Presentation of Thermal Power Plant

Presentation for Environmental Clearance before the
esteemed members of Karnataka State Level Expert

Appraisal Committee
Proposed Project
32 MW Captive Power Plant in Existing Ferro Alloy Unit
Proponent
M/s. Star Metallics & Power Pvt. Ltd.
Hospet, Karnataka.
Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd. 1
PROJECT HIGHLIGHTS
Name of company M/s. Star Metallics & Power Pvt. Ltd
Promoter of company EIEL, India & ETA group, Dubai.
Location Vyasankere, Ta: Hospet, Dist.: Bellary

District: Karnataka
EXISTING PROJECT DESCRIPTION
Plot Area 95 Acre
Project Ferro alloy plant
Location Vyasankere, Ta: Hospet, Dist.: Bellary

District: Karnataka
Activity status The existing Ferro alloy plant is not operational

since last 10 years due to unavailability of feasible
power source.
PROJECT HIGHLIGHTS Contd…….
Product Silicomanganese (SiMn )
Capacity of plant 44,700 MTPA (SiMn )
No. of Furnace (Type) Two ( Submerged Arc Furnace)
Rating of furnace 1 x 15000 KVA, 1 x 20000 KVA
Projected operating load of 24000 KW

ferroalloy plant
Total Connected Load 33 MVA
Raw Materials Manganese ore, Metallurgical coke,

Limestone & Quartz.
Water requirement and Source 148 m3/ day, Tungbhadra dam

reservoirs
Effluent Generation & Disposal 46 m3/ day
Gardening & dust suppression
Source of power GESCOM Grid (It is used to run
15,000 MVA furnace only, untill the
proposed CPP will not be operational)
PROPOSED PROJECT DESCRIPTION

Project Installation of new 32 MW Captive Power
Plant in existing ferro alloy unit.
Location Within existing ferro alloy unit.
Power generation 32 MW
Area for proposed plant 25 Acre ( Within existing plant)
No of Boilers One
Type of Boilers Fluidized Bed Combustion type
Capacity of boiler 140 TPH
Fuel Low sulphur containg Indonesian Coal
Fuel Consumption Rate 1,30,000 MTPA
Cont.
No of Turbogenerator One
Type of Turbogenerator Straight Condensing With Air Cooled
Condenser
Water Requirement for CPP 418.4 m3/ day (Tungabhadra Dam)
(Source)
Effluent Generation 245 m3/ day
Cost Of Project 102.78 crore
LOCATION OF PROJECT
STAR METALLICS AND POWER PVT. LTD.
EXISTING UNIT
Product Silicomanganese
Production Capacity 44,700 MTPA
Raw Material Manganese ore, Metallurgical coke,

Limestone & Quartz. All these material
are locally available
Power Power requirement of ferroalloy industry
i.e. 181 million KW will be provided by
GESCOM Grid ( It is only for 15,000
MVA furnace and untill proposed CPP
will not be operational)
WATER Water requirement of the existing unit is
148 m3/ day and it will be fulfilled by
Tungabhadra dam reservoir.
MAJOR REQUIREMENT
RAW MATERIAL:
Raw Materials /Consumables Unit Qty/year

Manganese ore T 1,07,000
Lime stone T 9,120
Coke T 30,000
Quartz T 11,000
Electrode paste T 1,150
WATER CONSUMPTION AND EFFLUENT
GENERATION
Usage Quantity (m3/ day)
Water Consumption Effluent Generation
(1) Domestic 36 31
(2) Industrial
- Cooling tower - -
-Process Nil Nil
- Washing Nil Nil
- Boiler Nil Nil
100 15
- DM back wash Nil Nil
-Gardening 12 Nil
TOTAL 148 46
PRODUCTION PROCESS
 The raw materials will be taken to a set of day bins by a set of belt
conveyors.
 The raw materials will be fed into the furnace through chutes.
 The manganese ore added in the form of lumps will be smelted in the
smelting furnace.
 Coke will be used as reductant, quartzite as silicon additive and
lime stone as flux.
 The energy required for this reduction will be supplied by means of
submerged arc through three self-baking electrodes.
 Liquid Silico Manganese along with slag will be tapped out at suitable
intervals.
Cont.
 The metal will be tapped into on to refractory lined beds dressed with
Silico Manganese powder to form cakes.
 The cakes after cooling will be sent to a product sizing yard. The sized
Silico Manganese will then be weighed and bagged. Thereafter, it will
be ready for despatch by road transport.
 Slag produced during the operation is granulated. This slag is poured
into a stream of high pressure water, which converts the liquid slag into
granules and this slag will go for reprocessing.
MATERIAL FLOW CHART FOR SILICOMANGANESE
T/T TPM TPY
2.25 8300 100000 MANGANESE ORE
REPROCESS
0.588 2200 26300 COKE
0.23 850 10300 QUARTZ RAW MATERIAL STOCK PILE
00.2 740 8900 LIME STONE T/T TPM TPY

0.025 92 1100 ELECTRODE PASTE DAY BINS PROCESS 0.7 2600 31300
Kwh/T GWH/M GWH/Y

BACTH
WH/Y
3750 14.0 168 ELECTRIC POWER
SMELTING
SLAG 0.7 2600 31300
SUBMERGED ARC ELECTRIC
FURNACE - SMELTING
300 1.1 13 ELECTRIC POWER
AUXILLIARY
4050 15.1 181 TOTAL

FURNACE GAS
CUM/T CUM/ CUM/Y
M
13.06 48649 583782 WATER BAG HOUSE 0.04 150 1700
T/T TPM TPY LIQUID SILICO MANGANESE LADLES

FINES 0.04 150 1800
1 3725 44700
CASTING
1 3725 44700
REPROCESS 0.04 150 1180

CRUSHING & SCREENING
0.95 3540 42460 SILICO MANGANESE

0.05 186 2240 SILICO MANGANESE
Karnataka SEAC PPT For EC of Star Metallics & Power Pvt. Ltd.
CONSUMER 14
SOURCE OF POLLUTION IN EXISTING PROCESS
EFFLUENT:
 There is no process effluent generation.

 Only domestic effluent i.e. 31 m3 /day and cooling tower blow down i.e.
15 m3 /day will be generated.
 The quality of cooling tower blow down will be as per the standards
prescribed by Pollution Control Board for discharging into inland for
irrigation.
 Sewage (31 m3 /day) from various buildings of the unit will be conveyed
through separate drains to septic tank connected to soak pit.
AIR POLLUTANT :
GASEOUS EMISSION :
 The gas emissions from furnace will contain dust particulates, Sulphur
dioxide, oxides of nitrogen, carbon monoxide.
 The exit gases would be cleaned by dry gas de-dusting system.
 In the bag house fine particulate matter will settle in the settling
chamber. Resultant clean gas will be vented out to atmosphere at
appropriate height
DUST EMISSION :
 Dust will be produced during product sizing ,finishing and packing
will be managed by dust extraction system
SOLID WASTE
 Raw material handling fine( 7800 TPA) , product fine(2240 TPA) and
furnace slag (31300 TPA) will be the main solid waste in the existing
process
 The dust and ash generated during operation will be collected, packed
in bags and finally disposed off for commercial usage.
 The slag will be reprocessed and finally reused for commercial

purposes
NEED OF PROJECT
The existing Ferro alloy plant had been stopped since last ten years due to
unavailability of power. Since the state grid power supply is economically
unviable in long run and every effort to restart the ferro alloy plant using
power from other sources were unsuccessful, it has decided to install a 32
MW Captive Power Plant to augment the power requirement. The
proposed 32 MW captive power plant is coal based with fluidized bed
combustion technology. Power from the CPP will be used to run ferro
alloy plant and the surplus power will be exported to consumers.
PROPOSED PROCESS
Product Power
Production Capacity 32 MW
Raw Material Indonesian coal with vary little percentage

of sulphur.( Calorific value 5250 kcal/kg)
Fuel Consumption Rate 1,30,000 TPA
Water Water requirement of the proposed unit is

418.4 m3/ day and it all will be provided by
Tungabhadra dam.
Boiler Fluidized bed combustion type of 140 TPH
capacity.
POWER PLANT PERFORMANCE INDICES
Sr. Description Index
No.
1. Plant Rated Capacity, MW 32
2. Rated Capacity, Million Units/Annum 262.8
3. Plant Load Factor, % 90
4. Annual Power Generation, Million Units 236.52
5. Auxiliary Power Consumption Of Power 28.38
Plant, Million Units
6. Annual Send Out Power, Million Units 208.14
7. Annual Imported Coal Consumption, Tons 1,30,000
8. Grade Of Coal To Be Used Calorific value of
5250 kcal/kg
9. Annual Ash Generation (Total), Tons 1300
10. Annual Make-Up Water Requirement, m3 About 1,52,716
GENERAL LAYOUT OF PROPOSED POWER PLANT
WATER CONSUMPTION AND EFFLUENT
GENERATION
Usage Water requirement Effluent generation
(1) Domestic 24 20
(2) Industrial -
Nil
- Process Nil
- Cooling tower Nil
- Washing Nil
- Boiler 120 114

188 25
- Dm plant back wash 86.4 86
- Gardening - -
TOTAL 418.4 245
SCHEMATIC DIAGRAM FOR WATER SYSTEM
SOURCE OF POLLUTION IN PROPOSED PROCESS
EFFLUENT:
 Effluents are generated during regeneration of ion exchangers.
Alkalies effluents are generated during the rinsing of anion and
mixed bed exchangers.
 Blow down from the plant consists of cooling tower blow down and
boiler blow down.
 The effluents from the water treatment plant are led to a properly
sized neutralisation pit having a holding capacity of two
regenerations.
 The quality of cooling tower blow down will be as per the standards
prescribed by Pollution Control Board for discharging into inland.
Residual chlorine in cooling tower blow down will be maintained
within acceptable levels.
 Sewage from various buildings in the power plant area will be
conveyed through separate drains to a septic tank before being
discharged into soak pit.
AIR POLLUTENT :
GASEOUS EMISSION :
 The flue gases from the boiler exhausted into the atmosphere carry with
them considerable quantities of pollutants such as SPM, SO2, NOx, CO
etc.
 Boiler of Circulating Fluidised bed combustion type of firing to reap the
inherent advantages of very low liberation of NOx in the furnace.
 Electrostatic precipitator at boiler outlet for extracting the dust
pollutant from flue gas for achieving the dust concentration at the
outlet of chimney as low as 100 mg/Nm3.
 The flue gas emission from DG sets contains significant proposition of
SO2 since HSD will be used as fuel.
 DG set are also provided and will be used in case power emergency.
Stack of adequate height is provided for effective dispersion of
pollutants.
DUST EMISSION :
 Raw material handling process is one of the main sources of dusting.

Coal will be drawn from stockyard and ground in hoppers leads to
dusting.
 The dust would be captured by dust extraction (DE) system and taken
to a bag filter to separate out the dusts and clean air finally vented
through a stack.
 For open yard operation, provision will be made to spray water to
reduce the dust generation during handling operation.
FLY ASH :
 Fly ash generated from the boiler will be collected in dry form and
disposed for commercial utilisation.
NOISE POLLUTION:
The major noise producing equipment such as turbogenerator will be

provided with acoustic enclosures, pumps, fans, compressor etc. and will
be run at speeds less than 1500 rpm. Equipment will be statically and
dynamically balanced. Safety blow off valves, discharge pipes; relief
valves etc. will be equipped with silencers. Pipe lines will be liberally sized
for low velocities
SOLID WASTE:
Power plant ash, 1700 TPA will be the main solid waste in proposed
plant and will be collected, packed in bags and finally disposed off for
commercial usage.
WASTE WATER
EFFLUENT GENERATION FROM EXISTING AND PROPOSED UNIT
Effluent Generation
Usage (m3/ day)
Existing Proposed TOTAL
(1) Domestic 31 20 51
(2) Industrial Nil Nil Nil
- Process Nil Nil Nil
- Washing Nil Nil Nil
- Boiler blow down Nil 114 114
- Cooling tower blow
15 25 40
down
- DM plant discharge Nil 86 86
TOTAL 46 245 291
WASTE WATER MANAGEMENT
The final quality of the wastewater will meet the GSR 422 (E) on land discharge
standards. The treated waste water (348 m3/day) will be reused for dust suppression
(12 m3/day), green belt development (12 m3/day) and remaining (324m3/day) will
be used for ash handling system. There will be no discharge of effluent outside the
plant site.
WATER BALANCE CHART FOR BOTH EXISTING AND PROPOSED UNIT
Soak pit
TOTAL WATER CONSUMPTION TOTAL EFFLUENT
GENERATION
Domestic water 36 m3/ day 31 m3/ day Septic tank

(51 m3/ day)
Cooling tower 100 m3/ day 15 m3/ day
Gardening 12 m3/ day

240 m3/ day
Ferro alloy unit 148 m3/ day
Gardening 12
m3/ day
Total Water Requirement
566.4 m3/ day
Dust supression12
m3/ day
Ash handling
CPP 32 MW 418.4 m3/ day 216 m3/ day
Domestic water 24 m3/ day 20 m3/ day

ZERO
Boiler 120 m3/ day 114 m3/ day DISCHARGE
DM Backwash 86.4 m3/ day 86.0 m3/ day
Cooling tower 188 m3/ day

25 m3/ day
AIR POLLUTANTS
SMELTING FURNACE:
Hot SAF off gas emissions contain dust particulates, Sulphur dioxide, oxides of
nitrogen, carbon monoxide and traces of oxides of silica
FINISHED PRODUCT SIZING & PREPARATION:
The cast product would be cooled, ground and screened for final bagging.
Such operation would generate fugitive dust .
BOILER EMISSION :
The flue gases from the boiler exhausted into the atmosphere carry with them
considerable quantities of pollutants such as SPM, SO2, NOx, CO etc. Followin
measures are provided to control flue gas emissions:
DG SET:
Two DG set will be used as power back up. The flue gas emission from
DG sets contains significant proposition of SO2 since HSD will be used as
fuel.
AIR POLLUTION MANAGEMENT
SMELTING FURNACE:
Hot off gases from submerged arc furnace (SAF) and tap hole secondary
emissions laden with fine product dust would be cooled to 150-250oC by air
dilution prior to passing it through fume extraction system. The exit gases
would be cleaned by dry gas de-dusting system. Bag filters are provided
to remove fine particulate matter will settle in the settling chamber.
Resultant clean gas will be vented out to atmosphere at appropriate height.
FINISHED PRODUCT SIZING & PREPARATION:
Significant amount of fugitive emission mainly in form of dust will be

envisaged during coal and raw material handling. Dust extraction system
will be provided at all material transfer points The dust would be captured
by dust extraction (DE) system and taken to a bag filter to separate out the
dusts and clean air finally vented through a stack
Cont.
For open yard operation, provision will be made to spray water to reduce
the dust generation during handling operation.
BOILER & DG SET EMISSION :
Electro Static Precipitator (ESP) will be provided to control dust emission

from the boiler. Further low sulphur content coal will be used to reduce SO2
generation. The flue gas will be dispersed into the atmosphere through a
stack of around 60 meter height for effective dispersion of pollutants.
DG set are also provided and will be used in case power emergency. Stack of
adequate height is provided for effective dispersion of pollutants.
Max. Conc. Zone of Pollutants from Stack discharge at above height Simulati
Distance w.r.t. stack discharge Pollutant concentration (microgram/m3)

(m) SO2 NO2 SPM
817 32.18 11.57 18.44
877 34.06 12.24 19.52
937 35.19 12.65 20.16
997 35.71 12.83 20.47
1057 35.77 12.85 20.50
1117 35.4768.5 12.75 20.32
1177 3
34.90 12.54 20.00
1237 34.14 12.27 19.56
1297 33.25 11.95 19.05
1357 32.27 11.60 18.49
GAUSSIAN PLUME DISPERSION MODEL
The dispersion of pollutants in the atmosphere is determined using

Gaussian plume dispersion model. For the present study, this model is
used for the prediction of maximum ground level concentration (GLC).
The different air emissions from the unit are PM, SO2, NOx and CO from
boiler and process vent. Maximum ground level concentration is
predicted using dispersion model. The maximum ground level
concentration for different parameters is shown in Table 6.3 for proposed
scenario. Equal concentration contour plots for the PM, NO2, and SO2
are shown in Figure 6.1 to 6.5 for the proposed scenario.
Based on KSPCB limit of pollutants, calculated ground level

concentration is superimposed on existing ambient air quality to obtain
proposed scenario for the purpose of prediction and evaluation of impact
of stack and process emission on surrounding
OTHER MEASURES
 Regular ambient air quality monitoring should be carried out within

premises and nearby area for PM, RSPM, SO2, NOX and CO.
 Occasionally ambient air quality should also to be monitored for work

area to check fugitive emissions, if any.
 A greenbelt around the factory and near the possible source of fugitive
emissions should be developed for reducing the air pollution and
attenuation of noise.
FLY ASH MANAGEMENT
Ash generated during the operation of power plant will be suitably
collected and disposed off. A system for collection and commercial
disposal of this waste product to end users’ works will be planned. Ash
generated in the furnace bed will be periodically removed by means of
wet scraper chain conveyor and discharged on to the ash silo meant for
wet ash. The fly ash collected from the Economizer, Air Heater and
Electro-Static Precipitator will be conveyed to the fly ash silo through
mechanical ash handling system. Ash shall be disposed manually or by
means of truck from the silos.
THERMAL POLLUTION MANAGEMENT
All equipments and pipelines whose surface temperature is 50 0C and

above will be provided with thermal insulation.
Further the plant building will be designed for adequate air circulation
through natural ventilation. In addition, air conditioning systems will be
provided for specific areas. Man coolers will be installed at hot work spots.
NOISE MANAGEMENT
The plant and equipment will be specified and designed with a view to
minimise noise pollution. The major noise producing equipment such as
turbogenerator, pumps, fans, compressors etc will be provided with
acoustic enclosures and will run at speeds less than 1500 RPM.
Equipment will be statically and dynamically balanced. Safety blow off
valves, discharge pipes; relief valves etc. will be equipped with silencers.
Pipe lines will be liberally sized for low velocities. Wherever necessary
insulation will be provided for reducing heat loss and noise pollution. In
effect, the abatement measures will ensure that noise levels are kept
below 90 dB (A) at a distance of 1 m from the equipment.
SOCIAL ENVIRONMENT MANAGEMENT:
The plant site is in the existing ferroalloy industry. The project did not involve
displacement of population as the project site is within the existing plant. Instead
of displacement project provides employment to about 45 persons in power plant.
SMPPL has also constructed a full-fledged colony consisting of houses for
the benefit of employees. Most of the employees shall be from the local area.
Hence, the influence of influx on environment is insignificant. It is anticipated
that the project would bring following benefits to the people of the surrounding
villages
Generation of employment and improved standard of living

Establishment of small and medium scale engineering ancillaries, agro
based industries with cascading employment opportunities
Superior communication and transport facilities etc.
WORK ZONE POLLUTION MANAGEMENT
The work zone pollution would be mostly due to fugitive dusts, heat and
noise. The fugitive dust emission in open area would be controlled by Dust
Extraction and Dust Suppression systems as described earlier.
As far as possible, natural draft ventilation would be enabled in the shop. All
the process vessels would be lined with adequately thick refractory bricks to
contain the surface heat emission and in some cases they would be indirectly
cooled by water. In addition to this, there would be provision for forced draft
cooling and ventilation of closed environment in the work zone.
The work zone noise would be mostly emanating from the rotary equipment
and machinery like fans, blowers, compressors and pumps. Proper equipment
design for control of noise at source, adopting proper protective appliances
and administrative control for rotation of manpower in noisy areas would
prevent exposure of workmen to high noise levels.
PLANT SAFETY MANAGEMENT
Plant safety measures would form an integral part of the environmental

management plan of the proposed plant. Workers’ safety would be given highest
priority so as to avoid any form of personal injury or lost-time accident. In-built
safety features of the plant and machinery would help avoid hazardous events
causing damage to the life and property.
GREEN BELT DEVELOPMENT
More than 100 trees are present all around existing industry including Fuel
storage area, Ash handling system and Administration building etc. There is no
tree cut and the area of 10 acre is proposed for tree plantation. The name of the
trees will be decided after the discussion with the Local Agricultural Authority
and Forest Department. The waste water from the plant after treatment will be
used for green belt development (i.e. 12 m3/day) within the plant premises.
POST PROJECT MONITORING
As a part of the Environmental Management Plan (EMP) to be implemented

for the Ferro Alloy Plant and Captive Power Plant as a whole, monitoring of
air and water quality both at source and in the ambient at the plant site will
be done regularly as per Central Pollution Control Board (CPCB) guidelines
after the plant is commissioned. For this purpose, appropriate equipment and
instruments will be procured along with necessary chemicals, consumables
and glassware.
To Summarise, the pollution control measures planned for the entire plant
will ensure that it will have the least adverse impact on the environment.
The adverse impacts of the plant on environment are planned to be prevented
by provision of preventive and control systems.

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Presentation for Environmental Clearance before the

esteemed members of Karnataka State Level Expert

Promoter of company EIEL, India & ETA group, Dubai.

Location Vyasankere, Ta: Hospet, Dist.: Bellary

Plot Area 95 Acre

Project Ferro alloy plant

Location Vyasankere, Ta: Hospet, Dist.: Bellary

Activity status The existing Ferro alloy plant is not operational

Capacity of plant 44,700 MTPA (SiMn )

No. of Furnace (Type) Two ( Submerged Arc Furnace)

Rating of furnace 1 x 15000 KVA, 1 x 20000 KVA

Projected operating load of 24000 KW

Raw Materials Manganese ore, Metallurgical coke,

Water requirement and Source 148 m3/ day, Tungbhadra dam

PROPOSED PROJECT DESCRIPTION

STAR METALLICS AND POWER PVT. LTD.

Production Capacity 44,700 MTPA

Raw Material Manganese ore, Metallurgical coke,

Raw Materials /Consumables Unit Qty/year

- DM back wash Nil Nil

00.2 740 8900 LIME STONE T/T TPM TPY

Kwh/T GWH/M GWH/Y

4050 15.1 181 TOTAL

13.06 48649 583782 WATER BAG HOUSE 0.04 150 1700

T/T TPM TPY LIQUID SILICO MANGANESE LADLES

REPROCESS 0.04 150 1180

0.95 3540 42460 SILICO MANGANESE

 There is no process effluent generation.

 The slag will be reprocessed and finally reused for commercial

Raw Material Indonesian coal with vary little percentage

Water Water requirement of the proposed unit is

- Boiler 120 114

 Raw material handling process is one of the main sources of dusting.

The major noise producing equipment such as turbogenerator will be

Domestic water 36 m3/ day 31 m3/ day Septic tank

Gardening 12 m3/ day

Domestic water 24 m3/ day 20 m3/ day

DM Backwash 86.4 m3/ day 86.0 m3/ day

Cooling tower 188 m3/ day

FINISHED PRODUCT SIZING & PREPARATION:

Significant amount of fugitive emission mainly in form of dust will be

BOILER & DG SET EMISSION :

Electro Static Precipitator (ESP) will be provided to control dust emission

Distance w.r.t. stack discharge Pollutant concentration (microgram/m3)

The dispersion of pollutants in the atmosphere is determined using

Based on KSPCB limit of pollutants, calculated ground level

 Regular ambient air quality monitoring should be carried out within

 Occasionally ambient air quality should also to be monitored for work

All equipments and pipelines whose surface temperature is 50 0C and

Generation of employment and improved standard of living

Plant safety measures would form an integral part of the environmental

GREEN BELT DEVELOPMENT

As a part of the Environmental Management Plan (EMP) to be implemented

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