Final Report_MOEF Feasibility Study_Essar Salaya_Rev-B

Feasibility Study on Compliance with
New Environmental Regulations of

MoEF & CC Dt. Dec-7, 2015
2x600 MW, SALAYA TPP, GUJARAT, INDIA
Essar Power Gujarat Limited, Dwarka

Gujarat | India
CONFIDENTIAL
5 August 2020
Final (Rev-B)
TRACTEBEL ENGINEERING pvt. ltd.
Intec House
37, Institutional Area, Sector 44
Gurgaon 122 002 (Haryana) – INDIA
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FEASIBILITY STUDY
Our ref.: P.011638-E-00001-001
TS:
Imputation: Project No. P.011638
CONFIDENTIAL
Client : ESSAR POWER GUJARAT LIMITED

Project : 2x600 MW, SALAYA TPP, JAMNAGAR, GUJARAT, INDIA
Subject : Feasibility Study on Compliance with New Environmental Regulations of MOEF & CC Dt. Dec-7, 2015
Comments:
Revision No. Date Prepared / Revision By Description
B 2020/08/05 TE-IN Final Report incorporating M/s. EPGL comments
This document is the property of Tractebel Engineering pvt. ltd. Any duplication or transmission to third parties is forbidden without prior written approval
B 2020/08/05 FINAL AMD SGE SGE SMA
A 2020/02/03 DRAFT AMD SGE SGE SMA
REV. YY/MM/DD STAT. WRITTEN VERIFIED APPROVED VALIDATED
TRACTEBEL ENGINEERING pvt. ltd. - Registered office: A-3 (2nd Floor), Neeti Bagh - New Delhi - 110049 - INDIA
CIN: U74899DL2000PTC104134
FEASIBILITY STUDY ON COMPLIANCE WITH NEW
ENVIRONMENTAL REGULATIONS OF MOEF & CC
DATED DEC-7, 2015
Contents
1.BACKGROUND .......................................................................................................................... 5
2. NEW EMISSION NORMS ........................................................................................................ 5
3. CURRENT EMISSION LIMITS ................................................................................................ 8
4. GAP ANALYSIS & MODIFICATION OPTIONS ....................................................................... 9
4.1. Particulate Matter (PM)............................................................................................... 9

4.1.1. Recommendation............................................................................................. 9
4.1.2. Conclusion ....................................................................................................... 9
4.2. Sulfur Dioxide (SO2) ................................................................................................. 10
4.2.1. FGD Technologies ......................................................................................... 10
4.2.2. Limestone Wet FGD Process and Variations ................................................ 14
4.2.3. Sea Water FGD Process ............................................................................... 18
4.2.4. Semi-Dry FGD Process and Variations ......................................................... 21
4.2.5. Major Components of FGD System............................................................... 25
4.2.6. Wet Stack ...................................................................................................... 28
4.2.7. Availability of Reagent and Logistics ............................................................. 31
4.2.8. Utilization of By-Products .............................................................................. 32
4.2.9. Adequacy of Available Space for FGD Plant ................................................. 33
4.2.10. Auxiliary Power .............................................................................................. 35
4.2.11. Commercial Comparison of Wet and Semi-Dry FGD systems. .................... 35
4.2.12. Schedule & Cost impact ................................................................................ 35
4.2.13. Recommendation:.......................................................................................... 36
4.2.14. Conclusion ..................................................................................................... 37
4.3. Nitrogen Oxides (NOx) ............................................................................................. 38

4.3.1. Handling of Spent SCR Catalyst ................................................................... 42
4.3.2. Recommendation:.......................................................................................... 43
4.3.3. Schedule & Cost impact ................................................................................ 44
4.3.4. Conclusion ..................................................................................................... 44
4.4. Mercury (Hg) ............................................................................................................. 45

4.4.1. Recommendation........................................................................................... 45
4.4.2. Conclusion ..................................................................................................... 45
4.5. Consumptive water and waste water ..................................................................... 46
P.011638-E-00001-001 • Rev.B CONFIDENTIAL

4.5.1. Recommendation........................................................................................... 46
4.5.2. Conclusion ..................................................................................................... 46
5. ELECTRICAL SYSTEM ......................................................................................................... 47
6. CONTROL SYSTEM .............................................................................................................. 48
7. CIVIL, STRUCTURAL AND ARCHITECTURAL WORKS ..................................................... 48
7.1. Foundation Design Philosophy .............................................................................. 49
7.2. Design Consideration .............................................................................................. 50
8. PATH FORWORD .................................................................................................................. 51
LIST OF ANNEXURES
ANNEXURE-1 Limestone Chemical Composition (Indicative)
ANNEXURE-2 Typical Layout of Limestone Wet FGD and SCR System
ANNEXURE-3 Typical Layout of Semi-dry FGD and SCR System
ANNEXURE-4 Typical Layout of Sea Water Wet FGD and SCR System
ANNEXURE-5 Typical Flow diagram for Limestone FGD System
ANNEXURE-6 Typical Flow diagram for Sea Water FGD System
ANNEXURE-7 Typical Flow diagram for SDA- Semi Dry FGD System
ANNEXURE-8 Typical Flow diagram for CDS- Semi Dry FGD System
ANNEXURE-9 Summary Cost Analysis for FGD
ANNEXURE-10 Summary Cost Analysis for SCR
ANNEXURE-11A Typical SCR Arrangement
ANNEXURE-11B SCR System Write-up and Suggested Changes in SG & Auxiliaries
ANNEXURE-11C Type of SNCR
ANNEXURE-11D Case Study of High Dust SCR System
P.011638-E-00001-001 • Rev.B CONFIDENTIAL

ESSAR POWER GUJARAT LIMITED
2x600 MW, SALAYA TPP,
JAMNAGAR, GUJARAT,INDIA
1. BACKGROUND
Essar Power Gujarat Limited (EPGL) has already set up a coal-based sub critical
thermal power plant “2x600 MW Salaya TPP, near 44 KM Stone, Jamnagar-Okha
Highway, Khambhalia P.O, Dist.-Devbhumi, Dwarka in the state of Gujarat and both
the units are in successful operation since 2012. Now, plant needs to be in
compliance with new environmental norms of MoEF declared on 07th Dec 2015 and
subsequent amendment dated 28th June 2018 and accordingly new De-NOx, De-
SOx system with other modification (as required) to be done to meet the new
environmental regulation of MoEF & CC. Tractebel Engineering Private Limited
(TRACTEBEL) has been appointed as the Owner’s consultant (OE) to carry out the
feasibility study for the same.
The steam generator & steam turbine for the plant are supplied by M/s Harbin Power
Engineering Company Limited, China (HPEC). M/s Harbin Boiler company Limited,
China (HBC) and M/s Harbin Turbine Company Limited, China (HTC) are the
manufacturer of steam generator and steam turbine respectively.
The commercial operation dates of the 2x600MW TPP units are as below:
• Unit #1; 1st April 2012

• Unit #2; 15th June 2012
2. NEW EMISSION NORMS

The Ministry of Environment, Forest and Climate Change (MoEF & CC) in their
notification dated 7th Dec 2015 and subsequent amendment dated 28th June 2018,
has stipulated new emission and consumptive water norms for thermal power
stations. The summary of the new environmental norms is produced in the below
tables:
P.011638-E-00001-001 • Rev.B 5/51 CONFIDENTIAL

Table 2-1: New Emission Norms 2015
Emission Norms (mg/Nm3)

Category 1 Category 2 Category 3
TPPs to be
TPPs installed
PARAMETER TPPs installed after installed
before
from
PREVIOUS
NORMS 01-Jan-2004 up to
(mg/Nm3) 31-Dec-2003 01-Jan-2017
31-Dec-2016
< 500 > 500 < 500 > 500
For all Units
MW MW MW MW
Particulate
150/50 100 50 30
Matter
Sulphur
None 600 200 600 200 100
Dioxide (SO2)
NOx None 600 300 100
Mercury None NA 0.03 0.03 0.03
All monitored values for SO2, NOx and Particulate Matter shall be corrected to 6%
Oxygen, on dry basis (As per Amendment rules dated 28th June 2018).
• Category 1 & 2 Projects: to comply within 2 years

from the date of Notification
Timeline for compliance
• Category 3 Projects have to comply prior to
Commissioning
Table 2-2 Specific Water Consumption Norms 2015 (old)
Specific Water Consumption Norms (m3/MWh)

Category 1 Category 2 Category 3
New plants to be
PREVIOUS Once Through Cooling Existing CT Based
Installed after
NORMS (OTC) Based Plants Plants
01-Jan-2017
3.5m3/MWh (with
None installation of cooling 3.5m3/MWh 2.5 m3/MWh
tower (CT))
• Category 1 & 2 Projects: to comply within 2 years from the date

Timeline for of Notification
compliance
• Category 3 Projects have to comply prior to Commissioning

Table 2-3: Water Consumption Norms 2018 (Amendment)
Specific Water Consumption Norms (m3/MWh)
New plants to be
PREVIOUS Power Plants using Existing CT Based
Installed after
NORMS Sea Water Plants
01-Jan-2017
Refer Table-2-2 No Regulation 3.5m3/MWh 3.0 m3/MWh with ZLD
Table 2-4: Wet Stack Height Norms 2018 (Amendment)
Wet Stack Height (m)

Description Less than 100MW 100MW and above
Thermal Power Plants

H=6.902 (Q X 0.277)0.555 H=6.902 (Q X 0.277)0.555
with wet Flue Gas
or 30 m, whichever is more or 100 m, minimum
Desulphurization (FGD)
Q=Emission rate of SO2 in kg/hr. #

H=Physical stack height in meter
# These standards shall apply to coal/lignite based Thermal Power Plants.
It is evident from the above that the current norms are much more stringent than the
previous norms (wherever existing). Also, the running 2x600 MW Salaya TPP falls
under category 2, which requires full compliance of MoEF & CC regulation. Hence,
these new emission norms shall now be applicable to this project.
This document is the feasibility study that concludes the final selected technologies
from among various technology options, modifications in current design and way
forward, required as a minimum, to comply with the new environmental norms. The
engineering, procurement and site erection status of associated equipment and
packages plays an important role in the decision of the nature and extent of
modifications that can be optimally applied to keep the overall changes and cost to
the minimum.

3. CURRENT EMISSION LIMITS

In fossil fuel boilers, oxides of Nitrogen i.e. NOx (NO & NO2) are formed during
combustion in furnace from fuel bound Nitrogen and atmospheric Nitrogen. Sulphur
dioxide (SO2) is formed by oxidation of Sulphur in coal at the operating furnace gas
temperature. A fraction of SO2 in flue gas is converted to SO3 during combustion or
along with selective catalytic reduction (SCR) reaction due to presence of heavy
metals at elevated temperature. The Mercury (Hg) is found in oxidized and elemental
form in flue gas.
The ash content in coal after combustion is separated into coarse boiler bottom ash
(~20%) and the finer fly ash (~80%). While the bottom ash is collected at the bottom
of the boiler furnace, the fly ash escapes along with the flue gas and separated in
the electrostatic precipitator (ESP) before being discharged through the flue gas
stack into atmosphere.
The present available emission limits for the running 2x600 MW Salaya TPP, under
the provisions of existing contract requirement are indicated in the below table:
Table 3-1 Current Emission Limit
LIMITS
PARAMETER REMARKS
(mg/Nm3)
Particulate
Matter 50 Worst coal with all ESP fields in service
(fly ash)
Sulphur
None Not a major pollutant under existing norm
Dioxide (SO2)
Based on Schedule-1, Performance
NOx specification, NOx at chimney inlet for design
718.75
(NO & NO2) coal at 100% TMCR (350 ppm corrected at
6% O2)
Mercury None Not a major pollutant under existing Contract

4. GAP ANALYSIS & MODIFICATION OPTIONS

The following discussion deals with the gap analysis between the available emission
limit under provisions of current contract and the limit set by the new environmental
norms for each of the above parameters. It will also explore the available reduction
options that are technically proven, cost effective and essential to comply with the
new norms.
4.1. Particulate Matter (PM)
Table 4-1 : Gap in Particulate Emission
Available Limit Required Limit

Parameter
(mg/Nm3) (mg/Nm3)
Particulate Worst coal with all ESP fields in 50
50
Matter (PM) service
4.1.1. Recommendation
It may be seen from the above comparison that the present available particulate
emission level for both the ESPs of Unit-1 & Unit-2 does not exceed the required
norm (i.e. 50 mg/Nm3), since the plant falls under Category-2 of MoEF & CC norms.
Thus, no modification in the existing ESPs are recommended.
4.1.2. Conclusion
The current available emission level of ESPs for both units (Unit #1 & 2) are within
the permissible limit as per MoEF & CC norms, so there is no requirement of any
modification in present ESPs. In addition to this, wet/dry type flue gas desulfurization
plant also reduces the PM emission level, which is being planned to be adopted for
this plant.

4.2. Sulfur Dioxide (SO2)

Table 4-2: Gap in Sulphur Dioxide
Achievable Limit Required Limit

Parameter
(mg/Nm3)* (mg/Nm3)
Sulphur Dioxide (SO2) None 200
*There was “NO” limit for Sulphur Di-Oxide (SO2) as per MoEF & CC norms before
7th December 2015.
Based on data analysed for 100% TMCR operating conditions on worst coal
parameters and composition, the SO2 emission comes out to be approx. 2380
mg/Nm3 at 6% O2, dry condition.
In order to reduce SO2 level from existing 2380 mg/Nm3 to 150 mg/Nm3 (considering
stringent norms as per CEA guidelines at guaranteed condition), an efficiency of not
less than 93.7% will be required for 100% flue gas capacity to meet the
environmental norm. Such high-level reduction efficiencies are only achievable with
installation of separate flue gas desulfurization (FGD) plant.
The existing SO2 value indicated above is calculated based on worst coal analysis
given by M/s EPGL. This represents the SO2 levels obtained due to the combustion
process burning the range of “worst” coal at 100% TMCR load conditions. However,
there will be alteration to the flue gas analysis after addition of SCR module in the
boiler (due to SO3 conversion, ammonia slip etc).
4.2.1. FGD Technologies

FGD technologies are well established internationally and come in broadly under
wet type FGD systems and semi-dry type FGD systems. Limestone based wet
system and Sea water based systems comes under wet type FGD systems.
Whereas, SDA/ CDS comes under semi-dry type FGD systems.
The following table provides a basic comparison including pros & cons of proven
technologies available for FGD, relevant to this project.

Table 4-3: Technical Comparison of Wet FGD & Semi-Dry FGD Technologies
Limestone Wet Sea Water FGD

FGD Spray Tower (SWFGD) Semi-Dry FGD
Attribute
/ Jet Bubbling (SDA/ CDS)
Reactor (JBR)
Commercial Units with single Units are in Units are in operation

Status absorber modules operation in in facilities up to 500
are in operation up facilities up to 1000 MW. Multiple absorber
to 900 MW unit MW. modules are required
capacity. for units above 350 -
400 MW range.
Installation Installed after the Installed after the Typically installed

power plant dust power plant dust between air pre-heater
collector. collector and dust collector to
catch the dry reaction
product carry over.
For Retrofit plant,

installed after the
power plant dust
collector
Reagent Limestone (CaCO3) Sea Water (H2O) Lime (CaO)
By-product Saleable gypsum No by product, Calcium sulphite

(CaSO4) to building dissolved sulphate (CaSO3) and calcium
-2)
(gypsum board) (SO4 is formed, sulphate (CaSO4)
industry, cement which is already along with some fly
industry or landfill. present as a ash.
Purity impacts natural component Not saleable. Mostly
saleability of in seawater. used in landfill.
gypsum, preferred
is 85% or more
purity.
Sulphur in <6% <2.0% <2.5%

coal


Attribute
Reactor (JBR)
SO2 Removal >98% Up to 98% 90-95%

Efficiency
SO3 Removal Does not remove Does not remove Efficiently removes SO3
SO3 SO3
Stack design Flue gas at outlet is Flue gas at outlet is Flue gas at outlet is
saturated with saturated with super-heated (typically
water, requiring a water, requiring a 15 - 30 deg. C above
gas-gas heater to gas-gas heater to dew point), reducing or
operate as dry operate as dry eliminating visible
stack. Alternatively, stack. Alternatively, moisture plume.
wet stack is wet stack is
adopted for adopted for
eliminating the gas- eliminating the gas-
gas heater. gas heater.
Corrosion Corrosion
protection lining is protection lining is
required for stack & required for stack &
associated associated
ductwork. ductwork.
Footprint Small in power Small in power Relatively smaller than

island and large island and, large Limestone wet FGD.
overall. overall
Pros • Large reference • Moderate • Lower Capital
list Capital Cost Cost
• Fuel flexibility • No By-product • Lower Power
• Ease of retrofit disposal cost Consumption

• No Reagent • Dry by-product
cost • Operational
• Operational simplicity
simplicity


Attribute
Reactor (JBR)
Cons • Acid corrosion • Acid corrosion • Difficult to retrofit
potential potential • High cost reagent

downstream downstream • Limited By-product
• Higher Capital • High Power use
Cost Consumption • High Maintenance
• Higher power • Less Fuel Cost
Consumption flexibility
• Wastewater • Huge sea water
generated consumption at
needs absorber tower
treatment for as well as sea
reuse/disposal water make up

for pH control.
• Spent sea
water after
absorber needs
treatment for
disposal
• Not Easy to
retrofit, even
sea water used
as condenser
cooling water

4.2.2. Limestone Wet FGD Process and Variations

The following figures illustrate process flow scheme of Limestone Wet FGD.
Figure-1: Process flow diagram - Limestone Wet FGD
Depending on the process licensor, the wet FGD process may have the following
major variations:
Counter Current Spray Tower: This is the most widely used absorber types. The
reaction takes place between the SO2 in flue gas flowing upward and limestone
slurry (10-15% solids) sprayed from the top (see Figure-2). Recycled slurry is
pumped continuously from the reaction tank to the slurry spray headers having
numerous spray nozzles. The spray grids may be arranged in several layers with
rotated configuration to obtain maximum coverage. In the reaction tank the SO2
absorbed from flue gas reacts with soluble calcium ions in the recycle slurry to form
insoluble calcium sulphite and calcium sulphate solids. In forced oxidation process,
air is bubbled through the slurry to convert all the solids to calcium sulphate
dehydrate (gypsum). Limestone reagent slurry is added to the reaction tank to
replace the calcium consumed.

To control the solids content of the recycle slurry, a portion of the slurry is discharged
from the reaction tank to the by-product dewatering equipment which includes hydro-
cyclones and vacuum filters. The liquid that is separated from the slurry is reclaimed
and reused in the absorber reaction tank as make-up. The saleable dewatered
gypsum is disposed of outside the plant by truck.
Figure-2: Counter current spray tower
Jet Bubbling Reactor (JBR): In this technology, the surface area required for
absorption of SO2 from the flue gas is created by bubbling the flue gas through a
pool of slurry (see Figure-3). Flue gas is pre-cooled with make-up water & limestone
slurry before entering the JBR inlet plenum. From this plenum flue gas is directed
through multiple sparger tube openings. These tubes are submerged a few inches
beneath the level of slurry in the integral reaction tank located at the base of JBR.
The bubbling action of the flue gas as it exits the sparger tubes and rises through
the slurry promotes SO2 absorption. The gas then leaves the reaction tank area and
through the outlet plenum.
In both the above two variations, energy is required for the effective gas to liquid
contact. In spray tower this is achieved by spray pumps that produce large number
of fine droplets. In JBR this energy is provided by the fans necessary to account for
the pressure drop across the sparger tubes. Therefore, the JBR has higher gas

pressure drop requirement than the spray tower. But JBR also consumes less than
20% of the pumping power requirement.
JBR has a compact & shorter reaction tower due to elimination of spray header
system and simpler system operation & control due to elimination of spray pumps.
JBR also provides additional benefit of high particulate removal capability compared
to spray tower.
Figure-3: Jet Bubbling Reactor (JBR)
Table 4-4: Indicative Process Details of Limestone Wet FGD System for 2x600 MW
Parameter Unit Value Remarks
Limestone Ton/h 10 ~ 11 Per absorber considering

consumption rate 79% limestone purity
Gypsum generation Ton/h 16~17 Per absorber on dry basis,

corresponding to limestone
purity of 79%
Gypsum quality
Chloride Content PPM <100

Moisture content % <10
Purity % >90%
Flue gas temperature Deg. C ~ 55 Without GGH

at stack inlet
Pressure drop on flue mmwg 250 Without GGH

path due to FGD
Auxiliary power kW 25200 Without GGH

consumption
Noise level dBA < 85
Make up water M3/h 350 - 400 Both units
requirement (max.)
Effluent water M3/h 60 - 65 Both units

generation (max)
Effluent quality
Chloride ppm 10,000
Temperature Deg. C 37 - 65
pH 5-6
Note: Above parameters are calculated based on worst coal & TMCR basis. The
numbers are indicative and supplier specific and should be confirmed during
detailed engineering.
Refer to Annexure-5 for Typical Flow diagram for Limestone FGD System.

4.2.3. Sea Water FGD Process
First choice of Sea water FGD may be considered in case plant located at coastal
area and type of condenser cooling system is sea water based open cycle. Due to
its natural alkalinity (pH value >7), seawater is suitable for use as an additive in wet
desulphurization. In flue gas desulphurization with seawater, dissolved sulphate
(SO4-2) is formed, which is already present as a natural component in seawater.
Flue gas desulphurization using seawater is particularly attractive in case of power

plants located on an ocean coast and seawater is used as condenser cooling water
for power plant. The seawater for FGD system is supplied to a dedicated sea water
pit from condenser outlet or from sea through independent sea water intake supply
pumps. From this pit the sea water shall be supplied by absorber spray pump to
absorber tower for SO2 absorption.
Normally seawater has a pH of 7.6 to 8.4 with an inherent alkalinity of approx. 100-
110 mg/L as CaCO3 (in terms of CO3–2 and HCO3-1). Untreated flue gas is passed
through an absorber tower from bottom and spray water from top of absorber tower
by absorber spray pump. The flue gas pass through first moretana plates and finally
through mist eliminator. The absorption of SO2 takes place in absorber, where sea
water & flue gas are brought in close contact in a counter-current flow for effective
scrubbing. Absorption of SO2 in sea water creates bi-sulphite (HSO3-1) and reduces
its pH by formation of hydrogen ions (H+). Spent Sea water in absorber tower goes
to relay Pit and then to Pre-Aeration Pit and Aeration pit. The sparging air is passed
through FGD aeration pit by oxidation air blowers to complete the oxidation of
absorbed SO2 as bi-sulphites into sulphates. The alkalinity in sea water present as
carbonates and bi-carbonates neutralizes the hydrogen (H+) ions to increase
seawater pH.
The contact between the flue gas and sea water in the absorber bring forth the
following chemical reaction;
After the contact between SO2 in flue gas and sea water, bisulphate (HSO3-) ion
generated it is partially oxidized to Sulphate ion (SO42-).

As the result of the above reaction, the pH value of the sea water reduces up to
3~4 due to increase in hydrogen (H+) ions in it.
Spent sea water from absorber is sent to sea water treatment plant (SWTP) by
channel or pipeline. Sea water treatment plant mainly consist of Aeration pit. Since
pH of the spent sea water is extremely lowered due to removal of SO2, it is
neutralized for pH recovery in the Aeration pit.
Secondly, COD (Chemical Oxygen Demand) is removed by oxidation of HSO3- and

dissolved oxygen recovered by means of supplying of oxidation air
During aeration, CO2 gas dissolved in the spent sea water is stripped to gaseous
phase. This reaction contributes pH increase because of the relation between pH
and dissolved CO2 concentration,
As sulphate is completely dissolves in the sea water, no waste is produced in the

SWTP. Besides, sulphate being a natural component of the sea water, SWFGD is
friendly to the oceanic environment.
Figure-4(i): Process flow diagram – Sea Water FGD (TYPICAL)

Figure-4(ii): Process flow diagram – Sea Water FGD (TYPICAL)
Table 4-5: Indicative Process Details of Sea Water FGD for 2x600 MW
Sea water flow m3/h 68,000~70,000 Both units
Auxiliary power kW 31800 Both units

consumption
numbers are indicative and supplier specific and should be confirmed during detailed
engineering stage.
Refer to Annexure -6 for Typical Flow diagram for Sea Water FGD System.

4.2.4. Semi-Dry FGD Process and Variations

Spray Dryer Absorber (SDA): This is the most common semi-dry FGD technology
using a vertical absorber either co-current (downward) or combined co & counter
current gas flow. Atomizers are located at the top of the absorber. Rotary or two-
fluid nozzles produce an umbrella of atomized lime reagent slurry through which flue
gas passes. The SO2 in flue gas is absorbed into the atomized droplets and reacts
with calcium to form calcium sulphite and calcium sulphate.
Before the slurry droplet can reach the absorber wall the water in the droplet
evaporates and a dry particulate is formed. The flue gas containing the dry fly ash
and dry FGD by-products leaves the absorber and passes through a fabric filter to
separate the fly ash and by-product solids. This is pneumatically conveyed for
disposal. The by-product solids may be recycled by slurry and re-injected into spray
dryer along with the fresh lime reagent.
SDA systems are typically installed after the boiler proper. Capacity of single
absorber SDA is limited to 400 MW commercially. Hence, for a 600 MW plant two
(2) absorber towers may be required.
Figure-5: Process flow diagram (SDA Technology)
Major issues with SDA technology are as listed below:

• Physical installation of SDA in the present boiler or chimney back end will be
more problematic due to two (2) absorber towers (per unit) or total four (4)
absorber towers in 2x 600 MW.
• SDA installed upstream of ESP will impact the dust loading of the existing ESP
(over and above that as explained under section 4.1), which will call for further
upgradation by addition of collection area/fields which is not possible considering
present layout.
• SDA system installed downstream of ESP will still require a fabric filter to capture
the carry-over of reaction products. This will call for additional space which is
about twice that of NIDTM.
• With two absorbers towers per unit, SDA is expected to lose its first cost benefit
over wet FGD.
Circulating Dry Scrubber (CDS): This technology has been commercially
established and modified by some OEMs and many installations are successfully
running overseas. Apart from SO2, CDS can also remove HCl, HF and trace
metals like mercury. This system is preferably installed downstream of the main
particulate collection system i.e. ESP. The reaction products including residual fly
ash is mixed with lime and water in a hydrator/mixer before being injected into the
CDS reactor. In addition to the formation of calcium sulphite and calcium sulphate
like in other semi-dry process, calcium carbonate is formed because of the CO2
present in flue gas:
The absorber duct removes ~80% of the SO2 and other acid gases. The fly ash
and calcium mixture are collected in the fabric filter and transported via a fluidizing
trough to the hydrator/mixer. In the hydrator, water and fresh lime (CaO) required
to maintain SO2 control are added. The moist recycled fly ash and calcium
material are gravity fed into the reactor duct to cool and humidify the gas. This
creates optimum conditions for SO2 to be removed from the flue gas stream via
reaction with lime. The moist fly ash and calcium material then proceed up to the
absorber duct, continue to dry and capture SO2 & other acid gases. The absorber
duct is designed to maximize flue gas and moistened recycle material mixing while
minimizing dust fall out. The material is sufficiently dry before entering the fabric
filter where the dry particulate is removed.

CDS system can operate by using commercially available powdered quicklime or

hydrated lime. Quicklime is a preferred choice due to cost, transportation and
handling/storage equipment capacity. Crushed quicklime is slaked into hydrated
lime in the integrated CDS hydrator. An integrated CDS hydrator would be
supplied for each individual absorber reactor/duct. The water consumption for
CDS is dependent on the superheat to maintain desired humidity level for
reaction. This is ~15 deg. C above saturation. This may be marginally higher than
SDA. The water quality of CDS is flexible and can be sourced from cooling water
blowdown and treated wastewater.
Some established CDS technologies in the market come in a modular concept
with each module suitable for up to 90 MW. Hence, for a 600 MW plant, upto eight
(8) modules of absorber duct may be required. CDS is a compact system requiring
only 50% of the footprint for an equivalent SDA + bag filter system for a 600 MW
application. A dust emission guarantee of < 50 mg/NM3 can also be achieved in
CDS technology.
Figure-6: Process flow diagram (CDS Technology)

Novel Integrated Desulphurization (NIDTM): Novel Integrated Desulphurization
(NID) is a modified version of Circulating Dry Scrubber (CDS) patented by Alstom-
GE. This system is made up of a patented integrated hydrator/mixer, a J-duct
reactor and a fabric filter. Hydrated lime is used as a reagent to react with gaseous
pollutants like SO2, HCl, and HF. Mercury collection can also be controlled by
injecting PAC (Powdered Activated Carbon) upstream. The collected particles are
then either recirculated to J duct or disposed to the by-product silo.

.
Figure-7: Process flow diagram (NIDTM Technology)
Table 4-6: Indicative Process Details of 2x 600 MW Semi-Dry FGD System
Lime (CaO) Ton/h 9~10 Per unit @ 90%
consumption rate Lime purity
Flue gas Deg. C ~ 65 - 70

temperature at
reactor outlet
Auxiliary power kW 28500 Both units

consumption
Make up water M3/h 330-350 Both units (CT

requirement (max) blowdown grade)
numbers are indicative and supplier specific and should be confirmed during detailed
engineering stage.
Refer to Annexure-7 for Typical Flow diagram for SDA- Semi Dry FGD System.
Refer to Annexure-8 for Typical Flow diagram for CDS- Semi Dry FGD System.

4.2.5. Major Components of FGD System
Table 4-7
Limestone Sea water Semi- Remarks

Wet FGD FGD dry FGD
(Spray (SWFGD) (SDA/C
Tower DS)
Absorber
/JBR)
Main process Y Y Y NIDTM uses a

absorber towers patented modular
& reaction tank mixer, hydrator,
with internals reactor concept
(unitized)
Centrifugal Y Y N Oxidation Air

blowers for Blowers shall be
(unitized) (Common)
forced oxidation used in SWFGD for
of sulphite to aeration in Sea
sulphate water treatment
plant
Limestone Y Y N JBR wet system

Slurry does not require
(unitized) (Common)
Recirculation recycle pumps.
pumps / Sea
For SWFGD,
water spray
Absorber sea water
pumps and
spray pumps shall
spray
be required
distribution
system

Reagent Y N Y Semi-dry FGD

(limestone/lime) system usually does
unloading, not require
storage, elaborate crushing
crushing and systems as lime can
handling & be sourced in
conveying powder form. Lime
system is handled via
(common) pneumatic
conveying; hence
layout is flexible
Reagent slurry Y N Y NIDTM has a much

preparation and more compact and
feed system integrated system
including day consisting of only
silo, weigh hydrator/mixer
feeder, ball mill,
For SWFGD,
classifier, slurry
common dedicated
tank and pump
sea water intake
(common)
supply pumps are
required to supply
sea water from sea
to plant and
separate pump
house shall be
constructed at
seashore.
Make up water Y Y Y
storage tank
and pumps
(common)

By-product Y N N For semi-dry FGD

gypsum slurry by-product is dry
primary and handled
dewatering pneumatically up to
hydro-cyclone storage silos for
(common) truck disposal
Gypsum Y N N
secondary
dewatering
vacuum belt
filter system
(common)
By-product in Y N Y Either a building

plant storage (WFGD) or silo
and offsite (semi-dry FGD)
disposal system
(common)
Local area Y N N
sump, sump
pumps and
agitators
Gas to Gas Y (Optional Y N

Heater - See Note) (Optional -
See Note)
Fabric filter N N Y
system
Flue gas Y Y Y To handle the

booster fan additional pressure
drop through the
FGD system and
reduced draft

Note: A gas-gas heater may be required and included in Wet (spray tower/ JBR/
Sea water) FGD system, as an option. In a wet desulfurization process, the flue gas
exhausting from the reaction tower/absorber is in saturated state at the adiabatic
saturation temperature. The gas-gas heater function is to reheat the exhaust gas
after wet desulfurization.
The advantages gas-gas heater is:

• Better diffusion of the exhaust gas.
• Prevent the white plume at stack outlet.
• Minimize low-temperature corrosion of the downstream duct and chimney.
• Saves make up water consumption by pre-cooling the flue gas before reaction
thereby minimizing evaporation loss.
The disadvantages gas-gas heater is:

• Flue gas leakage across GGH will demand for higher SO2 reduction requirement
in absorber & consequently more power requirement of recirculation pumps (on
a/c of higher L/G ratio) in addition to higher flue gas draft loss across absorber
impacting ID/Booster fan power consumption.
• Accordingly, GGH will also increase running cost along with high maintenance
requirements.
• Adds to auxiliary power and CAPEX.
• Generally regenerative type heaters are used which costs 10% of CAPEX.
As a means for meeting above requirements, a regenerative type or a no-leakage

tubular type gas-gas heater may be used. However, the final decision regarding
inclusion of a gas-gas heater can be taken only after detailed discussions with
suppliers with due consideration to cost economics and practical difficulties in
operation & maintenance.
4.2.6. Wet Stack

Semi-dry FGD systems do not require any stack lining to be used. This is because
the system effectively removes SO2 as well as SO3. Secondly the system operates
sufficiently above the saturation temperature with 15 to 20 Deg.C superheat. This
leaves no risk of acid condensation. Hence, a semi-dry FGD system will be able to
use bare carbon steel as flue and duct material. Wet FGD technology has little or
limited SO3 absorption capability. SO3 is an unavoidable component of flue gas as
a result of combustion of coal. Secondly, additional SO3 conversion is affected by

heavy metal content of catalysts due to the use of SCR (de NOx). Since, wet FGD
operates at saturation temperature, there is strong risk of acid condensation in the
downstream flue gas path in a wet stack configuration. Use of gas to gas heater
serves a dual purpose of water reduction as well as temperature elevation of flue
gas. But although the SO2 component is eliminated, due to the presence of SO3, risk
of acid condensation still remains. Hence, wet FGD systems have to provide anti-
corrosion lining on absorber downstream ducting as well as in flue stack. Popular
commercially available liners for the steel flues are indicated below:
a. Borosilicate Glass blocks: These closed cell, light weight glass blocks are
installed by local semi-skilled workers under supplier supervision. Its low weight
makes block linings compatible with a variety of construction methods. Block
linings can be installed in completely erected steel chimneys / flues or they can
be applied to steel segments (cans) at ground level first, prior to erection. The
chimney flue is then erected by welding the pre-lined cans together or by using
bolted flange connections. Only the field welds or flange areas are lined after
erection. The flue does not require additional external insulation.
b. Glass flake reinforced vinyl ester co polymer: This is the spray applied on flue
sections on ground before erection. However, the field welds in the flue are to
be properly applied after flue erection.
c. Metallic liners like Titanium or Hastelloy C: These are the costliest but offer
maximum protection against acid corrosion
Table 4-8: Chimney Flue Can Lining Material Comparison
Chemical Temperature Life Relative Remarks

Resistance Resistance Cost
deg. C
Borosilicate blocks Suitable for 200 Long life / 2 Can

on steel/concrete wet flue minor withstand
gas, with maintenance higher
38 mm or 51 mm
high SO3 temperature
level for short
periods
Vinyl Ester FRP --Do-- 150 Long life 2 --Do--

Glass flake vinyl --Do-- 140 Needs 1 --Do--

ester on steel, reapplication/ (lowest)
maintenance
3 mm in medium
term
Alloy cladding --Do-- 427 - 900 Long life 3 Suitable for

(C276 or Ti) steel, (highest) all boiler
2.0 mm upset
conditions
a. For existing chimney lining a downtime of 3 to 4 months shall be planned. In

case of multiple flues, it is customary practice to shut down all units while the
lining work proceeds. This is to promote safe working environment near the flue
can and shell as access is provided from top.
b. For ductwork lining, the preferred choice is glass flake vinyl ester copolymer
coating of minimum 1.5mm thickness.
In order to avoid existing stack lining work (in case wet FGD is selected) and
generation loss due to 3 to 4 months shutdown, it is recommended to construct a
new RCC chimney of height 150 m consisting of two (2) number of wet flues for
retrofitting of limestone/sea water wet FGD system in the 2x600 MW, Salaya TPP.
Treated flue gas from the absorber shall be discharged through this new wet
chimney and the existing chimney shall be used during full bypass of FGD plant.
The new wet chimney shall be suitably lined. Provision shall be made for collection
of the condensate/ acidic water droplets depositing on cold surfaces during unit start-
up condition etc. and for its proper disposal.
As per CEA guidelines, the new chimney flue liner cladding shall be made of 2 mm
thick Titanium (ASME SB265 Gr.2) or C-276 alloy over 8 mm thick (minimum) mild
steel base metal of flue liner. Alternatively, other applicable materials such as C22
alloy, Borosilicate Block lining (minimum 38 mm thick), acid resistant tiles, flake
glass lining (minimum 3 mm thick) or complete flue(s) of fire-retardant GRP/ FRP
can also be considered as per proven experience.

4.2.7. Availability of Reagent and Logistics
Limestone
Limestone mines are distributed all over India. Good quality limestone is mostly
available in Rajasthan, Madhya Pradesh, Orissa, Andhra Pradesh, Telangana,
Karnataka, Tamil Nadu as well as in Gujarat.
As per the Indian Minerals Yearbook 2018 (Part- III) 57th Edition Minerals Reviews;
The production of limestone in 2017-18 at 338.55 million tonnes increased by about
7.59% as compared to that of the previous year.
Rajasthan was the leading producing State accounting for (22%) of the total
production of limestone, followed by Madhya Pradesh (13%), Andhra Pradesh &
Chhattisgarh (11% each), Karnataka (9%), Telangana (8%), Gujarat (7%) and Tamil
Nadu (6%). The remaining 13% was contributed by Maharashtra, Himachal
Pradesh, Meghalaya, Odisha, Uttar Pradesh, Assam, Jharkhand, Jammu &
Kashmir, Kerala and Bihar.
As per the Indian Minerals Yearbook 2018 (Part- I) 57th Edition State Reviews
(GUJRAT); the mines of limestone are in Amreli, Banaskantha, Bharuch,
Bhavnagar, Jamnagar, Junagadh, Kheda, Kachchh, Panchmahal, Porbandar,
Rajkot, Sabarkantha, Surat, Vadodara and Valsad districts.
M/s EPGL to identify the mines for long term reliable limestone sourcing at least
85% purity from the nearby location.
Saleable gypsum grade for cement or fertilizer consumption requires minimum 80%
to 85% limestone purity. For indicative chemical analysis of limestone samples refer
to Annexure-1.
Limestone will be received to power plant through road by trucks. Maximum daily
requirement of trucks will be approx. 30~36 nos. for 2x600MW Salaya TPP
(assuming 15~18 tons /truck and limestone purity of 79%). This may be reduced
depending upon high purity limestone and burning of low sulphur coal. Optionally,
Indian Railway rakes with manual site unloading facility may also be utilized for the
purpose, depending on availability of rail loading facility at mine end.

Sea water
The distance of the plant from sea is approx. 18km. The sea water shall be required
approx. 69000~70000 m3/hr. for flue gas desulphurization for both units (2x600MW).
3x50% (2 Working +1 Standby) sea water intake supply pumps shall be required of
approx. 36,750m3/hr. flow capacity. Four (4) nos. GRP pipelines, two (2) nos. for
sea water supply and two (2) nos. for sea water return shall be required.
Lime
Lime (CaO) is formed by burning (calcination) of limestone. There are numerous
chemical suppliers in and around Gujarat for supply of Lime. Lime can be sourced
as pebble or powdered forms.
Limes will be received to power plant through road by trucks. Maximum daily
requirement of trucks will be approx. 26~32 nos. for 2x600MW Salaya TPP
(assuming 15~18 tons /truck and lime purity of 90%).
4.2.8. Utilization of By-Products
Limestone based Wet FGD

Uses of gypsum (calcium sulphate-dihydrate) is well established in industry.
Gypsum is utilized for the following:
(a) Making gypsum blocks & gypsum board for the building industry,
(b) Making fire-resistant panels.
(c) Additives for Portland cement industry.
(d) As soil conditioner in agricultural.
Minimum saleable gypsum purity requirement 90-95% for building industries which
can be achieved in the wet FGD process utilizing limestone of purity more than 90%.
Lower grade gypsum is used in manufacture of Portland cement. During the
operation phase, the power plant owner generally tie-up with cement and building
material industries nearby for by-product offtake linkage.
Lime based Semi-Dry FGD

The dry FGD by-product is majorly calcium sulphite hemi-hydrate. Since the retrofit
system is installed downstream of power plant main dust collector, there will be only
minor fly ash (< 10%) present in the by-product.

The characterization of dry FGD by-product is governed by the ash content which in
turn depends on the fly ash properties and efficiency of particulate collection
equipment. While there are major constituents of hydrated calcium sulphite, there
are varying amounts of oxides of Fe, Al & Si also present depending on the fly ash
component.
Fly ash adds to cementitious property of the by-product and for installations with
upstream ash collector, then by-product may be mixed with fly ash to increase its
utilization as a cementitious substance. Typical use of dry-FGD by-product with
cementitious property includes backfilling in mines, reclamation/restoration,
structural fills / embankments and stabilization. It has also been mixed with fly ash
and used for brick making.
4.2.9. Adequacy of Available Space for FGD Plant

As per the latest plot plan, the area available has been found to be adequate for
locating unitized absorber/reactor as well as common reagent storage for both the
units.
• FGD Absorber/Reactor Area
The area available is approximately 90m x 80m on both sides behind the
chimney and are adequate to locate the main wet FGD equipment (absorber,
booster fan, interconnecting flue gas ducting, pits and pumps etc.).
The available space is also adequate for installation of main equipment of semi-
dry FGD system like reactor, fabric filter, booster fan and interconnecting flue
gas ducting.
• Reagent Storage, Handling and Milling Area
A covered limestone receiving area and crushing plants envisaged, within the
plant. It is expected that limestone shall be received in lump size of + 250 mm.
hence a crushing system is envisaged in which the crusher will size the lumps
to below 22.5mm, which is accepted by the ball mills in the reagent slurry
preparation area.

This system will comprise of RCC underground reclaim hopper/surface feeder,

belt conveyors/bucket elevators, hammer mill (or other type depending on final
available limestone quality), crusher and crushed limestone conveyor up to unit
storage (day) silo. The limestone storage yard of 15 days capacity will be
considered. The limestone receiving/storage/crushing, limestone day silo & lime
slurry preparation, gypsum dewatering plant etc. facilities will be located behind
the road along the sea water pipeline.
The area available behind the road along the sea water pipeline is more than
the required area of 270m x 245m. The above facilities will be common for both
the unit of 2x600MW.
The above-mentioned available space is also adequate for lime storage silos
and conveying system required for semi-dry FGD system.
• By-product Storage & Handling Area

The dewatered gypsum with purity > 90% can be sold to manufacture cement or
plaster board. A gypsum storage cum truck-off facility will be located adjacent to
the secondary gypsum dewatering plant. The storage will be an enclosed
building comprising of gypsum belt conveyors at the discharge from vacuum belt
filters and travelling tripper located on an upper floor. The gypsum will be
dumped directly on the ground level for storage. There will be a facility to load
the gypsum on to the trucks for disposal off-site. The size (duration or volume)
of storage will depend on the logistics of gypsum off-take arrangement and will
be considered as 15 days minimum. In addition to this, a separate Gypsum
storage shed may be considered nearby limestone stock yard.
By-product of semi-dry FGD shall be stored in silos. The size (duration or

volume) of storage will depend on the logistics of by-product off-take
arrangement and will be considered as 15 days minimum.
Refer to Annexure-2 for Typical layout of wet FGD and SCR System.
Refer to Annexure-3 for Typical layout of semi-dry FGD and SCR System.
Refer to Annexure-4 for Typical layout of Sea water FGD and SCR System.

4.2.10. Auxiliary Power

As per the CEA guideline available for the enhanced auxiliary power consumption
limits due to addition of the limestone based wet flue gas desulfurization system.
Auxiliary Power Consumptions (APC) is estimated to be maximum 1% for FGD
operations for plant burning domestic coal with low sulphur content. In case GGH
(Gas to Gas Heater) is used, maximum 0.3% additional APC may be considered.
However, limestone based FGD for plants using imported coal with 1% sulphur
content, the APC shall be approximately 2%- 2.15% of the gross plant output, for
the plant without GGH. Auxiliary power consumption for sea water FGD system shall
be more than other FGD systems like limestone FGD system and Semi dry FGD
system.
Auxiliary power consumption for semi-dry FGD system shall be more than limestone
FGD system and less than sea water FGD system. This is based on inputs received
from various FGD suppliers.
4.2.11. Commercial Comparison of Wet and Semi-Dry FGD systems.
Table 4-9: Life Cycle Cost
Limestone Sea Water FGD Semi-Dry FGD

Wet FGD
Total Capital Cost High High Low
O&M Cost Moderate Moderate High
Life Cycle Cost High High Higher
4.2.12. Schedule & Cost impact

The EPC schedule of the design, supply, installation & testing of the limestone/sea
water FGD system is longer than the semi-dry FGD system. The overall schedule
from award of package to installation & commissioning as per the available FGD
technology vendors is
• 28-30 months for limestone/sea water FGD
• 20-22 months for semi-dry FGD

The above schedule includes the following:

• 3-4 months shutdown for chimney lining in case of wet FGD. (This can be
avoided by constructing independent short FRP stack with wet FGD absorber
tower, at additional cost)
• 3 weeks shutdown for interconnection with existing system (mechanical,
electrical, C&I)
All stakeholders should strive to improve upon the standard EPC schedule to meet
the target installation dates. The schedule can be finalized after the joint discussion
with M/s EPGL, OE and FGD suppliers.
Refer to Annexure-9 for indicative cost analysis of FGD systems.
However, the final cost and schedule impact can be assessed during tendering
stage and finalization of supplier.
4.2.13. Recommendation:
By the above considerations, technically speaking, either of limestone/ sea water
FGD or semi-dry CDS/NIDTM systems may be considered for this project, from
retrofit, layout & installation points of view.
The sea water based FGD installations are also there in India at various power plants
located near the seashore, but these FGD installations were designed for partial
treatment of flue gas and operating with once through sea water condenser cooling
water system. For 2x600 MW Salaya TPP, which is located approx. 18km from the
seashore and operating with Induct Draft Cooling Tower (IDCT) condenser cooling
water system. For sea water FGD system, a new sea water intake pump house &
intake structure shall be required at seashore. The location of this structure may be
near to the existing sea water intake facility.
However, since there is no limestone (JBR technology) based FGD System or sea
water FGD (for 100% flue gas treatment) or semi dry (SDA/CDS/NIDTM ) FGD
installations in India presently, M/s EPGL may like to visit running installations to
gather first-hand information on performance and operating feedback about these
technologies.

The capital cost of limestone FGD is higher than Sea water FGD & Semi-dry FGD
system due to more complex systems. The O&M cost for Semi dry FGD system is
higher mainly due to more auxiliary power consumption, costly reagent and fabric
replacement issues. The overall lifecycle cost for semi-dry FGD System tends to be
on the higher side even after considering additional capex loading for lining in
existing chimney (height - 275 meter) or separate new wet chimney of lower height
with lining and reagent handling system applicable for Sea water / Limestone wet
FGD.
The commercial aspects as indicated in this study are based on budgetary

estimates.
The final choice of the FGD technology has to be made after studying the raw
material/reagent sourcing and transportation logistics. The objective is to
ensure uninterrupted supply of good quality reagent for all operating and
future units of the site, throughout the life cycle of the plant.
4.2.14. Conclusion
Considering relative merits and demerits and overall lifecycle cost, it has been
recommended to install either Sea water based FGD system or Limestone based
FGD system in both the units for controlling the SO2 emission.

4.3. Nitrogen Oxides (NOx)

Table 4-10 Gap in Nitrogen Oxides
Present Guaranteed Limit Required Limit

Parameter
(mg/NM3) (mg/NM3)
Nitrogen Oxides
718.75 (Note 1) 300
(NOx)
Note: Based on Schedule-1, Performance specification, NOx at chimney inlet for

design coal at 100% (350ppm corrected at 6% O2)
The above comparison shows that the NOx reduction efficiency of 58.26% (approx.
60%) will be required to meet the new environmental norms.
Table 4-11: Technical Comparison of De-NOx Technologies

In Combustion Post Combustion
Available Selective Non-
Technology Combustion Selective Catalytic
Catalytic
Modification Reduction (SCR)
reduction (SNCR)
Low NOx Burner, Catalyst type:

Reagent:
Variants & Wind box Plate / Honeycomb
Anhydrous /
Measures to modification Reagent:
Aqueous
control NOx Various type of Anhydrous / Aqueous
Ammonia or Urea
over fire air Ammonia or Urea
Reduction
30% - 40 % 25% - 40 % 90% & Above
Efficiency
Installation
Low Moderate High
Cost
High (Aux. Power,

Operational High (mainly
None reagent cost &
Cost reagent cost)
catalyst replacement)
Using NH3
4NO + 4NH3 +O2→4N2+6H2O

2NO2 + 4HN3 + O2→3N2 + 6H2O
Process of NOx Staging of
Using Urea
reduction combustion air
4NO + 2CO(NH2)2+O2→4N2+4H2O+2CO2
2NO2 + 2CO(NH2)2+ O2→3N2 +

4H2O+2CO2

In Combustion Post Combustion

Available Selective Non-
Technology Combustion Selective Catalytic
Catalytic
Modification Reduction (SCR)
reduction (SNCR)
Temperature
NA 870° to 1200°C 300° to 400°C
required
Notes:
1. Anhydrous ammonia (> 99.5% commercial concentration) is highly hazardous in
nature and requires strict safety and regulatory compliance (CCoE) for
transportation, storage and handling.
2. Anhydrous ammonia requires lesser storage and handling space as compared
to aqueous ammonia which is only 19% to 30% concentrated.
3. Anhydrous ammonia is overall cost effective due to lower transportation
logistics.
4. Due to lower temperature requirement for reaction, SCR is installed in between
the economizer and air pre-heater. Whereas in SNCR the reagent is injected in
the furnace convection zone for optimum reaction temperature.
Figure-7: Flow Diagram SCR

Figure-8: Flow Diagram SNCR
Following options are available to address the NOx reduction issue in a cost-
effective manner:
Table 4-12: Combustion Control Options for De-NOx
Reduction Impact on
Options Methods Actions
Effectiveness existing system
Combustion Low NOx High NOx Modification in M/s EPGL to discuss
Control Burner reduction the present with boiler OEM (HBC)
combined potential (30% combustion for modification in the
with staged to 40%) system (burner existing combustion
combustion and wind box). system for installation
air / over fire of low NOx burner
air and staging the
combustion air in
furnace.

Table 4-13: Post Combustion Control Options for De-NOx
Impact on existing
Reduction
Options Methods system/boiler Actions
Effectiveness
modifications
All impact issues
requiring boiler
modifications will be
• Requirement of space addressed by boiler
for ammonia OEM (HBC). In this
unloading, storage regard a preliminary
and handling facility paper of some similar
boiler OEM is
attached under
Annexure-6B.
• Modification of duct
layout and boiler
Additional pressure
structure between
drop due to SCR will
economizer and air
be absorbed by ID
preheater for locating
Fans.
SCR modules
• Effect on the boiler

Selective back end heat transfer
Post Additional auxiliary
catalytic Efficient surface and flue duct
Combustion power will be to the
reduction (~90%) for installation of low
Control tune of 0.1%
(SCR) load economizer
bypass
• Protection of APH cold
O&M costs are
end due to
discussed under
ammonium bi-
Annexure-5.
sulphate
• Effect on boiler draft
system
• Additional
requirement of
auxiliary power
• Effect on plant O&M
and spares cost
• Adequacy of capacity
of present utilities (i.e.
steam, service water,
fire water,
compressed air etc.)

Impact on existing
Reduction
Options Methods system/boiler Actions
Effectiveness
modifications
• Upgradation of
related electrical
supply system
• SCR catalyst disposal
hazard
• Additional control
system and interface
with DCS
Generally, as above,
except there is option to
use urea as a reagent and
the injection is at the
Selective boiler furnace convection
non Less zone. Supplier specific Refer to Annexure-6C
catalytic efficiency technology can reduce for OEM report on
reduction (~40%) the number of spray SNCR technology.
(SNCR) lances drastically. One
OEM claims a single lance
per 100 MW. Hence
modification to boiler and
structure is minimal.
4.3.1. Handling of Spent SCR Catalyst

Current practice for handling spent catalyst includes catalyst recondition
(regeneration/washing), disposal and recycling. There are mainly three (3) options
for spent catalyst handling philosophy.
First Option is to dispose as landfill and this landfill disposal cost are a strong
function of the location in which the waste is generated and whether it is treated as
a hazardous or non-hazardous waste. Current global scenario shows that most
spent catalyst has been land filled.
Second Option is to recover bulk heavy metal and other ceramic material to be
disposed. Recycle has primarily been limited to recover of bulk metals associated
with the catalyst modules. The removed metals are typically sold as scrap and
ceramic materials are typically landfill disposed.
Third Option is to regenerate the spent catalyst which may be a viable option for
some spent catalyst depending on the application and characteristics of the catalyst.
This may be an alternate to catalyst disposal or recycle. Catalyst regeneration facility

can be arranged on site by mobilization regeneration facility provided by few OEM

over the globe. This is very rare option because globally there is few listed suppliers
can do the catalyst regeneration. Regeneration process removes catalyst
deactivation compounds and restores catalyst activity almost back to the original
OEM level (90%). And since it reuses modules, it provides environmental
compliance. Honey-comb catalyst can be regenerated many times until they are
mechanically destroyed. For regeneration catalyst to be taken to shop and then
catalyst go through a multi-stage process after arriving at the facility:
• Cleaning to remove fly ash and other particles which cause blockage.
• Immersion in a series of chemical baths to remove deposits that reduce
performance.
• Undergoes Selective Impregnation, restoring full catalyst activity by infusing the
module surfaces with oxides of base metals.
• Recalcination, a heated drying process that re-establishes mechanical strength
and fixation of the active metal oxides.
Further, as far as Catalyst regeneration is concerned, it is recommended to analyse

its requirement critically with due consideration of expected mechanical Vs. chemical
life of catalyst and new catalyst cost Vs. regeneration cost.
Even though, the operational experience on catalyst with Indian Coal application is
yet to be gained / established in India, we presume that one cycle of regeneration
might be considered.
4.3.2. Recommendation:
From the above discussion it is seen that in order to meet the new NOx emission
limits of 300 mg/Nm3, at the chimney exit, a reduction efficiency in the range of 58%
to 60% is required based on the ex-furnace NOx level. Such efficiency is only
achievable by SCR technology.
However, M/s EPGL is required to get boiler OEM (HBC) feedback and support for
SCR installation.

As there is no installation of SNCR technology in the utility boiler at present in India,

25% reduction efficiency may be considered on conservative side which can help to
achieve a NOx emission level of approx. 540 mg/Nm3 after reduction in present
contractual in-furnace NOx level. In case combustion modification technology is
adopted, it will further reduce the NOx level by ~30% of NOx emissions and achieve
NOx level of 378 mg/Nm3. Although this value is quite close to the required emission
limit, it may be noted that SNCR suppliers still have not demonstrated capability to
control NOx below 300 mg/Nm3 at all conditions.
The space available in boiler island will be utilised to locate the SCR modules with
flue gas inlet and outlet duct to the main flue gas exit. The common ammonia/urea
storage and unloading facility is proposed to be located as demarcated in the
attached typical layout.
Refer to Annexure-2 for Typical layout of wet FGD and SCR System.
Refer to Annexure-3 for Typical layout of semi-dry FGD and SCR System.
Based on above discussion SCR system is recommended for this project subject to
OEM furnishing satisfactory proven credential.
4.3.3. Schedule & Cost impact

The overall impact on project implementation schedule due to addition in SCR
system is expected to be 12-15 months.
Refer to Annexure-10 for indicative Cost Analysis for SCR.
However, the final cost and schedule impact needs be assessed with the OEM after
M/s EPGL decision to move ahead with De-NOx system.
4.3.4. Conclusion
Considering the present NOx level range of boiler, M/s EPGL is suggested to install
De-NOx system based on SCR technology. Installation of SCR system will call for a
retrofit of the boiler. As such, a brief summary-level write up of steam generator OEM
for modification expected to be carried out (Annexure-6B) has been enclosed. Once,
the decision to go forward with SCR will be taken, a detailed retrofit study along with
the steam generator OEM (HBC) needs to be carried out.

4.4. Mercury (Hg)

Table 4-14: Gap Mercury
Available Limit Required Limit

Parameter
(mg/NM3) (mg/NM3)
Mercury (Hg) Not Available 0.03
The trace of mercury content of the used coal for EPGL Salaya 2x600 MW project
is not available. Generally, the Indonesian coals are inherently low in mercury
content. The Mercury (Hg) is found in oxidized and elemental form in flue gas. The
oxidized mercury is captured along with fly ash in ESP hoppers as well as in the wet
/ semi-dry flue gas desulfurization system. Since mercury capture is affected as a
co benefit of other pollution control methods proposed to be provided, no separate
mercury control system is envisaged for this project.
However, to substantiate the above stand, it is suggested that the future coal be
tested for mercury content. The chimney emission monitoring system will also
include necessary mercury analysers.
4.4.2. Conclusion
Since, the mercury capture is affected as an additional benefit of other pollution
control methods like ESP and wet / semi-dry FGD which is to be adopted for this
project, hence no separate mercury control system is envisaged here.

4.5. Consumptive water and waste water

There is no regulation on specific water consumption for sea water based thermal
power plant as per new norms of MoEF & CC dated 28th June 2018 (an amendment
to MoEF & CC dated Dec.7, 2015 norms).
Limestone based wet FGD system requires process water mainly for limestone
slurry preparation. The amount of water consumed in a limestone FGD scrubber
depends on various factors like flue gas flow rate, quantity of sulphur dioxide
produced, limestone purity & slurry concentration, gypsum quality etc. This
additional raw water requirement on account of FGD, will impact the plant
consumptive water requirement. Approx. 330-400 m3/hr clarified water shall be
required for wet FGD system. Make-up water required for semi-dry FGD system is
less than wet FGD system.
FGD make up water supply may also be considered from Effluent Treatment Plant
based on water quality and availability.
SCR system does not require any consumptive water.
Wastewater (approx. 60-65 m3/hr.) from limestone wet FGD effluent have very high
suspended matter, dissolved solids, chlorides and SO4. As per CEA guidelines, The
FGD effluent water may be disposed to Ash slurry sump of ash handling plant after
lime dosing for pH control.
Concluding from above, it is recommended to M/s EPGL for arrangement of clarified
water of approx. 400 m3/hr. This quantity shall be further reviewed after the
discussion of FGD supplier during detail engineering stage. Additional 2x100%
pumps shall be installed nearby source for pumping FGD make-up water to FGD
plant area.
4.5.2. Conclusion
Since, there is no norm for the sea water-based power plant for specific water
consumption. M/s EPGL to arrange clarified water for limestone wet FGD.

5. ELECTRICAL SYSTEM
Power supply is the main concern for FGD system. Power requirement of FGD
system is approximate 32MW. Depending upon contingency in existing unit/ station
transformer & 11kV unit/ station switchgears, possibility of feeding the entire FGD
system load from existing unit/ station transformer & 11kV unit/ station switchgears
shall be checked, at different operating conditions. Separate new 11kV FGD unit
switchgear (one number for each unit) shall be considered for FGD system, which
shall get supply from existing 11kV unit & station switchgear. One number of new
11kV FGD common switchgear shall be considered for all auxiliary LV loads &
common FGD MV loads. 11kV FGD common switchgear shall be supplied via one
feeder from each 11kV FGD unit switchgear. One no. of LV auxiliary switchgear is
considered for all unit & common LV loads, which shall be fed from 11kV FGD
common switchgear via 2 nos. of 11/0.433kV LV FGD Auxiliary transformer.
In case the existing unit/ station transformer & 11kV unit/ station switchgears are not
suitable to take the entire load of FGD system it shall be proposed to have a separate
400kV/11kV FGD transformer, which shall feed entire FGD loads, directly from
400kV station switchyard. Future Bay space at 400kV switchyard can be utilized for
upcoming 400kV/11kV Main FGD transformer, if required. Separate new 11kV FGD
unit switchgear (one number for each unit) shall be considered for FGD system. In
case a separate 400kV/11kV FGD transformer is envisaged redundant cable/ tie
from 11kV unit/ station switchgears may also be considered to improve the reliability
of the system. One number of new 11kV FGD common switchgear shall be
considered for all auxiliary LV loads & common FGD MV loads. 11kV FGD common
switchgear shall be supplied via one feeder from each 11kV FGD unit switchgear.
One no. of LV auxiliary switchgear is considered for all unit & common LV loads,
which shall be fed from 11kV FGD common switchgear via 2 nos. of 11/0.433kV LV
FGD Auxiliary transformer.
Planning for power distribution system at Sea water intake pumphouse is done
considering that 2 nos. of 11kV feeders from local distribution company/ electricity
authority are available. One number of 11kV Sea water switchgear with 2 numbers
of separate 11kV incoming feeder are considered. All MV loads shall be fed form
11kV MV switchgear. 2 numbers of 11/0/433kV LV auxiliary transformer (fed from
11kV Sea water switchgear), connected to LV switchgear are considered for all LV
auxiliary loads at pumphouse at Sea water intake.

Decision regarding the power distribution arrangement will be taken during tendering
stage after proper coordination and detail review of layout, existing loads &
contingency in the existing system.
For the study indicative load details from reference project has been considered.
The load details may change during engineering stage for this project. However,
study with these indicative loads can give some first-hand idea about power
distribution arrangement for FGD system.
6. CONTROL SYSTEM
The FGD plant shall be operated & controlled by a dedicated control system
(PLC/DCS). This Control system shall have hardwired as well as soft interface with
the existing Plant DCS. The additional operator station for FGD plant operation shall
be placed suitably in Existing Plant Central Control Room.
Local Control room shall be provided in FGD plant area for installation of Control
cabinets of FGD Control system (PLC/DCS) along with a Local Operator cum
Engineering station.
7. CIVIL, STRUCTURAL AND ARCHITECTURAL

WORKS
The civil, structural steel and architectural works shall include, but not be limited to,
the following major activities.
• Survey, site levelling and grading including cutting, filling and compaction as
required.
• Geotechnical investigations.
• Excavation for foundation, trenches, ducts and channels etc. in all types of
soils/rocks including dewatering as necessary.
• Plain & Reinforced concrete work in substructure and superstructure at all
elevation.
• Supply, fabrication and erection of structural steel works.
• Slab on grade and base preparation with boulder/ stone fill.

• Brick masonry work in cement mortar at all elevations and levels.
• Cement plaster internal and external on walls, Columns, ceilings, parapet etc.
• Backfilling in plinth, around the foundation / excavation etc.
• Providing steel doors, windows and ventilators including glazing complete.
• Painting of steel, masonry and concrete surfaces including ceilings, walls, doors,
windows etc.
• All types of floor finishes including granite marble, IPS, heavy duty ceramic /
terrazzo tiles, floor hardener etc. as per drawing.
• Roof water proofing treatment.
• Roof gutters and rainwater down comer pipes.
• Plinth protection and garland drains.
All sanitary and sewage fittings and plumbing work for water supply and
sewerage including sewage treatment.
• Septic tank, soak pits and inspection chambers.
• Aluminium glazed doors, windows and partitions, Aluminium / GRG False

Ceiling.
• Staircases and lift shafts including pit and machine room as applicable.
• Colour pre-coated metallic cladding (double sheet insulated/single sheet).

Colour pre coated decking sheet.
• Construction of Roads and drains. Cable Duct banks, cable / pipe trenches and
trestles.
• All other miscellaneous Civil, structural steel and Architectural works.
7.1. Foundation Design Philosophy

The foundations will be designed using reinforced concrete of appropriate grade so
as to resist the loading imposed by the building, structure or equipment to be
supported.

The foundation design criteria will be established based on actual geo-technical

investigation report to be carried out at present site location. Foundation system to
be adopted must ensure that settlement/ relative settlement shall be as per provision
of relevant standards.
7.2. Design Consideration

Design of civil and structural works shall be in accordance with the relevant Indian
Standards. Design loading will take into consideration the following loads, as
applicable:
• Dead Load
• Live load / Imposed load
• Wind load
• Seismic load
• Earth Pressure
• Temperature
• Water Pressure
• Dynamic loads
• Test loads
• Construction Load
• Crane load
• Monorail load
• Special loads
Imposed loads considered shall be as determined by Code of Practice or as per
advice by the plant design. Plant loading, lay-down, construction and maintenance
loading shall be as per the load data supplied by the plant manufacturers. Design
and detailing will also take due account of locally available materials, such as bricks,
aggregate, reinforcement etc.

8. PATH FORWORD
A. Sea water based FGD system or limestone based FGD system and SCR retrofit
systems are required to be added for flue gas treatment. The OEM(s) will be
required to ensure suitability of integration and interfacing with the existing
equipment / systems, adequacy of available footprint for installation and
guaranteed performance to meet MoEF & CC stipulations.
B. EPC/OEM/Supplier to ensure that addition of Wet FGD and SCR, will be

adequate for meeting particulate limits during off-design ESP operation i.e. with
design coal firing and one field out of service.
C. EPC/OEM/Supplier to ensure that addition of Wet FGD and SCR will be

adequate for meeting mercury limits in the flue gas, if the specified range of coal
is used.
D. Approx. 350~400 m3/hr clarified water is required for limestone wet FGD make-
up water.

ANNEXURE -1
Limestone Chemical Composition (Indicative)
Sr. No. Parameter Unit Range

1. Calcium as Cao % by mass 45.9-51
2. Magnesium as MgO % by mass 0.9-3.8
3. Fe2O3 % by mass 0.45-1.0
4. Alumina ( Al2O3) % by mass 1.19-2.1
5. Si2O3 % by mass 2.1-4.5
6. Mn2O3 % by mass <0.12
7. P2O5 % by mass Traces
8. Cl2 % by mass <0.015(150ppm)
9. Na2O % by mass <0.16
10. K2O % by mass <0.01
11. TiO2 % by mass <0.02
12. Total Sulphur (as S) % <0.1
13. LOI % 38.0-41.3
14. Bond Index Kwh/t 13

AMMONIA
UNLOADING &
SUPPLY BUILDING
FOR SCR
ISSUED
WITH FEASIBILITY STUDY
ESSAR POWER GUJARAT LTD.
ANNEXURE-4
TP
TP TP
TP
TP
TP
TP
TP
TP
TP
TP
TP
ANNEXURE-5
ANNEXURE-5
TP
TP
TP TP TP
TP
TP TP
H
ANNEXURE-6
TP
TYPICAL FOR UNIT#1
TP
TP
TP
ANNEXURE-7
A
A
B TP B TP
TP
TP
TP
TP
TYPICAL FOR UNIT#1 ESSAR POWER GUJARAT LTD.
TP
TP
A
A ANNEXURE-8
B TP B
TP
ESSAR POW ER GUJARAT LIMITED
Feasibility Study
Annexure -9: Summary of Cost Analysis for FGD (2 x 600 MW)
S.No. Description Limestone FGD Lime Semi-Dry Sea Water FGD Remarks
(LSFGD) (SDA/CDS) FGD (SWFGD)
A CAPITAL COST
1 Supplies (All equipment including mechanical, electrical INR (in Cr.) 475 275 370.5 1. Price excludes Gas to Gas
and C&I etc.) heater for WFGD.
Supply of all equipment including technological and misc. 2. Price includes C-276/Alloy
structure with all accessories including design, engineering, 59 for absorber lining in
manufacturing, shop testing, packaging, forwarding, freight Limestone WFGD.
and transportation charges upto site etc. including marine 3. Price includes Glass flake
insurance. for absorber lining in Sea
Water FGD.
2 Erection, Supervision and Commissioning INR (in Cr.) 92 55 71.76
Unloading, handling, storage and preservation at site,

erection, testing, commissioning & PG test, training of O&M
staff etc. including erection insurance.
3 Civil works INR (in Cr.) 105 78.75 81.9
Supply of cement, reinforcement steel, structural steel, all

construction material, foundation bolts etc. at site cost
including design and engineering and construction of entire
civil work.
4 Mandatory Spares and tools & tackles INR (in Cr.) 40 25 31.2
6 Total Cost excluding taxes INR (in Cr.) 712 434 555
INR (in Cr.) / MW 0.59 0.36 0.46
7 Taxes (GST) INR (in Cr.) 128.16 78.075 99.9648
8 New wet stack (height-150m) INR (in Cr.) 60 0 60 Boros ilicate lining for W FG D
9 Total cost including taxes INR (in Cr.) 900 512 715
INR (in Cr.) / MW 0.75 0.43 0.60

B O&M COST
1 O&M labor INR (in Cr./Yr.) 0.13 0.13 0.13
2 Aux. power INR (in Cr./Yr.) 83.45 89.71 110.58
3 Reagent (Limestone) INR (in Cr./Yr.) 32.76 89.35 0
4 WWTS reagents INR (in Cr./Yr.) 0.03 0 0
5 Gypsum (marketable) INR (in Cr./Yr.) -17.72 0 0
6 Repair/maintenance INR (in Cr./Yr.) 18.0032 10.24 21.46
Total cost including taxes and duties INR (in Cr./Yr.) 116.7 189.4 132.2
O&M 25 yr NPV INR (in Cr.) 1385 2249 1569
Plant 25 yr lifecycle cos t INR (in Cr.) 2285 2761 2284
Assumptions :
1 The above cost estimate is indicative and is as per our internal working.
2 The cost mentioned is inclusive of price escalation @ 3% ( per annum) during the execution period of 30 months.
3 GST @ 18 % considered both for domestic and imported materials.
4 Above cost does not include IDC, financing charges and overheads.
5 Plant life considered as 25 years.
6 Plant capacity factor is considered 85%.
7 O&M staff per shift is considered 4 Nos.
8 O&M labor rate is considered INR 900 per day.
9 Aux. Power consumption is considered 2% for LSFGD, 2.15% for SDFGD and 2.65% for SWFGD.
10 Power cost is considered INR 4.67/KWh.
11 Limestone consumption is considered 22 tons per hour for WFGD.
12 Limestone (>79% purity) cost is considered INR 2000 per ton including transportation.
13 Lime consumption is considered 20 tons per hour for SDFGD.
14 Lime(>90 %purity) cost is considered INR 6000 per ton including transportation.
15 Gypsum production is considered 34 tons per hour.
16 Gypsum price is considered INR 700 per ton for sale.
17 Repair/maintenance cost is considered 2% of FGD plant capital cost.
Feasibility Study
Annexure -10: Summary of Cost Analysis for SCR (2 x 600 MW)
S.No. Description SCR Remarks

A CAPITAL COST INR (in Cr.) 439.41
INR Cr/MW 0.37
B O&M COST
1 O&M labor INR (in Cr./Yr.) 0.066
2 Aux power INR (in Cr./Yr.) 3.48
3 Ammonia INR (in Cr./Yr.) 7.78
4 Catalyst INR (in Cr./Yr.) 11.75
5 Repair/Maintenance INR (in Cr./Yr.) 6.59
Total cost including taxes and duties INR (in Cr./Yr.) 29.67
O&M 25 yr NPV INR (in Cr.) 352
Plant 25 yr lifecycle cost INR (in Cr.) 792
Assumptions :
1 The above cost estimate is indicative and is as per our internal working.
2 The estimated cost is for 2x 600 MW.
3 The cost mentioned is inclusive of price escalation @ 3% (per annum) during the execution period of 15 months.
4 GST @ 18 % considered both for domestic and imported materials.
5 Above cost does not include IDC, financing charges and overheads.
6 Plant capacity factor is considered 85%.
7 Plant life is considered as 25 years.
8 O&M staff per shift is considered 2 Nos.
9 O&M labor rate is considered INR 900 per day.
10 SCR power consumption is assumed 1000 KW for both units.
11 Power cost is considered INR 4.67/KWh.
12 Catalyst cost is considered USD 160 per cu. ft based on market input.
13 For catalyst replacement one layer at a time is considered.
14 Catalyst service life is considered 24000 operating hours per supplier input.
15 Annualized catalyst replacement cost is worked out considering catalyst service life.
16 Anhydrous ammonia consumption is considered 210 kg/hr per unit.
17 Landed cost of anhydrous ammonia is considered 25 INR/kg.
18 Repair/Maintenance cost is considered 1.5% of plant capital cost (excluding catalyst).
ANNEXURE-6C: TYPE OF SNCR
ANNEXURE-3E: TYPE OF SNCR
Annexure-6E : Case Study for High Dust SCR System
At the helm of the Energy Transition, Tractebel provides a full range of engineering and advisory services
throughout the life cycle of its clients’ projects, including design and project management. As one of the world’s
leading engineering and advisory companies and with more than 150 years of experience, it's our mission to
actively shape the world of tomorrow. With about 5,000 experts and presence in more than 70 countries, we are
able to oﬀer our customers multidisciplinary solutions in energy, water and urban.
TRACTEBEL ENGINEERING PVT. LTD.
GURGAON OFFICE
Intec House, 37
Institutional Area, Sector 44
122002 - Gurgaon - India
tractebel-engie.com
Satyan GOEL
tel. +91 1244698500
satyan.goel@tractebel.engie.com

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Feasibility Study on Compliance with

New Environmental Regulations of

Essar Power Gujarat Limited, Dwarka

Client : ESSAR POWER GUJARAT LIMITED

Revision No. Date Prepared / Revision By Description

B 2020/08/05 TE-IN Final Report incorporating M/s. EPGL comments

B 2020/08/05 FINAL AMD SGE SGE SMA

A 2020/02/03 DRAFT AMD SGE SGE SMA

REV. YY/MM/DD STAT. WRITTEN VERIFIED APPROVED VALIDATED

2. NEW EMISSION NORMS ........................................................................................................ 5

3. CURRENT EMISSION LIMITS ................................................................................................ 8

4. GAP ANALYSIS & MODIFICATION OPTIONS ....................................................................... 9

4.1. Particulate Matter (PM)............................................................................................... 9

4.2. Sulfur Dioxide (SO2) ................................................................................................. 10

4.3. Nitrogen Oxides (NOx) ............................................................................................. 38

4.4. Mercury (Hg) ............................................................................................................. 45

4.5. Consumptive water and waste water ..................................................................... 46

P.011638-E-00001-001 • Rev.B CONFIDENTIAL

5. ELECTRICAL SYSTEM ......................................................................................................... 47

6. CONTROL SYSTEM .............................................................................................................. 48

7. CIVIL, STRUCTURAL AND ARCHITECTURAL WORKS ..................................................... 48

7.1. Foundation Design Philosophy .............................................................................. 49

7.2. Design Consideration .............................................................................................. 50

8. PATH FORWORD .................................................................................................................. 51

ANNEXURE-2 Typical Layout of Limestone Wet FGD and SCR System

ANNEXURE-3 Typical Layout of Semi-dry FGD and SCR System

ANNEXURE-5 Typical Flow diagram for Limestone FGD System

ANNEXURE-6 Typical Flow diagram for Sea Water FGD System

ANNEXURE-9 Summary Cost Analysis for FGD

ANNEXURE-10 Summary Cost Analysis for SCR

ANNEXURE-11A Typical SCR Arrangement

ANNEXURE-11B SCR System Write-up and Suggested Changes in SG & Auxiliaries

ANNEXURE-11C Type of SNCR

ANNEXURE-11D Case Study of High Dust SCR System

P.011638-E-00001-001 • Rev.B CONFIDENTIAL

• Unit #1; 1st April 2012

2. NEW EMISSION NORMS

P.011638-E-00001-001 • Rev.B 5/51 CONFIDENTIAL

Table 2-1: New Emission Norms 2015

Emission Norms (mg/Nm3)

Mercury None NA 0.03 0.03 0.03

• Category 1 & 2 Projects: to comply within 2 years

Table 2-2 Specific Water Consumption Norms 2015 (old)

Specific Water Consumption Norms (m3/MWh)

• Category 1 & 2 Projects: to comply within 2 years from the date

P.011638-E-00001-001 • Rev.B 6/51 CONFIDENTIAL

Table 2-3: Water Consumption Norms 2018 (Amendment)

Specific Water Consumption Norms (m3/MWh)

Refer Table-2-2 No Regulation 3.5m3/MWh 3.0 m3/MWh with ZLD

Table 2-4: Wet Stack Height Norms 2018 (Amendment)

Wet Stack Height (m)

Thermal Power Plants

Q=Emission rate of SO2 in kg/hr. #

P.011638-E-00001-001 • Rev.B 7/51 CONFIDENTIAL

3. CURRENT EMISSION LIMITS

Table 3-1 Current Emission Limit

Mercury None Not a major pollutant under existing Contract

P.011638-E-00001-001 • Rev.B 8/51 CONFIDENTIAL

4. GAP ANALYSIS & MODIFICATION OPTIONS

4.1. Particulate Matter (PM)

Table 4-1 : Gap in Particulate Emission

Available Limit Required Limit

Particulate Worst coal with all ESP fields in 50

P.011638-E-00001-001 • Rev.B 9/51 CONFIDENTIAL