work, site preparation, shed and building construction, excavation, and earthmoving,
water treatment plant and water storage tanks, roads and drainage and erection of other
infrastructural facilities. These activities will involve movement of a substantial quality
of soil and debris. During dry season, it is necessary to control the dust nuisance created
by excavation and transportation activities. Using proper dust suppression measure on the
site like spraying of water at regular intervals shall be adopted.
Sanitation: During construction stage, suitable sanitation and other essential
facilities shall be provided for workers. These facilities shall be well designed and
maintained to minimize environmental impacts. Adequate drinking water supply
should be provided for on-site workers.
Noise: To keep the ambient noise levels within the permissible limits, the following
measures shall be taken:
i. Innovative approaches of using improvised machinery designs, with in-built
mechanism to reduce sound emissions like improved silencers, mufflers and closed
noise generating parts.
ii. Procurement of drill, loaders and dumpers and other equipment with noise proof
system in operator's cabin.
iii. Regular and proper maintenance of noise generating machinery including the
transport vehicles to maintain the low noise levels.
Provision shall be made for noise absorbing pads at foundations of vibrating
equipment to reduce noise emissions. It shall be ensured that no worker is exposed
to a noise generating construction equipment for more than 8 hours a day.
Construction Equipment and Waste: It shall be ensured that all the construction
vehicles specially trucks, bulldozers etc are properly maintained to minimize smoke
in exhaust emissions. The waste generated should be collected in garbage bins. The
temporary garbage bins be provided in the area. The waste generated and collected
shall be disposed off at an approved dumpsite.
Site Security: The site shall be secured by fencing and entry point shall be manned.
Operation Stage
Various Sources of Pollutants generated from PTDR-1000 facility with their abatement
method is described as under
Air Environment
Flue Gas Emission from PTDR system after Syn gas combustion: Following table
shows the details of mitigation measures proposed to meet emission norms:
Sr
No
Name of
Equipment
Location Brief Specification
1 Bag Filter After
Spray
Dryer
Type: Reverse Pulse Jet Type bag filter
system
Duty: To remove particulate matter from syn
gas.
Inlet Gas Flow: 3500 kg/hr
Inlet Gas Temperature: 220 deg C Max
Inlet Gas Particulate Matter: 4200 mg/NM3.
Max
Outlet Particulate Matter: < 80 mg/NM3 (All
submicron particles and mostly un burnt
carbon)
Bag Filter removal efficiency: Min 95%
Ash Removal System: Sequentially controlled
reverse jet pulsing of Nitrogen gas. Bottom
collected ash is removed through rotary air
lock valve.
Material of Construction: Casing: SS Lined
MS / SS, Bags: Teflon lined / Teflon and
antistatic type.
2 HCl Scrubber After Bag Type: Ventury Scrubber followed by Packed
Filter bed scrubber.
Duty: To capture HCl from Syn gas in
scrubbing liquor
Inlet Gas Flow: 3552.03 kg/hr
HCL Removal Efficiency: 98% Min
Scrubbing Media: Dilute HCl solution.
Other details:
Side stream filter provided to maintain min
suspended solids in scrubbing liquor.
External Heat Exchanger provided to remove
heat of condensation of water and heat of
formation of dilute HCl solution.
Material of Construction:
Ventury Scrubber: SS with Rubberlined and
Tile lined.
Packed Bed Scrubber: FRP (Vinyl Ester
resin) / MSRL with PP Packing
Pump: PVDF
Piping: HDPE / PP / MSRL
Side Stream Filter: PP / MSRL
Heat Exchanger: Graphite Tubes & Tubesheet
3 Alkali
Scrubber
After HCl
Scrubber
Type: 2 Stage packed bed scrubber.
Duty: To scrubb H2S and traces of HCl from
syn gas in caustic solution and to produce
Na2S solution as by product
Inlet Gas Flow: 2530.56 kg/hr
H2S removal efficiency: Min 99%
Scrubbing Media: Lower Section: 9 pH Na2S
solution; Upper section: 10 pH NaOH
solution.
Other Details:
External heat exchanger provided to remove
heat of reaction.
Polishing treatment provided for Na2S bleed
solution.
Mist Eliminator provided at the top of
scrubber
Material of Construction:
Packed Bed Scrubber: FRP (Vinyl Ester
resin) / MSRL with PP Packing
Pump: PVDF / SS
Piping: HDPE / PP / MSRL
Side Stream Filter: PP / MSRL
Heat Exchanger: SS Tubes & Tubesheet
4 Syn Gas
Utilization
System (Steam
Boiler)
After
Alkali
Scrubber
Cleaned syn gas from alkali scrubber is
combusted in steam boiler to use chemical
heat available in syn gas. Syn gas from alkali
scrubber is completely cleaned with respect to
acidic gases. Any carried over carbon
particulate matter with syn gas will complete
burn in steam boiler. Flue gas generated in
syn gas boiler at 180 deg C will be exhausted
from the stack of steam boiler at 30 M high.
Emission Standard for PTDR-1000 project
Parameter Emission Limit (mg/Nm3)
Particulates 50
HCl 50
SO2 200
CO 100
TOC 20
HF 4
NOX (NO and NO2 expressed 400
expressed as NO2)
Note: All values above shall be corrected to 10% oxygen on dry volume basis.
Hydrocarbon: 10 ppm, over an hourly rolling average on dry basis, measured as
propane.
Opacity: While operating properly at 100% rated capacity, the system shall have
visible emission rate of less than on equal to 10%, except for condensed water
vapour, from the discharge of stack (one hour rolling average ).
Dioxin / Furans: While operating at 100% rated capacity, the system shall have an
emission of dioxin and furans less than or equal to 0.1 ng TEQ / Nm3 corrected to
10% Oxygen. Sampling period shall be minimum 6 hours and maximum 8 hours.
Metals: While operating properly at rated capacity, the system shall have an
emission rate from the discharge of stack to atmosphere less than or equal to
Metals: Emission Limit (mg/NM3)
Cd+Th (& it’s compounds) 0.05
Hg (& it’s compounds) 0.05
Sb+As+Pb+Cr+Cu+Mn+Ni+V (& it’s compounds) 0.5
Note: All values above shall be corrected to 10% oxygen on dry volume basis.
In order to continuously monitor emissions from the flue gas stack and also to optimize
plant performance on line gas analysers shall be provided as under
DG Set exhaust:
DG Set will be installed at emergency power supply for safe shut down of plant in
case of power failure. DG set capacity will be 450 KVA and will be based on LDO as
fuel.
Emission monitoring plan
Sr No Location of on line gas
analyser
Parameter to
be monitored
Frequency of
Monitoring
1 Stack gas HCl, SO2, CO,
O2
On line continuous, 24
hrs
NOx, VOC,
Particulate
Matter
Every week by self
analytical facility
Every Month by
monitoring agency
approved by the GPCB
HF, Heavy
Metals
Every Month by
monitoring agency
approved by GPCB
2 Syn Gas at the outlet of
Plasma Reactor
CO, O2, H2 On line continuous, 24
hrs
3 DG set exhaust PM, Sox, Nox
Fugitive emissions expected from PTDR-1000 system: Source and mitigation of
these fugitive emissions are tabulated as under
Fugitive emissions and abatement method
Name and source of
fugitive emissions
Abatement Method
VOC from liquid
storage tank
All vents from the liquid storage tank will be connected to
exhaust header. Exhaust header will be connected to
exhaust blower. Exhaust blower discharge will be
connected to inlet of Steam Boiler furnace where syn gas
will be combusted.
VOC/Odorous air from
haz. Waste storage area
Combustion air fan for syn gas boiler will draw air from the
hazardous waste storage area. Suction of combustion air fan
will be taken from hazardous waste storage area.
Emergency Vent from
Plasma Reactor
Emergency vent will open in abnormal plant condition
only. Exhaust of emergency vent will be connected at the
inlet of syn gas boiler.
Scrubber Circulation
Tank vents
Scrubber circulation vent will be connected to down stream
gas ducting of syn gas which will be always under negative
pressure.
Mitigation of other air pollutants
o Air borne particulate may results during handling and transportation of waste due
to wind. The status of ambient air quality shall be closely monitored.
o Ambient air quality at the facility and at the vicinity shall be monitored to meet
the prescribed standards prescribed by CPCB.
o Watering of road as well as constructing of metalled roads shall be carried out.
o Approx 3000 M2 Green belt development shall be carried out.
o Traffic Operation Plan for better traffic management shall be worked out.
o Ambient air monitoring will be carried out as per following plan
Ambient Air quality Monitoring Plan
Sr No Environmental Monitoring Frequency
1 Ambient Air Quality ( SPM, NOx, CO2, SO2,
CO,HC and CH4)
Once in two months at
two locations
2 Noise level monitoring Once in two months and
two locations
Water Environment
WATER CONSUMPTION
Average daily water consumption of unit is about 261.936 m3. Water consumption is
primarily for scrubber, washing, boiler, cooling and domestic purpose. The entire water
requirement is meeting through GIDC water supply system. GIDC Ankleshwar has its
own water reservoir and distribution network throughout the industrial estate. The detail
of water consumption is shown in Table 7.1.
Table 7.1
DETAILS OF WATER CONSUMPTION
Sr. No. Water Consumption Consumption
(litres/Day)
1. Domestic 12,000
2. Industrial
Process and Washing 26,580
Boiler and Cooling 2,23,356
Total 2,61,936
Bleed stream generated from plant and its mitigation measures are tabulated as under
WASTE WATER GENERATION AND MANAGEMENT
The average total wastewater generation will be 105.691 m3/day. The details of waste
water generation and treatment disposal mechanism are given in table 7.2 .
Table 7.2
DETAILS OF WASTE WATER GENERATION AND ITS DISPOSAL
Waste Water Generation Quantity
(Liters / day)
Remark
(1) Domestic 10,000 Sewage will be disposed
through septic tank and
soak pit system.
(2) Industrial
Stream 1: MEE condensed
water generated from the
12000 Stream will be reused to
cooling tower.
MEE
Stream 2: Scrubber Bleed
Stream 3: Boiler BD
Stream 5: MB Plant bleed
Stream 7: Softener BD
36771 Stream will be reused in
gas quencher and slag
quench tank.
Stream 6: RO plant reject
Stream 8: Filter back wash
20220 Stream will be discharged
into CETP line as per
CETP norms for further
treatment and disposal.
For zero discharge:
stream will be reused for
wheel wash make up,
dedusting road and green
belt development etc.
Stream 4: Cooling tower
BD
26700 Stream will be discharged
into CETP line as per
CETP norms for further
treatment and disposal.
For zero discharge:
Stream will be fed as RO
feed water after
pretreatment
section of RO
plant.
TOTAL 1,05,691
Water Pollutants and Abatement Plan
Name and source of
bleed stream
Quantity
(liters/day)
Quality Abatement Method
Stream 1: MEE
condensed water
generated from the MEE
during concentration of
liq aq waste stream
12000 pH; Neutral
TDS: < 100 ppm
COD: < 100
mg/lit
BOD: < 30 mg/lit
MEE condensed water
is provided polishing
treatment using
activated carbon to get
rid of any expected
VOCs in worst
conditions. This stream
is reused as make up
water to cooling tower.
Stream 2: Scrubber
Bleed
Stream 3: Boiler BD
Stream 5: MB Plant
bleed
Stream 7: Softener BD
36771
pH; Neutral
TDS: 2-3 by wt
(almost all due to
inorganic salts,
mostly NaCl)
SS: < 50 mg/lit
All taken is taken to
High TDS bleed water
storage tank. From this
tank mixed high TDS
water is used in spray
dryer and slag quench
tank.
Stream 6: RO plant
reject
Stream 8: Filter back
wash
20220 pH; Neutral
TDS: < 1600
mg/lit
SS: < 100
mg/lit
COD: < 100
mg/lit
BOD: < 30 mg/lit
For zero discharge
condition this stream
will be reused for
wheel wash make up,
dedusting of road,
green belt
development, toilet
flushing and cleaning,
fire water tank make
up, plant floor
washing.
For discharge
condition this stream
will be discharged into
CETP line as per
CETP norms for
further treatment and
disposal.
Stream 4: Cooling tower
BD
26700 pH; Neutral (after
neutralization)
TDS: < 1000
mg/lit
SS: < 50 mg/lit
COD: < 100
mg/lit
BOD: < 30 mg/lit
For zero discharge
condition this stream
will be fed as RO feed
water after pre-
treatment section of
RO plant.
For discharge
condition this stream
will be discharged into
CETP line as per
CETP norms for
further treatment and
disposal.
Sewage 10000 Sewage will be
disposed through
septic tank and soak pit
system through
separate drain.
Spillage collection from
haz waste storage area
- - Spillages and wash
water from haz waste
storage area will be
collected in separate
pit located in haz waste
storage area and will
be pumped back to
liquid waste storage
tanks for disposal
through MEE or
through PTDR plant
depending on nature
and type of spillage.
Bleed water collection, treatment and distribution system will consist of following units:
Low TDS Water Collection and neutralization Tank
High TDS water collection and neutralization Tank
Neutralization system
Pressure Sand Filter and Activated Carbon Filter
From bleed water collection and neutralization tank bleed water will be reused in plant /
disposed into CETP discharge line as per details provided in above table.
Other Mitigation Measures
In order to minimize any potential negative impact on surface and ground water, the
mitigation plan shall include the following:
Hazardous waste storage area and plant area will be completely covered from top and
side. Strom water run off will be managed through separate storm water drains.
Before discharging storm water into GIDC drain, it will be passed through small RCC
pit where online pH sensor and recorder will be provided to keep check on pH of
outgoing storm water.
Prompt cleanup of any spillage of Haz Waste using dry method.
Regular monitoring of ground water quality through four monitoring wells one
upstream, one at site and two at downstream of the disposal site.
The water samples shall be analyzed for the 36 physical, chemical and bacteriological
parameters as per MOEF guidelines.
Following table describes water monitoring plan
Water Quality monitoring Plan
Sl. No. Description Frequency
1 High and Low TDS bleed quality Daily
2 Ground water quality – within the site Once in 3 months
3 Ground water quality – outside the site Once in 6 months
Resource Recovery
Resource recovery and its use is tabulated as under
Name and Source
Quantity Quality Use of resource
Vitrified Slag 5.6
Tons/day
Vitrified solid slag
in granules or in
solid lump form
Construction filler
material.
Sodium Sulphide
Solution (20%)
8 Tons/day
pH: Alkaline
Na2S: 20%
NaOH: 1-2%
NaCl: 1% Max
Balance: Water
Na2S Solution as raw
material for chemical
and dye manufacturer
Power 1.2 MW 415 V, 50 Hz In plant consumption
and balance approx 0.2
MW export to grid
Hazardous Waste Management
Type of hazardous waste generated and its abatement method is described in
following table for construction and operation phase of plant.
CATEGORY
NO.
TYPE OF WASTE QUANTITY DISPOSAL METHOD
CONSTRUCTION PHASE
- Brick-bats, debris etc.
As per
generation
Used in pavements, roads, etc. / through
existing solid waste disposal facility
- Steel scrap Sold to steel scrap dealers
- Packing wood scrap Sold to wooden scrap dealers
OPERATON PHASE
Category of
waste
Type of solid waste Total Qty Disposal Method
34.3 Inorganic Salts from
Gas Quencher and filter
cake from scrubbing
system
1.24 Tons/Day
Recycled back to PTDR plant
for vitrification into slag
5.1 Used/ Spent Oil 0.50 KL/Year Disposed off through PTDR
plant
33.3 Discarded drums/
Carboys/ Liners/ bags
As Per generation
Bags will be used for repacking
of waste and will be fed to
PTDR plant.
Drums/carboys will be crushed
in drum crusher and will be fed
to PTDR plant. Metallic drum
will get vitrified and plastic
drum will be disposed off in
plasma reactor
28.2 spent carbon and bag
house bottom solids
450 kg/day Disposed off through PTDR
plant
Soil Environment
Waste spillage may lead to soil pollution. Therefore, regular monitoring of soil is
required. Soil monitoring plan is given in following table
Sr No Environmental Monitoring Frequency
1 Soil Monitoring Once in a two season at
2 locations
Noise Environment
Plant and equipment will be designed to ensure that noise generated is limited to CPCB
norms. Equipment will be provided with noise control measures such as acoustic
insulation etc, to ensure noise abatement. Rotating equipment will be properly balanced.
Where high noise levels are produced, employees will be provided with ear protection
devices.
Green Belt Development
Approx 3000 m2 Green belt is proposed primarily for effective control of pollution. The
tolerant plants, having tremendous sink capacity, can help contain and attenuate pollutant
concentration in air and thereby restore and revitalize the stressed and impaired
environment on long term basis. The basic need for developing pollution sink or shelter
belt plantation is to use properly selected plants having pre requisites to tolerance and
detoxify pollutants and long life span endowed with large and dense canopy and
extensive foliage. The proposed green belt around the proposed site may be designed
taking into consideration the availability of space as the efficiency of green belt in
mitigating environmental impact mainly depends on the width of green belt, distance
from source and tree height. Locally useful species shall be selected in consultation with
forest departments.
The following criterion is to be considered while selecting the species for plantation:
The plant species should be fast growing.
They should have thick canopy cover.
They should be perennial and evergreen.
They should have high sink potential.
They should be effective in absorbing pollutants without significantly
affecting their growth.
Based on above following plant species are recommended for plantation:
Acacia nilotica (Babul)
Deldergia sissoo (Shishum)
Acacia auriculiformis (Australian Babul)
Azadirachta indica (Neem)
Lagerstroemia speciosa (Jamun)
Pongamia pinnata (Karanji)
Minimum two rows of plants are required for plantation on roadside to minimize the
pollution effects. While planting care should be taken to ensure that plants in second row
fall in between the two plants of the first row.
Management and Training
The site operator, waste transporters and the person responsible for monitoring and
management of the shall be provided regular training through structured training program
covering all aspects of waste storage, handling and transportation and plant operation and
maintenance besides the effective enforcement of regulations by CPCB/MPCB. This will
ensure safety of workers, general public and the environment.
The unit will become member of Disaster Prevention and Management Centre, GIDC,
Ankleshwar and get the benefit of trainings, surveys and expert third party inspections.