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Control Strategies for: 1. Power Plants, Cement, Aluminium and Integrated Iron & Steel are the major sectors from infrastructure development of the country. However, these are one of the major polluting in nature. Besides Green House Gas Emission, SO2, NOx, Fluoride & CO are the critical pollutants emitted from these industries. To contain emissions of these pollutants, environmental standards have been developed. Implementation of environmental standards has been taken up at National & State Level. To give impetus in implementation of environmental standards National Task Force for each industrial section have been constituted. Specific measure such as use of clean fuel, clean process technologies/alternate control systems have been suggested for each individual industrial section separately to tackle the serious issues related to air pollution, water pollution and solid waste disposal. Guidelines have also been evolved to deal with problem of flyash, (spent pot lining) and coke oven emissions.
2. 3. 4.
5.
Power Plants
Development of Environmental Standards Development of Environmental standards is based on the premise that the standards so developed are : Technically feasible; Best practicable Economically viable; and Technology(BPT) Socially acceptable Technical Feasibility : Representative industry Raw material use Processes of manufacture Water balance and mass balance Waste water characteristics Economic Viability : Various treatment alternatives & their economics(Annual burden: annual turn-over >3%) Evolve environmental standards & prescribe monitoring procedure Social Acceptability : The industry should provide to its effluent/emission, the minimal (at least) treatment
Power Plants
81 coal based thermal power plants comprising of 57799 MW electricity generating capacity as on March 2002
More than 200 million tonnes of coal with ash contents 35-45% is consumed in Thermal Power Plants
Power Plants
Environmental Issues
Use of high ash content coal in power generation leads to the following environmental issues : Air Pollution Emission of particulate matter (dust) Emission of sulphur dioxide and Oxides of Nitrogen Green House Gas Emissions Water Pollution Cooling water discharge Ash pond effluent Solid Waste Large volume of coal ash generation
Power Plants
210 MW or more
150 mg/Nm3
Depending upon the requirement of local situations, which may warrant stricter standards as in case of protected areas the State Pollution Control Boards and other implementing agencies within the provisions of the EPA, 1986 may prescribe limit of 150 mg/Nm3 irrespective of the generation capacity of the plant.
Power Plants
275
Power Plants
Air Pollution:
Water Pollution
Cooling Water Discharge: Once through with long channels/cooling tower Ash Pond effluent: Settling ponds
Solid Waste
Coal ash: Dumped into ash ponds. Emphasis is being given to utilize ash for the manufacture of builder products, cement,
Power Plants
Future Technologies for Pollution Prevention & Control in Power Section Adoption of Clean Coal Technologies (CCTs)
To meet increasing demand of power with minimal environmental impact for sustainable development, adoption of clean coal technologies with enhanced power plant efficiency, use of washed coal, efficient pollution control systems and proper by-product and waste handling & utilization, is necessary
.
Power Plants
Power Plants
As per Central Electricity Authority (CEA) estimation, the requirement of coal for existing and the plants to be installed under Ninth Plan would be 85.46 million tonnes per annum.
Coal India Ltd. would able be meet the requirement of 68.48 million tonnes per annum coal from their sources (by existing washeries and blending of domestic coals). The remaining quantity could be
Capacity (MW)
705 278 135 165 650 440 1260 840 425 274 220 850 410 1260 660
Category
UA UA UA UA >1000 km >1000 km >1000 km >1000 km >1000 km U.A. >1000 km U.A. U.A. >1000 km U.A.
16.
17. 18. 19. 20.
Ukai
Sikka (Units 1-2) Bhusawal Koradi Nasik
850
240 478 1080 910
>1000 km
>1000 km >1000 km U.A. >1000 km
3.36*
1.00* 2.24 5.50* 3.60
Capacity (MW)
1150 500 390 420 630 450 840 840 1050 820 350 420 210 210 420
Category
U.A. S.A. CPA >1000 km U.A. >1000 km >1000 km >1000 km >1000 km CPA CPA >1000 km >1000 km >1000 km >1000 km
21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.
36.
37. 38. 39. Total
North Chennai II
Mangalore Tranagallu Suratgarh-I
1050
1000 260 500
U.A.
>1000 km (Imported Coal)
IC
IC IC IC
>1000 km >1000 km
Total coal consumption based on 2002-2003 data upto ix plan 85.46 MTPA
* Revised based on data provided by SEBs/utilities UA : Urban Area, CPA : Critically Polluted Area, SA: Sensitive Area and IC: Imported Coal
Power Plants
Bihar
Orissa
1.5 Mt/y
Power Plants
Power Plants
Larger unit size (more than 500 MW) Higher thermal efficiency (of 5% and above) Low gaseous & soots emissions
2. Fluidised Bed Combustion (CFBC/PFBC/AFBC)
Can burn wide range of coals and other fuels such as pet coke, lignite etc. Higher thermal efficiency (>40%) Lower NOx emissions Low CO2 emissions Insitu SO2 control Sizes upto 250 MW commercially available indigenous Contd
Power Plants
Cement Industries
No. of Large Cement Plants in the country 113 Total Annual Installed Capacity Million Tonnes March 2000) 110.10 (As on
Per Capita Consumption of Cement (1999) Annual Cement Production 94.21 MillionIndia Tonnes World Average (As on March 97 kg/annum 256 kg/annum 2000)
Cement Industries
Continuous dust monitoring system & its calibration Industrial solid waste utilisation in cement manufacturing
Flyash Blast Furnace Slag Lime Sludge
Contd
Cement Industries
gases
Energy Conservation
Cement Industries
Fugitive Sources
Open air handling & storage of raw materials & clinker Transfer Points Leaking Joints Loading & unloading operation Vehicular movement on unpaved roads
Cement Industries
Source of Pollution
Crusher Raw Mill: Gravity Discharge Air Swept (e.g. Roller Mill)
3.
4.
5. 6. 7.
Cement Industries
Emissions of Pollutants
SO2 Emission from kiln Formation Mechanism *Oxidation of sulphur compounds present in raw material & fuel (300-600C) Emission Range: 300-2300 mg/Nm3 (Coal based kiln) Emission of SO2 may be very high in case of Pet Coke based kiln NOx Emission From Kiln
90% of NOx is in the form of NO Formation Mechanism: Thermal NO & Fuel NO Emission Range 200-2500 mg/Nm3 Literature indicates wide variation in emission range
Cement Industries
Control Equipment
Cement Industries
Cement Industries
clinker, flyash
Cement Industries
Cement Industries
Cement Industries
Steel Plant)
Phospho-gypsum (Solid Waste from Fertilizer Plant) Lime sludge (Solid Waste from Pulp & Paper Industry)
Cement Industries
Contd
Cement Industries
Complying units Non complying units Closed units Status Awaited Kiln + Raw Mill :
: : : :
58 16 14 25
Bed blending system : Reduces variation in coal quality : Reduces Problem of high CO : ESP operation more stable
Cement Industries
Cement Industries
Aluminium Industries
1.
NALCO, Angul, Orissa BALCO Korba, Orissa INDALCO Alupuram, Kerala INDALCO Belgaum, Karnataka INDALCO Hirakud, Orissa HINDALCO Renukoot, UP
8,00,00 0 2,00,00 0 -
2,18,000
2,43,000
15,75,00 0# -
3,45,000
2.
1,00,000
3.
13,500
8,000
4.
2,70,00 0 -
5.
30,000
30,000
57,200
57,200
6.
4,50,00 0
2,42,000
1,33,700
6,60,000
3,56,200
69,500
Aluminium Industries
Environmental Issues
Ambient Fluoride levels around Smelter Fluoride emissions from Smelters HC/PAH emissions from Smelters and Anode plant
Aluminium Industries
EPA Standards
Particulates (mg/Nm3) Stack Height (m) CO
PBSW
PBCW (ii) Green Anode Shop (iii) Anode Bake oven b) Alumina Plant
2.5
1.0 150 0.3 150 H = 14 (Q)0.3
(i) Primary 150 and Note: Secondary Q-Emission of SO2 in kg/hr, H-Stack Height in m Crusher Source: MoEF notification GSR 742 (E), dated 30.08.1990
Aluminium Industries
Fluoride Emissions
S. No.
Name of Smelter NALCO, Angul,Oris sa BALCO Korba, Orissa INDALCO Alupuram, Kerala
Consumption
(kg/t)* 17.28
Control System
1.
0.52
0.755
2.
VSS
36.513
932
g/N
m3
3.
HSS
26.22
1.82
2.55
4.37
Wet Scrubbing
4.
HSS
10.726
1.43 -2.53
1.40 2.23
2.83 4.76
Wet Scrubbing (Proposing to convert to Dry Scrubbing by 2005) Dry Scrubbing System
5.
HINDALCO PBSW 29.0 *kg/t Renukoot, of aluminum UP # MoEF condition 2.5 kg F/t after expansion
0.03 -0.39
0.44 1
0.4710.831
Aluminium Industries
Method of disposal
1.
2.
3,300
3,961
Secured landfill
Carbon - in covered storage shed Refractory -in unsecured landfill Carbon-stored under cover Refractory -Either land filled or stored under cover Secured Landfill Carbon-used for recovery of cryolite followed by
3.
484
4. 5.
500 2,382.5
Aluminium Industries
1. 2. 3.
4.
5.
632.5
6.
MALCO
59.0
Aluminium Industries
to Dry Scrubber Setting up a limit for fluoride consumption per tonne of aluminium Prescribing standards for ambient fluoride/forage fluoride Developing emission standards for HC/PAH Setting up a centralised SPL treatment and disposal facility Converting to Dry methods for disposal of Red Mud
Sintering Plant
Blast Furnace Refractory Material Plant
Emission Standards
Stack Emissions
Plants Particulate Matter Emission (mg/Nm3)
150 150 (during normal operation) 400 (during oxygen lancing) 150
Parameter
Fugitive Emissions
(c) Leakage from AP Covers (d) Charging emission (second/charge) 2. Stack Emission of Coke Oven (a) SO2(mg/Nm3) (b) NOx, (mg/Nm3) (c) SPM, (mg/Nm3) (i) SPM emission during charging (stack emission)
3
800 500 50 25
800 500 50 25
Contd
Iron & Steel Industries S. Industry No. Sulphur in Coke Oven gas used for heating (mg/Nm3) Sulphur in Coke Oven gas used for heating (mg/Nm3 Emission for quenching operation Particulate matter gm?MT of coke produced Benzo-Pyerine (BOP) concentration in work zone air (ug/m3) Battery area (top of the battery) Other units in coke oven plant 5 2 5 2 800 800 Parameter Standards New Existing Batteries Batteries
Further Requirement
Improvements in the systems controlling fugitive emissions. for
frame cleaner Air cooled Self Sealing doors Water sealed AP caps
Screw feeder Land based pushing emission control system Self sealing air cooled doors Possibility of coke dry quenching needs to be tried out Effluent treatment plant to treat cyanide, phenol ammonia, COD etc. Hazardous waste (tar sludge and ETP sludge) handling and disposal following Hazardous Waste Handling, Rules; or, tar sludge / ETP sludge charging alongwith the coal fines in the coke ovens.
Contd
Further Requirements
ESP / bag filters with higher efficiency of removal for process emissions.
process emissions ESP / bag filter / wet scrubber for work zone environment
and
Steel Melting Shop ESP / bag filter wet scrubber for the
process emissions Effluent treatment comprising settling unit and re-circulation system for the treated effluent
Proper operation and maintenance of air emission control and effluent treatment systems. Secondary emission control system.
Proper operation and maintenance of ESP / bag filter / wet scrubber for air emissions BF slag utilisation
Air-cooled self-sealing doors. The hydrojet cleaning system shall be provided for the door and door frame
cleaning with a facility of hydrojet pressure of 600 kg/cm2.
Provision of water sealed AP covers should be provided. To provide aspiration through high pressure ammonia liquor (HPLA) injection in
goose neck and emissions should be transferred directly to gas collecting mains.
The coke pushing emission should be treated in stationary land-based system with