Vidarbha Industries Power Limited

Flue Gas Desulphurization Plant

 Contents
Section I - Environmental Concern

Section II - FGD System

Section III - FGD Project at VIPL

Confidential Slide 2
 Section I – Environmental Concern

Confidential Slide 3
 Environmental Issues
Environment & Climate Change is the biggest concern of modern age
Prime Reasons
 Excessive Industrialization
 Burning of Fossil Fuel (Mainly Power plants and all Furnaces)
 Deforestation
 Raising livestock, dumping in landfills
 Damaging the land profile and hence the ecological disturbances
 Chemical, Fertilizers and Plastic Industries
 Use of Sulphur Hexafluoride (SF6)

 Modern Living Style

 Use of Fossil fuel - Mainly Automobile and other gadgets.
 Natural gas – Cooking and various other applications
 Refrigerators, Air Conditioners and increased cold storages
 Generation of excessive waste material, garbage, plastic waste
 Chemicals and Pesticides

Confidential Slide
 Green House Effect

In earth’s atmosphere, few of gases whose molecules have three

or more atoms like carbon dioxide (CO2), water vapor (H2O),
methane (CH4) etc. are the important greenhouse gases, that have
maintained Earth’s warm temperature for billions of years.
Confidential Slide
 Green House Gases
1. Carbon Dioxide (CO2)
388,500 parts per billion in the atmosphere, which is by number, 108,500 parts
increase since before industrialization. With such high concentrations in the
atmosphere, plants are unable to keep up by removing it from the air.
2. Methane (CH4)
Methane is 25 times stronger than carbon dioxide in terms of its global warming
potential. It also has a lifespan of 12 years. Pre-industrial levels were approximately
700 parts per billion. Today, that has increased to 1,870 parts per billion.
3. Nitrous oxide (N2O)
Nitrous oxide is produced by industrial manufacturing, the combustion of fossil fuels,
and the breakdown of agricultural fertilizer. Nitrous oxide is a compressed liquefied
gas that has an atmospheric life of 114 years and a global warming potential that is
298 times stronger than carbon dioxide. This means it traps heat in the earth’s
atmosphere at a much higher rate than carbon dioxide
4. Dichloro-difluoro-methane (CCl2F2)
Most commonly referred to as Freon-12, Dichlorodifluoromethane is used in aerosol
spray cans and as a refrigerant. It is believed to have an atmospheric life of
approximately 102 years, when it is finally degraded by solar radiation.
Unfortunately, its degradation actually allows it to destroy the ozone layer.

Confidential Slide
 Green House Gases (Contd.)
5. Sulfur Hexa-fluoride (SF6)
Sulfur hexafluoride is an electrical insulator, and generally is used in the form of a
liquefied compressed gas. It is not very water soluble, but does dissolve in organic
solvents. It has an atmospheric life of 3,200 years and global warming potential
23,900 times stronger than carbon dioxide. SF6 is considered one of the most
dangerous greenhouse gases known. It is banned as a tracer gas and is limited to
high voltage applications.
6. Ozone (O3)
Ozone presents itself in two forms, stratospheric and tropospheric. Stratospheric
ozone occurs naturally. Tropospheric ozone, however, is a greenhouse gas that
contributes to climate change. Humans produce this gas through industrial plants,
chemical solvents, and burning fossil fuels
7. Water Vapor (H2O)
Water vapor, although it sounds innocent enough, is one of the biggest contributors
to global climate change. Interestingly, water vapor is not directly emitted from
human activity. It is in response to already rising temperatures. As the atmosphere
becomes higher, the rate of water evaporation also increases. This water vapor
tends to stay in the lower atmosphere where it absorbs infrared radiation and
pushes it down to the earth’s surface, causing already hot temperatures to continue
to rise.

Confidential Slide
 Green House Gases (Contd.)
8. Chloro-difluoro-methane (CHClF2)
Most commonly referred to as Freon-12, Dichlorodifluoromethane is used in aerosol
spray cans and as a refrigerant. It is believed to have an atmospheric life of
approximately 102 years, when it is finally degraded by solar radiation.
Unfortunately, its degradation actually allows it to destroy the ozone layer.
9. Tetra-fluoro-methane (CF4)
It is used as a refrigerant. CF4 is a strong greenhouse gas that contributes to
climate change and has an atmospheric lifetime of 50,000 years.
10. Hexa-fluoro-ethane (C2F6)
Hexafluoroethane is a fluorocarbon that is used in the semiconductor industry, and
is sourced from byproducts of aluminum production processes. It has a 10,000-year
atmospheric lifespan and a global warming potential of 9,200.
11 Nitrogen Trifluoride (NF3)
It is recognized by the Kyoto Protocol as a greenhouse gas that contributes to
global climate change. It has an atmospheric life of between 550 and 740 years

Confidential Slide
 Impact of SO2 OR SOx
SOx property: Heavier than air, damaging to the Earth’s profile

 Impact of SOx on human health:

 Eye irritation, breathing problems, chest pain, asthma attacks,
lowered resistance to heart diseases.

 Impact of SOx on Environment:

 Affects human and also to animals and plants.
 Reduces yields of crops and may lead to deforestation.
Cause of acid rain, which affects the natural balance of rivers,
lakes and soils, resulting in damage to wildlife, aquatic life and
vegetation.
 Affects building materials and historical monuments
as it leads to the corrosion of metal structures

Confidential Slide 9
 Release of Sulphur in Atmosphere

 Amount of Sulphur released in environment:

(Estimated for 300 MW – 20 MT per Day or 2.7 Kg/MW/Hr)
(Considering 0.5% Sulphur in Coal)

 Amount of Sulphur released by a 300 MW unit/year = 7300 MT

Confidential Slide
 COP & Directives from Indian Government
 India has made the following commitments in COP 21 held at Paris, Dec-
2015
 It intends to reduce the emissions intensity of its GDP by 33 to 35 % by
2030 from 2005 level.
 To achieve about 40 percent cumulative electric power installed capacity
from non-fossil.
 Introducing new, more efficient and cleaner technologies in thermal power
generation.

 In December 2015, MOEF&CC added three more stack emission norms in

addition to existing SPM and issued stringent new environmental norms.
 SPM (existing)

 SOx (new)

 NOx (new)

 Mercury (new)

 VIPL received the directives from CPCB on per their letter 11-Dec-2017.
 Compliance Date for Unit 2 – 31 March 2021, Unit 1 – 30 June 21.

Confidential Slide
 New Emission Norms

Confidential Slide
 Section II
Flue Gas Desulphurization (FGD) System

Confidential Slide 13
 Flue gas Desulphurization

Objective: To control SOx emission from stack

Chemical reaction (Absorber tower)

Size Approx.16.5M (D) X 32M (H) [For 500 MW unit]

CaCO3 + SO2 + 3H2O + ⅟2 O2 = CaSO4.2H2O + CO2 + H2O

(limestone) (Flue gas) (Oxidation) ( Gypsum)

Confidential Slide
FGD plants installed in India

Out of 186 GW Coal Based Power plants in India following

have installed FGD plants —
1. Tata Power-Trombay (750 MW)

2. Dahanu Thermal Power Station (500 MW)

3. Udupi Thermal Power Station (1200 MW)

4. JSW Ratnagiri (1200 MW)

5. NTPC Vindhyachal stage-V (500 MW)

6. Adani Power Mundra Ph-III (1980 MW)

Confidential Slide
 Flue Gas Emission Control Process

Confidential Slide
 FGD Technologies

Confidential Slide
 Sea Water Based FGD

Confidential Slide
 Ammonia Based FGD Scheme

Confidential Slide
 Wet Lime Stone Based FGD

Confidential Slide
 Selection of Technology for FGD

Confidential Slide
 Environmental Concern of FGD
 Effect on earth underground structure due to extra limestone mining
 Limestone dust emission due to extra limestone mining
 Limestone dust emission during transportation
 Limestone dust emission during handling / crushing in FGD plant
 Emission of gypsum dust during handling and transportation
 Additional vehicle pollution due to Limestone & Gypsum transportation
 FGD discharge water contamination, if not neutralised properly
 Rain water contamination, if gypsum/ limestone kept in open
 Leakage of sulphuric acid mixed gas from absorber outlet duct
 Proper disposal of the system by-product Gypsum @ 22 Kg/MW/Hr

All India projection of Gypsum production & Lime Stone requirement by 2022
 FGD Gypsum production: 38 MMT/year

 Limestone requirement: 27 MMT/year

Confidential Slide
 Desired Quality of Gypsum

After Desulphurization process, it’s by-product i.e. the Gypsum

must have following characteristics for its effective utilization:

1. Purity > 90%

2. Moisture < 10%
3. Chlorides < 100 PPM

Confidential Slide 23
 Utilization of Gypsum
Cement Industries
 Annual cement production in India: 300 MMT
 Annual Gypsum consumption potential of cement industries: 15 MMT
In agriculture & Forest
 As per ICAR-CSSRI Karnal, there is about 3.77 mh of sodic land which can
be reclaimed for agriculture purpose by use of approx 45MMT of Gypsum.
[Indian Council of Agriculture Research /Central Soil Salinity Research Institute]

GFRG panel manufacturing

 Utilisation of GFRG (glass fibre reinforced gypsum) panels in low cost
housing projects.
Gypsum board, Wall plaster and Wall putty
 FGD gypsum is suitable for this application also.
Sundry Uses
 In FAL-G brick manufacturing as per IS:12894
 In interlinking tiles
 In statues manufacturing

Confidential Slide
 Wet FGD system

The entire WFGD System can be divided into the following

process systems:

 Flue Gas Handling System.

 Limestone Handling & Reagent Preparation System.

 Absorber & Oxidation System.

 Secondary Dewatering & Gypsum Handling System.

Confidential Slide
 FGD Process Flow Diagram

Confidential Slide
 FGD sub-system

1. FLUE GAS SYSTEM

BOOSTER FAN- 2 NOS
GAS TO GAS AIR HEATER- 1NO
DUCT, GATES, DAMPER

2. LIMESTONE HANDLING SYSTEM

UNLOADING HOPPER
CONVEYOR BELT SYSTEM
REGENT CRUSHER- 2 NO
BALL MILL- 2 NO
REGENT FEED TANK
REGENT FEED PUMP- 2 NO.

Confidential Slide
 FGD sub-system

3. ABSORBER TOWER (REACTION TANK)

 GYPSUM BLEED PUMP- 2 NO
 RECYCLE SPRAY PUMP- 3 NO
 OXYDATION BLOWER -2 no
 SPRAY NOZZLE
 MIST ELIMINATOR

4. GYPSUM HANDLING SYSTEM

 HYDRO CYCLONE CLASSIFIER
 BELT FILTER
 CONVEYOR BELT SYSTEM
 GYPSUM STACK BUILDING

5. CONTROL ROOM

Confidential Slide
 Equipment / System Flow Diagram

Confidential Slide
 Flue Gas System
ABSORBER
FGD GGH
SYSTEM

BOOSTER FAN
BOILER

GGH OUTLET DAMPER

ID FAN
ESP

BYPASS DAMPER

Emergency quench

Confidential Slide
 Lime Stone Handling & Reagent Preparation System
TO ABSORBER

Unloading LIMESTONE
Hopper
BUCKET
CRUSHER
(2+2) ELEVATOR (1+1) CRUSHED
CRUSHED
(1+1)
LIMESTONE
LIMESTONE
SILO
SILO
(1+1)
(1+1)
CONVEYO
R Bucket
(1+1) elevator
(1+1)

AGITAT0
R
(1+0)

LIMESTONE
SILO
(1+1) REAGENT FEED
TANK (1+0) REAGENT
FEED PUMP
MILL PRODUCT (1+1)
CLASSIFIER FROM: MAKE UP WATER
(1+1) PUMP

AGITATOR FROM: FILTER WATER

LIMESTONE
(1+1) PUMP
WEIGH BALL MILL
(1+1)
FEEDER FROM: REAGENT
AREA TRENCHES
(1+1) MILL AGITATOR
RECYCLE TANK MILL (1+0)
(1+1) RECYCLE
PUMP
Confidential (1+3) Slide
 Absorber & Oxidation System

Confidential Slide
 Secondary Dewatering & Gypsum Handling System

Confidential Slide
 Control Room - Operations

Confidential Slide
 Major FGD equipment and APC
SN Major Equipments Quantity Rating

1 Booster Fan 2 3600 KW

2 Absorber 3 1100 KW
Recirculation pump

3 Ball Mills 2 355 KW

4 Oxidation blower 2 337 KW

5 GGH ( Gas to Gas 1 177 KW

heater) & Aux.

6 Vacuum belt Filter, 2 100 KW

Pump & hydro
cyclone
7 Limestone Crusher 2 90 KW
Confidential Slide
 Major Equipents

Booster fan (2 No's) Absorber recycle pump (03 No’s) Oxidation blower (2 no’s)
3600 KW each 1100 KW each 337 KW each

Ball mill (02 No’s) VBF & Aux (02 no’s) Hammer Crusher( 02 No’s )
355 KW each 100 KW each 90 KW each

Expected APC in FGD plant: 1 To 1.5%

Confidential Slide
 Lime Stone Properties

Confidential Slide
Commitment by India in Paris climate summit – Dec 2015

Confidential Slide
 Earth’s Atmospheric Layers
Exosphere: 700 to 10,000 km
Thermosphere: 80 to 700 km
Mesosphere: 50 to 80 km
Stratosphere: 12 to 50 km
Troposphere: 0 to 12 km

Confidential Slide
 Section III
FGD Project at VIPL

Status and Challenges

Confidential Slide 40
 Vidarbha Industries Power Limited

Project Status
VIPL FGD and De-Nox System
Status - 15-April-2019
Confidential Slide
 Proposed FGD Plant Layout

COMMON FACILITIES WILL BE ON

THE NORTH SIDE

Confidential Slide 42
 Guidelines & Schedule for Completion

Guidelines and target given by CPCB for FGD and De NOx system

1. SOx- Emission Limit < 600 mg/Nm3 [2360 mg/Nm3]

VIPL Tender specified design value 550 mg/Nm3
Flue Gas Desulphurization Plant must be operational as per 43
following Schedule:
Unit 1 – 30-June-2021
Unit 2 - 30-March-2021

2. NOx- Emission Limit <300 mg/Nm3 [550 mg/Nm3]

VIPL Tender specified design value 275 mg/Nm3

Suitable De NOx system must be operational in sequence for

both units by the 31-Dec-2022

Confidential Slide 43
Status – Flue Gas Desulphurization plant

 ICB tenders for Installation of FGD system floated on 28.09.2016

 13 vendors submitted their offers
 After review of initial TER some missing as well as additional
scope of work identified.
 With inclusion of above missing/additional scope, CPG amended
the original tender for their revised offer.
 Revised TER finalized after receipt of revised offers.
 Techno-commercial Evaluation and short listing of Vendors for
Post commercial evaluation – Completed .
 Post commercial evaluation and negotiations are in progress.
Vendor is expected to be finalized by 15 Apr 2019.
 MERC shall be approached after completion of above ICB process.

Activities at a glance

Confidential Slide
 Status - DeNOx system

 CPCB however has suggested to implement installation of Low

NOx burners and Over fire Air (OFA) immediately and comply the
NOx norms progressively by Year 2022.

 WO for consultancy services issued to DCPL to study the

emission data along with combustion system and design the De-
NOx system using appropriate technology .

 DBR prepared by DCPL has been approved.

 Tender Specifications – Finalized and being forwarded for ICB

 Target to float the tender enquiry for DeNOx system by 30th April
2019
Activities at a glance

Confidential Slide
 Lime Stone and Gypsum

Lime Stone for FGD project

Lime Stone – Study of Resources and Logistics
Required Quantity (For Both Units)– 180 Tons Per Day

 Based on a consultancy order, the vendor M/s Satyamurthy

Yenamandra submitted the report.
 The location to source Limestone will be from Katni District in
MP
Gypsum – Outcome from FGD Project
Gypsum – Production and Consumption
Production – 210 Tons Per Day (Both Units)
 The Gypsum produced in VIPL Butibori can be completely
utilized by nearby cement plants in Maharashtra, MP and CG.

Confidential Slide
 FGD Project - Challenges
Challenges for Contract Management
 Chinese Vendor - Offshore contract
 Communication
 Establishment of site setup for Chinese Vendor
 Management of onshore subcontracts
 Completion of Detailed Engineering & Documentation
 To Organize the FAT & Delivery of all imported plant and
machinery, management of LCs, shipment, custom
clearances, insurances
 Receipt of all project Material at site, inspection, storage
and issue to vendor and sub-contractors.
 Statutory compliances of labor and working personnel.
 On site facilities (Fabrication, Special tools/tackles and
lifting equipment and machinery)
 Management of COS for disciplinary activities

Confidential Slide 47
 FGD Project - Challenges
Challenges – Execution of works
 Stiff Margin – Project completion time
 Difficult conditions for Civil work on account of
demolitions and relocating existing system
 Interface with existing system and locating the new FGD
equipment by retaining/modifying the existing system
(Especially the pipe rack, UG system and utilities)
 Allocation of big space for material stacking, Fabrication
and site facilities.
 Coordination of Limestone sourcing and storage at plant

Confidential Slide 48
 49
Confidential Slide
Intimation letter by CPCB

Confidential Slide
 Typical Process Parameters of FGD Plant

Confidential Slide
Confidential Slide
 Back Major Activities pertaining to FGD Project
SN Activity Details Remarks
1 DBR and feasibility report Completed
2 DPR Completed 20-Aug-16
3 Tender Document Completed 30-Aug-16
4 Appointment of Consultant for TER Placement of Order to DCPL 28-Jul-17
5 International Competitive Bidding Bidding process completed up Aug-17 - Dec 17
to TER stage
6 Bid Clarifications and preliminary Completed 28-Feb-18
TER
7 Review of TER and inclusion of Completed Mar-18 - Apr-18
additional scope of work for Amendment for Additional Scope
revised offer by vendors given from site on 15 May18
7 Final TER Completed 24-Jul-18
8 Finalization of Vendor and Vendor finalization / WIP
Placement of Order Placement of order is in
progress
9 Placement of WO to consultant for WIP PR raised from VIPL
PO Engineering
10 Limestone study Completed 21-May-18
11 Limestone Sourcing Location is under review and WIP – (Responsibility – Sasan)
finalization
Confidential Slide 53
 Back Major Activities pertaining to DeNOx Project
SN Activity Details Remarks
1 DBR and feasibility report Completed
2 DPR Completed 20-Aug-16
3 Appointment of Consultant Order to place to DCPL 05-Mar-18
4 Finalization of DBR Completed
5 Finalization of Tender Specifications Completed 28-Feb-18

6 Finalization of NIT in progress. BD group is taking up the matter 30-Apr-18

with CPG

Confidential Slide 54
 Project Team Essentiality

Intense collaboration among Procurement group, Contract

Manager and Contract Administrator

• Early identification of contract management skills and capability

needed to assign the Contracts Manager
• Contract managers contribute subject matter expertise and
experience
• Sourcing lead in best position to develop contract management
plan
Proper handover between Procurement
& Contract manager Smooths the
Execution of Project.

Don’t “Throw it Over The Fence!”

Confidential Slide
Roles and Responsibilities

Who is the:
• Contract Owner?
• Contract Manager?
• Contract Administrator?
Confidential Slide