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PRE FEASIBILITY REPORT

APPLICATION UNDER THE PROVISIONS OF MOEF&CC NOTIFICATION

S.O.804 (E) DATED 14TH MARCH, 2017

FOR

2X60 MW COAL BASED CAPTIVE THERMAL POWER PLANT AT

VILLAGE KARIAJHAR/MAJHGAWAN, RAMPUR NAIKIN TALUK,

SIDHI DISTRICT, MADHYA PRADESH

Submitted by:

UltraTech Cement Limited.

September, 2017

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Executive Summary

Project Name : 2x60 MW Coal Based Captive Thermal Power Plant at village

Kariajhar/Majhgawan, Rampur Naikin Taluk, Sidhi District, Madhya

Pradesh by Jaiprakash Associates Ltd.

Plant Location : Village Kariajhar/Majhgawan, Rampur Naikin Taluk, Sidhi District,

Madhya Pradesh

Geographical

Coordinates :

Latitude–24°19’41”–24°19’54”N

Longitude- 81°19' 45’’ – 81°19’59” E

Land Area : CPP is installed in an area of 25 ha, available within the existing

premises of cement plant. Project area is already in industrial use.

Water Requirement :

The total water requirement of entire project is around 1566

m³/day which is being met from Bansagar Canal.

Permission for withdrawal of 1600 m³/day of water from Bansagar

Canal by Water Resources Deptt., GoMP vide letter no:

94/2010/31/903 dated 19.08.2011.

Coal Requirement 1.0 MTPA

Man Power Requirement : During operation phase-54 persons

Nearest Railway Station : Rewa (24 km, NW)

Nearest Airport Khajuraho (150 km)

Nearest town : Rewa (24 km, NW)

Reserved Forests :

Govindgarh Reserved forest (0.2 km, NW)

Shikarganj Reserved forest (8.8 km (ESE)

Bardaila (Reserved forest (9.0 km, ESE)

Nearest River : Son River (9.0 km, SE)

Nearest Lake/Ponds : Govindgarh Lake (6.0 km, NW)

Bansagar Lake (7.6 km, SSW)

Ecological Sensitive

Areas

(Wildlife Sanctuaries)

: The Son-Gharial sanctuary is located at a distance of 9.0 km, SE

direction

1.0 BACKGROUND OF THE PROJECT

2x60 MW Imported Coal based Captive Thermal Power Plant of M/s Jaiprakash Associates

Limited at village Kariajhar/Majhgawan, Rampur Naikin Taluk, Sidhi District, Madhya

Pradesh was taken over by M/s UltraTech Cement Limited with effect from 29th June 2017 as

per the scheme of arrangement approved by National Company Law Tribunal Bench-

Mumbai on 15th February, 2017 in case of UltraTech and National Company Law Tribunal

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Bench-Allahabad on 2nd March, 2017 in case of Sellers (JAL/JCCL) for the transfer of “JAL

Business” and “JCCL Business to UltraTech on a going concern basis.

Jaiprakash Associates Ltd. (JAL) had set up an integrated Cement Plant (Unit-I) to

produce Cement - 2.00 MTPA, Clinker -1.5 MTPA along with Captive Power Plant (35

MW) at Majhigawan, Tehsil Rampur Naikin, Sidhi (M.P.) after obtaining

Environmental Clearance from MoEF vide its ref. No. J-110011/51/2007-IA II (I)

dated 09.08.2007. Subsequently, cement production capacity was expanded, by

setting up an additional production line (Unit-II), from 2.0 MTPA to 3.50 MTPA upon

receiving Environmental Clearance from MoEF&CC vide its ref. No. J-

110011/546/2010-IA II (I) dated 08.11.2011.

Further, to meet the uninterrupted power for above mentioned integrated cement

plant and other units of the company at different locations, subject project was

implemented, within the existing premises of integrated cement plant, upon

receiving environmental clearance from MoEF&CC, Govt. of India vide its reference

No. F.No. J-13012/94/2009-IA-II-(T) dated 30th January, 2012.

The Consent to Establish (CTE) was obtained from MPPCB vide its letter ref. No.

1611/TS/MPPCB/2012 dated 09.03.2012 to establish 2X60 Coal Based Captive

Thermal Power Plant and Consent to Operate from MPPCB vide its letter ref. No.

3037/TS/MPPCB/2012 dated 04.05.2012 under Air Act, 1981 & vide its letter ref. No.

3035/TS/MPPCB/2012 dated 04.05.2012 under Water Act, 1974.

2. 0 PURPOSE OF RESUBMISSION

The project was considered for Environmental Clearance before the EAC (Thermal) in

its 30th meeting held on 8-9, August, 2011. The Committee recommended the

project for Environmental Clearance. Subsequently, it was brought to the notice of

the ministry that JAL had gone ahead with the construction activities at site without

mandatory environmental clearance. This was brought to the notice of the EAC

(Thermal) in its 32nd meeting held during 12th - 13th September, 2011. The

committee decided that ministry may take the matter in accordance with the

procedures and policy decision taken in such matters.

As per the directions of MoEF, JAL had submitted the copy of resolution passed by

the Board of Directors of JAL during its meeting held on 11th January, 2012 and

Corporate Environment & Energy Policy. Further, as per the O.M. of MoEF dated

16.11.2010 for consideration of cases of violation, the Madhya Pradesh Pollution

Control Board had filed a petition with the Chief Judicial Magistrate of Sidhi, M.P.

on 14.12.2011 under Section 15 of the Environment Protection Act, 1986. Based on

the information and clarifications submitted to MoEF&CC, the Hon’ble committee

recommended environmental clearance to the project. Environmental Clearance was

issued by MoEF&CC vide its letter Ref. No. J-13012/94/2009- IA.II (T) dated

30.01.2012.

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Now, present application is submitted under the provision of MoEF&CC Gazette

Notification S.O.804 ( E) dated 14th March, 2017 as it is a violation case due to start

of construction and installation work without requisite prior Environmental Clearance

as per the provision of the EIA Notification, 2006 notified under Environment

(Protection) Act, 1986.

(i) Brief description of nature of the project

Jaiprakash Associates Limited had installed coal based Captive Thermal Power Plant

of 2 x 60 MW capacity adjacent to its existing cement plant at Kariajhar village, Sidhi

district, Madhya Pradesh.

(ii) Need for the project and its importance to the country and region

There is constant shortfall of power, and MPSEB resorts to frequent power

curtailment. In view of shortage of the power from the utility grid, JAL intends to

meet the continuous power requirement of cement plant and its auxiliaries.

In view of the above, JAL is constructed an alternative, sustainable and economic

power source for operation of the group units.

(iii) Demand- Supply Gap

Captive Power Plant was established to cater the need of exiting integrated cement

plant and company’s other units at different locations.

(iv) Imports vs. Indigenous production

Not applicable

(V) Employment Generation (Direct and Indirect) due to the project

The total manpower of power plant at present in the operating unit is about 54

persons.

3. 0 VIOLATION DETAILS

Jaiprakash Associates Ltd. had started partial construction activities in terms of

carrying out pre-project activities and construction/installation of certain Plant

structures. However, all construction activities were suspended in December, 2011

and restarted after obtaining Environmental Clearance from MoEF&CC dated

30.01.2012 followed by Consent to Establish from MPPCB dated 09.03.2012.

4.0 PROPOSED LOCATION

(i) Types of project including interlinked and interdependent project, if any.

In view of its captive requirement, Jaiprakash Associates Limited had set-up a coal

based Captive Thermal Power Plant of 2 x 60 MW capacity adjacent to its existing

cement plant at Kariajhar village, Sidhi district, Madhya Pradesh. The CPP have two

Circulating Fluidized Bed Combustion (CFBC) boilers having capacity of 60 MW each.

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ii) Location (map showing general location, specific location, and project

boundary & project site layout with coordinates.

The project is located at Kariajhar/Majhgawan village of Sidhi district of Madhya

Pradesh.The index map of the site is given in Figure-1. The study area map is shown

in Figure-2. The project area falls in Survey of India (SOI) Toposheet No.63 H/4, H/7

and 63 H/8.

(iii) Details of alternate sites considered and the basis of selecting the

proposed site, particularly the environmental considerations gone into

should be highlighted.

The alternative sites were not considered, since the location of CPP was within the

boundary of the existing Cement Plant, which is in industrial use.

iv) Size or magnitude of operation

The land requirement for captive power plant ultimate capacity of 2 x 60 MW and its

facilities is approximately 61.77 acres (25 hectares). The cost of the total project is

about Rs.519 Crores.

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FIGURE 1-INDEX MAP

Project Site

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FIGURE 2-STUDY AREA MAP

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6.0 DETAILS OF CAPTIVE POWER PLANT

The capacity of captive power plant is 120-MW, two (2) Circulating Fluidized Bed

Combustion (CFBC) boilers had installed for power generation. The details of captive

power plant are presented in Table-1.

TABLE-1

DETAILS OF PROPOSED CAPTIVE POWER PLANT

Sr. No. Features Description

1 Capacity 120 MW

2 Configuration 2x60 MW

3 Type of boilers Circulating Fluidized Bed Combustion (CFBC)

Boilers

4 Power evacuation Through SEB/PGL transmission line

7 Coal Requirement 1.0 MTPA

11 ESP efficiency >99.98%

13 Water

Requirement

1566 m3/day

14 Source of water Bansagar Canal (Permission for withdrawal of

1600 m³/day of water from Bansagar Canal by

Water Resources Deptt., GoMP vide letter no:

94/2010/31/903 dated 19.08.2011)

7.0 PROCESS DESCRIPTION

Capacity

The power plant with 2 x 60 MW has installed with a production capacity of 120 MW.

Process Technology

Conventional steam cycle operating in Rankine cycle, consisting of 2 nos of CFBC

boilers of 250 TPH and 2 nos Turbines 535 ºC at 110 ata pressure.

Process Description

Coal is fired in a high pressure boiler to produce steam which is fed to steam turbine

which drive the generator connected rigidly to it. The power output from the

generator through appropriate electrical system is fed to the grid for distribution to

consumers.

Exhaust steam from the turbine is cooled in the water cooled surface condenser and

the condensate water is recycled in the power cycle involving boiler, turbine and

condenser as mentioned. Water for cooling purposes is required in the condenser,

heat exchanger of auxiliary systems of boiler, turbine and generator etc. In addition,

water is required for bottom ash handling system, dust suppression system of coal

handling, fire fighting systems, drinking (in plant and colony), make up for the power

cycle etc. Hot water outlet of condenser and other heat exchangers is cooled in

suitable cooling tower and reused in the system. Similarly, water used in other

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systems mentioned above is recycled to the extent possible after suitable treatment.

However, make-up is required to be added for replenishing the loss due to

evaporation, blow down and other consumptive use. However, make up is required

to be added for replenishing loss due to evaporation, blow down and other

consumptive use. To minimize the make up, effluent water from different process in

the power station is chemically treated so as to make it suitable for use in the

development of greenbelt, sanitation, dust suppression etc.

The fly ash from the bottom of the ESP hoppers is collected in dry form and

pneumatically conveyed to fly ash silos. From these silos, fly ash is used in the

existing cement plant to manufacture PPC.

Effluent treatment plant along with guard pond system and sewage treatment plant

is provided for wastewater treatment.

Plant layout and process flow sheet is given in Figure-3 and Figure-4.

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FIGURE-3

PLANT LAYOUT

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FIGURE-4

PROCESS FLOW SHEET

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Power Generating Equipment

Thermodynamic Cycle

The thermodynamic cycle consists of the boiler, the steam turbine, the condenser,

the condensate extraction and boiler feed systems, the condensate and feed water

heaters along with all other necessary equipment for single reheat regenerative feed

heating.

Turbine Generator Unit

The steam turbine with standard multi-stage, multi-cylinder, tandem compound,

single reheat, condensing type machine operating at 3000 rpm with minimum of six

(6) uncontrolled extractions for regenerative feed heating.

Details of Air Cooled Condenser (ACC)

Air cooled surface condenser is a direct system using ambient air for rejecting the

heat to the atmosphere without cooling water as the mean of heat transport. The

turbine back pressure is a function of the ambient dry bulbs temperature. To reject

the heat to the atmosphere an adequate fin tube surface is necessary. To create and

maintain the necessary vacuum inside the condenser, air ejector is provided.

Details of Steam Generators and Accessories

The selection covers selection of mechanical equipment and system for efficient

operation of the Captive power plant.

The captive power plant consists of 2 numbers of 60 MW MCR capacity steam

Turbine generator and 2 numbers of CFBC boiler of 250 TPH capacity.

Steam Generator

The steam generating system for each unit of 2x60 MW the power plant consists of

two numbers of boilers of 250 TPH capacities with all the auxiliaries.

The boilers has circulating fluidized bed type, natural circulation, balanced draft, and

water cooled membrane wall radiant furnace design with three (3) stage super-

heaters and inter-stage desuperheater.

The steam generator is provided with a steam drum and the drum is of fusion-

welded type. The steam drum with necessary nozzle connections for the steam

outlets, safety valves, feed water inlets, down-comers, continuous blow down, level

indicators, chemical dosing, sampling connection, drains and vents to assure the

required steam purity.

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Furnace

The furnace envelope is constructed of fully water-cooled membrane/fin welded walls

and the construction is gas pressure tight

Super Heater

Super-heater system is of three (3) stage design with inter-stage desuperheating to

achieve the rated steam temperature over 60% to 100% MCR load. The super-

heater is combination of convection and radiation type.

Economiser

The economiser is located downstream of the super-heaters and evaporator sections.

The economiser is of bare tube construction, inline arrangement, counter flow type

and the economiser is designed for inlet temperature of 235C.

Air Heater

Air heater is arranged as the last heat recovery section downstream of economiser.

Air heater is recuperative type with flue gas flowing inside the tubes and the

combustion air flowing over the tubes.

Draft System

The draft system for the steam generator is suitable of producing a balanced draft

with sub-atmospheric pressure condition in the furnace.

HP & LP Dosing System

Steam generator with High Pressure (HP) dosing and Low Pressure (LP) dosing

system. The HP dosing system is based on ‘tri-sodium phosphate’ dosing and this is

dosed in boiler water to take care of the ingress of the hardness salts and to increase

the boiler water pH. The LP dosing system is based on ‘hydrazine’ dosing and this is

dosed in the feed water to scavenge the last traces of oxygen and to increase the

feed water pH.

Blow Down Tank

One Continuous Blow Down tank (CBD) and one Intermittent Blow Down tank (IBD)

is provided for each of the boiler. The flash steam from the CBD tank is piped to the

de-aerator and outlet of the IBD tank is vented to the atmosphere.

De-aerator

One De-aerator of de-aerating capacity equal to twenty percent (20%) higher than

the gross MCR steam generation capacity of boiler with a de-aerated water storage

tank of minimum 20 minutes operation.

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Boiler feed Water Pump

Two working and one standby boiled feed water pumps are installed. The one of

three boiler feed pump motor with soft starter for one set.

9.0 Site Analysis

(I) Connectivity

The project is well connected with NH-75 at a distance of 2.3 km, E and NH-7 at a

distance of 24 km, NW.

(II) Land form, land use and land ownership

The land requirement for captive power plant ultimate capacity of 2 x 60 MW and its

facilities is approximately 61.77 acres (25 hectares). The required land is available

within the existing cement plant that is spread over 120.62 ha

(III) Existing Infrastructure

The infrastructural facilities are common for cement plant and power plant.

10.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

No R&R issues involved

11.0 Greenbelt Development

Thick greenbelt have been provided with trees planted in rows. 33% of the total

project area developed as greenbelt and green cover as per CPCB/ MoEF, New Delhi

guidelines.

12.0 Socio-Economic Benefits

The industrial activity of the project coupled with the ancillary industries, contributed

to the overall socio-economic development of the region.

Direct Benefits to the National and state Exchequer

Power tarrif;

Excise duty

State sales tax or VAT

Income by way of registration of trucks, payment of road tax and payment of

tax for interstate movements

Income tax from individual as well as corporate taxes by the cement company

and ancillary units.

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Direct Employment

Unskilled/semi-skilled labor for the plant is drawn locally or from nearby places. The

employment of local personnel in skilled and executive staff category depend on

availability and sustainability of individuals.

Indirect Employment

Apart from direct employment, a lot of persons employed indirectly in truck transport

operation, repair garages, other ancillary units, market/shops etc.