NLC INDIA LIMITED PRE FEASIBILITY...

NLC INDIA LIMITED

PRE FEASIBILITY REPORT

2x660 MW SUPER-CRITICAL LIGNITE BASED POWER PLANT AT MUDANAI DISTT. CUDDALORE,

TAMILNADU

NOVEMBER 2016

DESEIN PRIVATE LIMITED

CONSULTING ENGINEERS DESEIN

HOUSE, GREATER KAILASH-II NEW DELHI – 110 048

NLC INDIA LIMITED

ISO 9001:2008 Registered Company Certificate No. 10692

CIN : U74899DL1970PTC005474

A D e v e l o p m e n t S e r v i c e f o r I n d u s t r i e s & U t i l i t i e s

INDEX

S.NO. DESCRIPITION SHEET NO.

1.00.00 Introduction and Background 1-2

2.00.00 Site Selection and Feasibility Studies 3-4

3.00.00 Project Highlights and Technical Features 4-9

4.00.00 Environmental Aspect 10-13

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1.00.00 Introduction and Background

Electricity is a basic human need and essential requirement for all facet of

our life. Power development is one of the key infrastructure elements for

the socio-economic growth of the country. The entire Indian Economy

hinges on the availability of reliable and quality power at competitive rates

to rural India for its overall growth and to Indian Industry to make it globally

competitive.

NLC India Limited (a NAVRATNA CPSU) is engaged in mining and power

generation since its inception and has contributed to the social and

economic development of the country for over 5 decades. NLCIL is

presently having lignite mining operations in Neyveli (Tamilnadu) and

Barsingsar with associated power generation units of 3289 MW capacity.

NLCIL is also owning and operating a 2X500 MW coal based station at

Tuticorin (in Joint Venture project with TANGEDCO, Tamil Nadu). .

NLCIL has the advantage of vast expertise in both mining and power

sectors giving it a unique position for setting up of cost effective power

projects. In addition to operation of Mine-I, Mine-IA and Mine-II, NLCIL

had initiated action for development of Mine-III and 2x500 MW lignite fired

thermal power project. Accordingly, NLCIL had appointed M/s Desein

Private Limited as a consultant for preparing the Feasibility Report.

The proposal for seeking approval of Terms of Reference (TOR) of

Environmental Impact Assessment (EIA) study was submitted vide

proposal no. IA/TN/THE/53173/2016 to Ministry of Environment & Forests

(MOEF). In response, MOEF has informed that “as per the Ministry of

Power’s O.M. dated 13.11.2009, the 13th Plan (01.04.2017 onwards)

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capacity addition will be through supercritical units only. Hence, necessary

action may be taken accordingly.”

The consultant was accordingly advised to examine the feasibility to revise

the project configuration from 2x500 MW to 2x660 MW taking in to

account all relevant aspects including availability of basic inputs like land,

water & fuel and availability of proven technology & equipment suppliers

for lignite based Super Critical Steam Generator units etc. Various rounds

of discussions were held with all prospective equipment suppliers to

ensure adequate competition in tendering process.

The above points have been suitably addressed and hence the present

proposal is for implementation of 2x660 MW Lignite based super critical

units at Mudanai (Neyveli) in Cuddalore District of Tamil Nadu.

It is worthwhile mentioning that the proposed plant would be the first lignite

fired 660 MW Supercritical Unit in India. Numerous references of installed

units of lignite fired Supercritical plants are found outside the country in

Germany, USA, Japan & China as given below:

LIGNITE BASED SUPER CRITICAL THERMAL POWER PLANTS IN OPERATION

Sl. No. Name of the Plant Country Capacity

1. LIPPENDORF TPS GERMAN 2 X 920 MW

2. BOXBERG TPS GERMAN 1 X 900 MW

3. SCHWARZE TPS GERMAN 2 X 800 MW

4. MEHRUM TPS GERMAN 1 X 660 MW

5. MATSUURA TPS JAPAN 2 X 1000 MW

6. MANL TPS USA 2 X 1100 MW

7. NIEDERAUSSEM GERMAN 1 X 1000 MW

8. NEURATH TPS GERMAN 2 X 1100 MW

9. BAICHENG CHINA 2 X 660 MW

10. HUANENG JIUTAI CHINA 2 X 670 MW

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2.00.00 Site Selection and Feasibility Studies

The present project site near village Mudanai was selected by the site

selection team of NLCIL for development of 2x500 MW lignite based

project after examining four alternative site based on the following

considerations:

1. Availability of suitable & adequate land

2. Availability of reliable source of water

3. Availability of road and railway access

4. Environmental aspects

5. Availability of infrastructural facilities

6. Conformity to Siting Criteria of MOEF

The Site Selection Committee Report is placed at Annexure-I. The salient

details of alternative sites are briefly elaborated below:

Site-I Near Village Kolliruppu

The site is on the western side of the village Kolliruppu adjacent to

upcoming Neyveli New Thermal Power Project (NNTPP) of NLC India

Ltd., and comprises of about 200 acres of land in possession of NLCIL. As

the land area is only 200 acres, the site is not considered suitable.

Site-II Near Village Mudanai

The site is on south west side of Thermal Power Station-II (TPS-II) near

village Mudanai and comprises of about 608 acres of land in possession

of NLCIL. The site is in close vicinity of Mine-II & III so the lignite could be

fed through conveyor system. There is an under-utilized ash dyke of the

TPS-II and water reservoir of TPS-II near the site-II, which could be used

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for the proposed TPS-II 2nd expansion project. The plant area and

associated facilities could be accommodated within the land in possession

of NLCIL. The site elevation is 50m to 57 m MSL. The site is therefore

considered suitable.

Site-III Near Village Marungur

The site is located at a distance of approx. 12 kms. South West of TPS-II.

There is no land in possession of NLCIL. The entire land is fertile

agricultural land and will pose lot of problem in acquisition. Further, it will

require crossing of river Manimutharu for transportation of Lignite through

conveyor system. Hence, this site was not considered suitable.

Site-IV Near Village Kammapuram

The site-IV is located at a distance of 8.5 kms. South of TPS-II and

comprises of 1452.98 acres of land for which administrative approval was

accorded by Govt. of Tamil Nadu. NLCIL has plan for augmentation of

Mine-II from 15 MTPA to 18.75 MTPA. It is learnt that this 1452.98 acres

land will be required for additional external dump area. Hence this site is

not considered suitable for for TPS-II 2nd expansion project.

3.00.00 Project Highlights and Technical Features

In line with the observations of MOEF and considering the feasibility

aspect brought out at 1.0 above, it is proposed to adopt Ultra Supercritical

technology. The advantages of supercritical technology are listed below:

Higher plant efficiency

Less Fuel Consumption

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Less Infrastructure Investment for Fuel Transport / Storage and Ash

Disposal

Less Emission (CO2, SOx, NOx, Dust/Ash)

Less Auxiliary Power Consumption of plant auxiliaries.

Less Water Consumption (No need of continuous blow down in

case of once through boiler.)

Lower operating costs

Greater operating flexibility

Location

The site is on south west side of Thermal Power Station-II (TPS-II) near

village Mudanai and comprises of about 608 acres of land in possession

of NLCIL. The nearest airports are at Trichy Airport at a distance of 150

kms. And Chennai airport at a distance of approx. 200 KMs. Nearest

railway station at Uthangal Mangalam on Vridhachalam- Cuddalore

section is at a distance of 1.5 kms.

Land Requirement

The plant & associated facilities including green belt, ash disposal and

Townships of the project is proposed to be accommodated within the land

under possession of NLC India Limited. The overall plant layout is shown

in the Plot Plan placed at Annexure-II.

Capacity : 2X660 MW - Present proposal

Mode of Operation : Base Load

Fuel : Lignite from the basket of captive mines

comprising of Mines I, IA, II & the

proposed Mine-III

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Lignite Availability and Transportation

The daily Lignite requirement for 2x660 MW units shall be about 32280

tonnes. Annual Lignite requirement for the plant shall be around 10 MTPA

considering PLF of 85% and the same is proposed to be met from nearby

mine blocks of NLCIL. The envisaged mode of Lignite transportation from

the proposed mine is by belt/ piped conveyor system as the site chosen is

very close to the mine block.

Cooling Water Source, Requirement and Commitment

Consumptive make-up water requirement of the project shall be 3400

m3/hr with ETP Recovery and 4221 m3/hr without ETP Recovery.

Makeup water from the source shall be pumped to an in-plant raw water

reservoir having storage capacity of about 10-15 days to take care of

emergencies. Presently, Natural Draft Cooling Towers NDCT have been

proposed for the project. It is envisaged to adopt Cycle of Concentration in

such a way to achieve zero discharge of plant’s treated effluents to any

water body outside the project area.

Steam Generator Technology

The Steam Generators (SG) shall be super-critical, once through type,

water tube, direct pulverized lignite fired, top supported balanced draft

furnace, single reheat, radiant, dry bottom type, suitable for outdoor

installation. The gas path arrangement shall be single pass (tower type) or

two pass type rated to deliver approx. 2100 t/hr of superheated steam at

270 kg/cm2(a) & temperature of 603±5ºC with feed water temperature of

about 305ºC at the economizer inlet. The reheat steam temperature

would be of 610±5ºC.

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The SG would be designed to handle and burn HFO/Light Diesel Oil

(LDO) as secondary fuel up to 30% SG MCR (maximum continuous

rating) capacity for flame stabilization during low-load operation. For unit

light up and warm up purposes, light diesel oil (LDO) would be used with

air atomization.

Steam Turbine Technology

The steam turbine shall be tandem compound, single reheat,

regenerative, condensing, multi cylinder design with separate HP,

separate IP and separate LP casing(s) OR combined HP-IP and separate

LP casing(s), directly coupled with generator suitable for indoor

installation.

Turbine shall be capable of operating continuously with valves wide open

(VWO) to swallow 105% of EMCR steam flow to the turbine at rated main

steam and reheat steam parameters. The steam turbine generator shall

also be capable of delivering at generator terminals at least 105% of rated

output (Guaranteed Output) without any constraints with all the valve wide

open, rated steam condition and condenser pressure as optimized by TG

supplier targeting lowest heat rate with 0% makeup.

Lignite Handling System

External Lignite Handling System (ELHS) shall comprise of two (2)

identical & parallel streams of around 3000 TPH rated capacity each to

deliver Lignite from mines to the power plant site. In view of long distance

( 10.5 km), Pipe Conveyor / Belt Conveyor System may be envisaged for

lignite transportation. Possibilities of having lignite crushing facilities and

the crushed lignite stockyard at the mine end shall be examined in detail

during FR formulation stage.

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Internal Lignite Handling System (ILHS) consisting of two (2) identical &

parallel streams to operate at rated capacity of around 3000 TPH each are

envisaged for the proposed Power Plant to cater to the fuel requirements

of 2X660MW Units i.e. Unit – 1&2.

Beneficiary States

The project is being set up to supply power to home state of Tamil Nadu &

other willing beneficiaries.

Project Implementation Schedule

Commercial Operation Date (COD) of the first 660 MW units is envisaged

in 48 months from the zero date and second unit at an interval of 6 months

thereafter. The zero date shall be reckoned as the date of main plant

award.

Associated Transmission System (ATS) Clearance

The power generated from the project will be evacuated through 2 nos.

D/C 400 KV transmission lines up to the nearest 400 KV Pooling

Substation of Central Transmission Utility i.e. Power Grid Corporation of

India Limited (PGCIL). Unit start-up power requirements shall be met by

back charging of one of 400 kV transmission line. The present provisions

for power evacuation are tentative and shall be reviewed based on the

finalized ATS of the project by PGCIL. Commitment from PGCIL shall be

obtained for the necessary infrastructure for power evacuation from the

proposed generating station, by erecting transmission lines as deemed fit

and necessary.

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Project Financing

The overall debt-equity ratio proposed is 70:30. Equity will be financed

through internal resources and the debt portion is proposed to be financed

from Domestic Commercial Borrowings.

Indicative Project Capital Cost

The indicative project capital cost of the proposed 2x660 MW project shall

be as under:

Cost of Project including IDC Rs. 9240 Crores

Cost per MW Rs. 7.00 Crores

The above estimated cost is of the order cost without any detailed

estimation of bill of quantities for the purpose of Pre-Feasibility Report

only. However, the detailed cost estimates and financial analysis will be

carried out during Detailed Project Feasibility Report stage based on the

site specific data.

Conclusion

On analysis of all aspect involved for the development of the project, it is

concluded that:

“It is technically feasible to establish 2x660 MW units based on Super-

critical Technology at the site identified for the project considering the

availability of infrastructural facilities subject to tying up of basic inputs and

obtaining the statutory & non statutory clearance of the concerned

authorities.”

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4.00.00 Environmental Aspect

A Draft Environmental Impact Assessment report for this project will be

prepared based on the TOR prescribed by MOEF. Tamil Nadu State

Pollution Control Board will then be approached for conducting Public

Consultation. Thereafter, the EIA report will be finalized incorporating

public hearing minutes & action plan for its submission to Ministry of

Environment & Forests (MOEF) for obtaining Environmental Clearance

(EC), in accordance with the procedure laid down in the MOEF Notification

dated 14th September’ 2006 and its further amendment dated 01st

December’ 2009. All relevant notifications in respect of environmental

protection measures/ guidelines including the December 2015 notification

shall be fully complied.

Air Pollution Control System

High efficiency electrostatic precipitators (ESPs) will be installed to limit

the particulate emission to 30 mg/Nm3 to facilitate wider dispersion of

particulate and gaseous pollutants. A twin flue chimney of appropriate

height will be provided for wider dispersion of pollutants. On-line

equipment will be provided for monitoring of stack emissions.

To control NOx emission, supercritical boilers having advanced low NOx

generation system will be installed. In addition, Selective Catalytic

Reduction (SCR) system will be installed to limit the NOx emission as per

latest environmental guidelines.

FGD system will be installed in flue gas duct to the chimney as per latest

environmental stipulation. The design and layout of steam generator and

its auxiliaries will take into account wet flue gas desulphurisation (FGD)

system to be installed taking suction from duct after ID fan and feeding the

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desulphurised flue gases back to the chimney with provision for bypassing

the FGD system.

For control of fugitive dust emissions within and around coal handling

plant, dust extraction/ suppression systems would be provided. Dust

suppression system shall also be provided in the coal stock yard.

Noise Pollution Control Systems

The major noise generating sources in a thermal power plant are the

turbines, turbo-generators, compressors, pumps, fans, coal handling plant

etc. from where noise is continuously generated. Acoustic enclosures

shall be provided wherever required to control the noise level below 90 dB

(A). Wherever required, the workers shall be provided with protective

equipment such as ear plugs and ear muffs.

Solid Waste Management Systems

Ash will be the major solid waste generated from the power project. An

ash management scheme shall be implemented consisting of dry

collection of ash, supply of ash to entrepreneurs for utilization and

promoting ash utilization to maximum extent and safe disposal of unused

ash. Ash utilization.

The proposed expansion project is based on lignite as fuel, which contains

low ash (approximately 5 to 8%) and hence the ash disposal burden is

quite less compared to a coal fired power station. Moreover Neyveli is

located in southern region surrounded by many cement industries and

there are many cottage industries who manufacture fly ash bricks,

window/ door frames, paver blocks using the ash. In fact 100% ash

utilization is achieved in the existing stations of NLCIL. Hence Emergency

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Ash Dyke of 125 Acres developed for TPS II is envisaged to be used for

this expansion project.

Water Pollution Control System

An effluent management scheme, consisting of collection, treatment,

recirculation and disposal of effluents shall be implemented in order to

optimize the makeup water requirement as well as liquid effluent

generation.

The liquid effluents shall be collected and treated/ recycled as per the

following design philosophy:

The sludge from clarifiers of water PT Plant shall be collected in a

sump/ pit and shall be treated in order to extract most of the water

from the sludge for reuse & solid particles in the form of semi-solid

shall be dispose of suitably either for land fill or in the bottom ash

dyke.

The waste effluents from neutralization pits of DM plant and

condensate polishing plant shall be collected in the common

neutralization pits and neutralized before pumping to dispose of in

bottom ash dyke along with bottom ash slurry.

Similarly service water waste from different parts of the power plant

such as ESP, BTG area etc. shall be dispose of in bottom ash dyke

along with bottom ash slurry.

Oily waste from the power plant shall be collected & treated in oil

water separator in order to separate oil. Clear water shall also be

dispose of in bottom ash dyke along with bottom ash slurry.

Re- circulating type cooling water (C.W) system with cooling

towers, with C.W. blow down from cold water side to ensure no

thermal pollution. The blow down shall be led to central monitoring

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basin after treating through clarifiers/ tube settlers, filters, UF filters

& RO, the RO permeate shall be reuse in CW make up. The

sludge from clarifiers/ tube settlers, & RO reject shall be disposed

of in bottom ash dyke along with bottom ash slurry.

Lignite particle settling pond shall be provided to remove lignite

particles from lignite handling plant waste. Decanted water shall be

pumped back to the lignite dust suppression system

An independent plant effluent drainage system would be constructed to

ensure that plant effluents do not mix with storm water drainage. Efficient

operation of various treatment schemes shall be ensured so that the

quality of treated effluent from CMB conforms to relevant standards,

prescribes by regulatory agencies.

The sewage from plant and township shall be treated in a sewage

treatment plant. The treated sewage conforming to prescribed standards

shall be utilized for plantation to the extent possible.

Description of the Environment

In order to identify the environmental impacts due to the construction and

operation the project and associated facilities, an EIA study is proposed to

be undertaken to establish baseline environmental status for various

environmental attributes within the study area. The major environmental

disciplines to be covered in the EIA report includes ambient air quality,

water quality, noise, soil, ecology (terrestrial and aquatic), land use,

geology, hydrology and demographic & socio-economic conditions.

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Annexure 1

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1 KOLLIRUPPU

2.MUDANAI

4.KAMMAPURAM

3.MARUNGUR

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Annexure 2

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