Project Design Document(DRI Kilns)

8/12/2019 Project Design Document(DRI Kilns)

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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 03.1.

CDM Ee!"#i$e %o&r' page 1

CLEAN DEVELOPMENT MECHANISMPROJECT DESIGN DOCUMENT FORM (CDM-PDD)

Version 03 - in ee!" #s o$ %& J' %00*

CONTENTS

A. General description of project activity

B. Application of a baseline and monitoring methodology

C. Duration of the project activity / crediting period

D. Environmental impacts

E. ta!eholders" comments

Anne+es

Anne# 1$ Contact information on participants in the project activity

Anne# %$ &nformation regarding public funding

Anne# '$ Baseline information

Anne# ($ )onitoring plan

Anne# *$ Abbreviations

Anne# +$ ,eferences

This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.


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SECTION A, Gener# es!ri."ion o .ro/e!" #!"ii"

A,1 Ti"e o "2e .ro/e!" #!"ii"$

Bhushan -oer and teel imited0aste 2eat ,ecovery based Captive -oer -roject.3ersion$ 4%Date$ 45/14/%446

A,%, Des!ri."ion o "2e .ro/e!" #!"ii"$

Bhushan -oer and teel imited 7B-8 have set up an &ntegrated teel -lant at 9hel!oloi: -ostapanga: ,engali 9ehsil: ambalpur District: ;rissa for manufacturing &ron and teel. 9he plant

produces about 4.+ )illion tonnes of 3alue Added special steels annually.

9he comple# consists of a Coal ashery: ponge &ron units:


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Pro/e!"s !on"ri4'"ion "o s's"#in#4e eeo.5en"

9he project activity has contributed to ustainable Development of &ndia" because the project activity is

generating poer using aste heat gases from the process. By generating clean poer: B- has replacedpoer generation from a coal: coal ashery rejects: coal char based C--. 9herefore: the project activityenables reduction in C;% emissions and saves the conventional fuel.

9he project imparts a direct positive impact by improvement of uality of life of local people by providinginflo of funds: additional employment: technological and managerial capacity building etc. 9he folloing

paragraphs illustrate briefly ho the project activity contributes to the four pillars 7indicators8 ofsustainable development of &ndia$

So!i# #s.e!"s

9he location of the project in rural setting contributes toards poverty alleviation by generating bothdirect and indirect employment.

E!ono5i! #s.e!"s

9he project"s initial investment is to the tune of &>, +(+.5 million in addition to hich there ill becontinuous inflo of funds considering CD) revenues. &n the absence of the project such an inflo offunds to the region as not envisaged. 9he project ill also earn additional revenue for the local andcentral government.

Eniron5en"# #s.e!"s

)ajority of the poer generation in the country is from the fossil fuels li!e coal: oil and gas. 2oever:the project activity generates the electricity from the aste flue gas and thereby reduces the G2Gemissions. 9he project activity utili=es the enthalpy of the hot flue gas: hich ill protect the environmentfrom thermal pollution.

Te!2noo6i!# #s.e!"s9he project activity is based on the 2, technology: a clean technology for poer generation from astehot flue gas: hich ould otherise be vented to the atmosphere. 9he project comprises of four boilers of*1 tons per hour 79-28 capacity and ith the outlet steam parameters of 55 !g/cm % 7ma#imum pressureof 141 !g/cm%8: and *%4F C.



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CDM Ee!"#i$e %o&r' page (

A,3, Pro/e!" .#r"i!i.#n"s$

N#5e o P#r" inoe(2os" ini!#"es # 2os" P#r")

Pri#"e #n7or .'4i! en"i"(ies) .ro/e!" .#r"i!i.#n"s

(#s #..i!#4e)

8in ini!#"e i "2e P#r"inoe 9is2es "o 4e!onsiere #s .ro/e!"

.#r"i!i.#n"(:es7No)

&ndia Bhushan -oer teel imited7B-8

>o

A,;, Te!2ni!# es!ri."ion o "2e .ro/e!" #!"ii"$

A,;,1, Lo!#"ion o "2e .ro/e!" #!"ii"$

A,;,1,1, Hos" P#r"(ies)$

&ndia

A,;,1,%, Re6ion7S"#"e7Proin!e e"!,$

;rissa

A,;,1,3, Ci"7To9n7Co55'ni" e"!$

9hel!oloi 3illage: -ost apanga: ,engali 9ehsil: ambalpur District: ;rissa

A,;,1,;, De"#i o .2si!# o!#"ion< in!'in6 inor5#"ion #o9in6 "2e

'ni='e ien"ii!#"ion o "2is .ro/e!" #!"ii" (5#+i5'5 one .#6e)$

9he -roject has been implemented in and around @hata >o. %14/1+?: -lot >o. '%'4 of 9hel!oli village:-ost apanga:,engali 9ehsil: ambalpur District: ;rissa. &t is located at a latitude of %1(*(%H > andlongitude of 5(41%4H E. 9he project site is situated at '5 !ms from ambalpur ton in ;rissa state.&nfrastructural reuirements including ater: motorable road: electricity etc. are available at site.



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;rissa tate

ambalpur District-lant ite

A,;,%, C#"e6or(ies) o .ro/e!" #!"ii"$

9he project activity is generating electricity from the aste hot gas generated from the sponge iron plant.&t comes under category 1$ Energy &ndustries 7reneable/non reneable sources8 as per Iist of ectoralcopesJ: 3ersion 4(. 9he methodology used for this project activity is IApproved Consolidated Baseline)ethodology AC)444(J$3ersion$ 4%Date $ 4' )arch %44+



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A,;,3, Te!2noo6 "o 4e e5.oe 4 "2e .ro/e!" #!"ii"$

B- integrated comple# consists of a captive poer plant ith to Am'/hr at ?*4 4C. 9he rotary !iln is directly connected to the( 2,B: ith steam generation capacity of *1 9-2 each. 9he total aste flue gas generated is ductedto the 2,B to generate steam at 55 @g/Cm%and *%44C.

9he generated steam is then fed introduced in to the ingle flo ith donard e#haust condensing9urbo Generator for poer generation. After transferring the heat: the aste flue gas is passed through

the Electro tatic -recipitator 7E-8 and vented to atmosphere.E='i.5en" Te!2ni!# De"#is

Sr, No P#r#5e"er De"#is

A, T'r4ine >I

1. )a!e iemens

%. 9ype ingle flo ith donarde#haust condensing

'. ,ating (4 )

(. &nlet steam pressure 5( ata

*. &nlet steam temperature *14 K * 4C

+. 9urbine peed 64*? rpm

?, T'r4ine-II

6. )a!e B2E

5. 9ype ingle flo ith donarde#haust condensing

?. ,ating +4 )

14. &nlet steam pressure 5( ata

11. &nlet steam temperature *14 K * 4C

1%. 9urbine peed '444 rpm

?, ?oier

1'. 9ype aste 2eat ,ecovery

1(. >et teaming Capacity at )C, *1 9-21*. uper heater outlet pressure 55 ata

1+. uper heater outlet temperature *%4K* 4C

16. Gas temperature ?*4 4C



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A,;,; Es"i5#"e #5o'n" o e5ission re'!"ions oer "2e !2osen !rei"in6 .erio$

9he project ould result in a C;% emission reduction of %@0


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?,1, Ti"e #n reeren!e o "2e #..roe 4#seine #n 5oni"orin6 5e"2ooo6 #..ie "o "2e.ro/e!" #!"ii"$

9itle$ IConsolidated baseline methodology for aste gas and /or heat and /or pressure for poergenerationJ.

,eference$ Approved consolidated baseline methodology AC)444(.

3ersion $ 4%:

ectoral cope $ 41

Date $ 4' )arch %44+

?,% J's"ii!#"ion o "2e !2oi!e o "2e 5e"2ooo6 #n 92 i" is #..i!#4e "o "2e .ro/e!" #!"ii"$

9he methodology AC)444( is applicable to project activities that generate electricity from aste heat orthe combustion of aste gas in industrial facilities.

9he methodology applies to electricity generation project activities$

9hat displace electricity generation ith fossil fuels in the electricity grid or displace captiveelectricity generation from fossil fuelsM

here no fuel sitch is done in the process here the aste heat or the aste gas is produced afterthe implementation of the project activity

9he methodology covers both ne and e#isting facilities.


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CDM Ee!"#i$e %o&r' page ?

?,3, Des!ri."ion o 2o9 "2e so'r!es #n 6#ses in!'e in "2e .ro/e!" 4o'n#r

So'r!e G#s In!'e J's"ii!#"ion7E+.#n#"ion

Baseline Grid Electricity

GenerationC;% >o E#cluded. >ot applicable to the project

activity as the project displaces captivepoer generation based on coal coalchar and coal ashery rejects and notgrid poer

C2( >o E#cluded for simplification. 9his isconservative

>%; >o E#cluded for simplification. 9his isconservative

Captive Electricitygeneration

C;% Les )ain emission source as the baselineould be the coal: coal char and coalashery rejects based captive poer

plantC2( >o E#cluded for simplification. 9his is

conservative

>%; >o E#cluded for simplification. 9his isconservative

-rojectActivity ;n site fossil fuel

consumption due to theproject activity

C;% Les &ncluded. hile there is no fossil fuelconsumption for au#iliary firing in the

project activity: poer from coal basedAo E#cluded for simplification.

>%; >o E#cluded for simplification.

As per the methodology AC)444( 0 version 4%: th e spati al ex tent of the project

boundary compri ses the was te hea t or gas sources , cap ti ve power genera ting

equ ipmen t , any equ ipmen t u sed to prov ide auxiliary hea t to the was te hea t

recovery process , and the power plan ts connected physica lly to the e lec tr ic ity grid

that the proposed project activi ty will af fect ".

&n the pro jec t act iv ity the projec t boundary comprises $

The waste heat or gas sources$ 9he source of aste heat is the After Burning Chambers 7ABCs8

here the aste gas from the D,& !iln is combusted. ABC is included in the project boundary The captive power generating equipments$ 9his includes the aste heat recovery boilers: related

accessories for steam distribution: team 9urbine Generator 79G8: captive poer plant and thepoer evacuation system

Equipment used to provide auxiliary heat to the waste heat recovery process$ 9his is not relevant

to the project activity

Power plan ts co nnect ed ph ysicall y to th e el ectri ci ty grid tha t th e propos ed

project ac ti vi ty will af fect$ 9he cap tive poer plan t ou ld e#por t poer to

the Eastern regional electr ici ty grid if the poer is in surplus.


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@iln

After burning chamber7ABC8

aste heat recovery boiler72,B8

-roject Boundary


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?,;. Des!ri."ion o 2o9 "2e 4#seine s!en#rio is ien"iie #n es!ri."ion o "2e ien"iie4#seine s!en#rio$

As per the approved methodology: AC)444(: all the alternative baseline scenarios involved in the conte#tof project activity should include all possible options that provide or produce electricity for captiveconsumption only. 9he project activity shall e#clude baseline options that$

do not comply ith legal and regulatory reuirementsM or depend on !ey resources such as fuels: materials or technology that are not available at the project

site.

9he alternative baseline scenarios are listed and e#plained belo$

Alternative 1$ -roposed project activity ithout CD) benefitsAlternative %$ &mport of electricity from local grid

Alternative '$ E#isting or ne captive poer generation on site usinga. coal:coal ashery rejects: coal char

b. dieselc. natural gas

Alternative ($ A mi# of alternative % ' e.g. mi# of coal :coal ashery rejects :coal char based captivepoer plant 7A


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could e#pand the e#isting capacity: the e#pansion being euivalent to the capacity of the 2,B system7the project activity8. B- already had planned % A


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2oever considering that B- already have a captive poer plant based on coal: coal ashery rejects:coal char it ma!es economic sense to go for the same 7considering adeuate availability of fuel from coalashery: as ell as coal from captive mines8 rather than a combination of the to 7grid and C--8.

9herefore the options %: 'a and 'b are most li!ely hen compared to option (. 9herefore this option isruled out for further consideration.

A"ern#"ie - O"2er 'ses o 9#s"e 2e#" #n 9#s"e 6#s

ince there is practically no other use of aste gases 7emanating from the !iln8 in the steel plant: inabsence of the proposed project the aste gas thus generated ould have been uenched: cleaned andreleased into the atmosphere and the heat content ould have been asted. 2ence this alternative ise#cluded from consideration.

E#'#"ion o #"ern#"ies or 4#seine see!"ion$

Among the five alternatives discussed above that could be a part of baseline scenario: to select theappropriate baseline scenario: the alternatives have been discussed belo$

Among all these alternatives: the one that does not face any prohibitive barrier and is the mosteconomically attractive should be considered as the baseline scenario. 9hus from the above identifiedalternatives: it can be found that alternatives %: 'a 'b are the most li!ely alternatives for the baselinescenario. All identified alternatives are compared on capital investment reuired and cost of poergeneration in the table belo 0

P#r#5e"er Gri ?#se Po9er Co#< 4#se Po9er.#n"

Diese 4#se .o9er .#n"

Capital Cost >il &>, (* )illion/) &>, (4 )illion/)

Cost of -oer &>, (.44 per !h &>, 1.*+/!h'

asper CEA data&>, 1.'4 / !h forB-"s coal: coalchar and coalashery rejects

based C--

&>, *.?+(

/!h

9he Central Electricity Authority 7CEA8 report namely ,eport of the E#pert Committee on


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coal char based poer plant as the availability of coal: coal ashery rejects: coal char from the e#istingcoal asheries of B- further reduces the cost of generation to 1.'4 &>,/!h.

Considering the various factors available: the most li!ely baseline scenario ould be Alternative'a: i.e. acoal: coal ashery rejects: coal char based C-- to cater to the euivalent poer as that of the 2,Bsystem considering the economic attractiveness of a coal: coal char and coal ashery rejects based C-- asdetailed above.

?,, Des!ri."ion o 2o9 "2e #n"2ro.o6eni! e5issions o GHG 4 so'r!es #re re'!e 4eo9 "2ose"2#" 9o' 2#e o!!'rre in "2e #4sen!e o "2e re6is"ere CDM .ro/e!" #!"ii" (#ssess5en" #n

e5ons"r#"ion o #i"ion#i")$ QQ

As per the decision 16/cp.6: paragraph (': a CD) project activity is additional if anthropogenicemissions of green house gases by sources are reduced belo those that ould have occurred in absence ofregistered CD) project activity. 9he methodology reuires the project proponent to determine the

additionality based on 9ool for the demonstration and assessment of additionality 0 ver 4'" as per EB %?meeting.

Additionality of project activity as described is discussed hereunder.

tep 1. &dentification of alternatives to the project activity consistent ith current las and regulations.

Sub- step a! "efine alternatives to the project activity#

All the plausible and credible alternatives to the project as per the reuirement of AC) 444( have beendiscussed in section B(.9he alternatives to the project activity have been evaluated based on theireconomic attractiveness and hence a coal: coal ashery rejects: coal char based A


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&n this substep it is reuired to establish that there are realistic and credible barriers that ould preventthe implementation of the proposed project activity from being carried out if the project activity as notregistered as a CD) activity.

9hese realistic and credible barriers include the folloing$

Ines"5en" ?#rrier

B- have installed to A


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Te!2noo6i!# ?#rriers

9he folloing technological barriers ere evidenced in the project activity$

(A) Tr#inin6 re#"e

As per additionality tool definition it is reuired to prove that S%illed and&or properly trained labour tooperate and maintain the technology is not available, which leads to an unacceptably high ris% ofequipment disrepair and malfunctioning or other underperformance"M

hen B- decided to go ahead ith the 2,B boiler for steam generation at high pressure andtemperature configuration hich as the first of its !ind in the tate of ;rissa: the management hadenvisaged operational difficulties and ris!s due to its technical configuration *. 9herefore B- ensuredthat their personnel obtain relevant training


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operation also hamper smooth functioning of electric furnaces. 9hus all these technical difficulties lead tocolossal operational barriers: hich need to be properly addressed to ensure smooth functioning of theunit. 9he operational barriers can probably be handled/ managed by providing appropriate training to

personnel ho ould operate the 2, boilers 7discussed above8.

hereas all these technical barriers do not appear or arise for the baseline alternative i.e. the A


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9-D !iln and hence 9herma# could not identify an immediate solution to the various technologicalproblems.

9he screen tube failure during -hase 1 72,B 1 %8 occurred for several months and during each time:a short term action as ta!en but that as not sufficient to prevent the recurrence of the problem as boilertube lea!age problems ere encountered in the -hase % 72,B '(8 as ell. After several deliberations

beteen B- and 9herma# td: modifications ere proposed in the 2,Bs considering repeated screentube failures. As apparent from the above discussion the problems ere uniue to the project activityconsidering its high technical configuration.

As evident from the above discussions: boiler operational problems occurred in the 2,B hereas anA


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CDM Ee!"#i$e %o&r' page %1

e. 9echnological ris!s / uncertainties of the 2,B in the project activity: is primarilyon account of high technical configuration 7high pressure and temperature8 hich isfirst of its !ind in the region: here as such ris!s are not associated ith the A


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carbon benefits. &t is evident that similar options occurring in the region are considering inflo of CD)revenues due to the ris!s/ challenges faced by them.


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9he net uantity of energy supplied to the manufacturing facility by the project activity during the year isderived as e#plained in section B.+.' and is based on the contribution of the 2,Bs to the poergeneration.

c8 Leakage

>o le a!age is co nsidered as per the methodology AC)44 4(.

Emiss ion Reduction

9he e mi ss io n re du ct io n ERy by th e proj ect ac tiv it y du ri ng a given ye ar y is t h e

differ en ce be t e en th e ba se li ne e mi ss io ns tho ug h sub st it uti on of elec tri cit y

generat ion ith fossi l fuels 7BEy8 and pro jec t emiss ions 7PEy8: as follos$

ERy= BEy PEy

here$

ERy a re the emissions r educt ions of the project act ivi ty during the yea r y

in tons of C;%:

BE,y a re the base line emissions due to d isplacemen t of e lect ri ci ty dur ing

t he ye ar y in tons of

C;%:

PEy a re the project emissions during the yea r y in tons of C;%:



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CDM Ee!"#i$e %o&r' page %(

?,*,%, D#"# #n .#r#5e"ers "2#" #re ##i#4e #" #i#"ion$

$opy this table for each data and parameter

D#"# 7 P#r#5e"er$ E< of (4 ) unit 72,B 1%: A


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-Ey V -roject emissions from use of fossil fuel based poer for start up purposes 7coal based A


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U9G1V team at turbine inlet in !g 7actual in the year %44+468 for (4 ) C--

29G1V Enthalpy of steam at turbine inlet in !Cal/!g 7based on steam pressure and steam temperature at

turbine inlet8 for (4 ) C--

b" 'or +% M) C**:

Eff+4 )WC--V -+4 )WGen O 2e/ 7U9G%O 29G%8

-+4 )WGen V -oer generated in !h 7actual in the year %44+468 from +4 ) C--

2eV 2eat euivalent in !Cal/!h

U9G%V team at turbine inlet in !g 7actual in the year %44+468 for +4 ) C--

29G%V Enthalpy of steam at turbine inlet in !Cal/!g 7based on steam pressure and steam temperature at

turbine inlet8 for +4 ) C--

9he baseline emissions are given as

BE electricity: y V EGy# E


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Step 0$ 9he uantity of steam lost due to steam venting and blo don 7U loss8 is calculated as *P of thetotal steam generation from both the 2,B and AetO 2

2,B

Step 6$ 9he heat content of the steam at the inlet to the turbine 72 9g8 is estimated as 29gV U9gO 29g.

Step 7$ 9he percentage contribution from 2,B toards poer generation is derived as belo

PContribution from 2,B V 9he heat content of the steam from 2,B 72 2,B8 / 9he heat content ofthe steam at the inlet to the turbine 72 9g8 V 722,B8/ 729g8

For ;0 M CPP (HR? 1% #n AF?C1)$

9he percentage contribution from 2,B1% toards poer generation in the (4 ) C-- is derived asbelo after folloing the above steps 1 to 5.

PContribution from 2,B1% V 722,B1 K 22,B% 8/ 729g(4 )8

here

22,B1 V 2eat content of steam from 2,B1 V U 2,B1WnetO 22,B122,B% V 2eat content of steam from 2,B% V U 2,B%WnetO 22,B%29g 0 (4 ) V 2eat content of steam at the inlet to the turbine V U 9gO 29g 0 (4 )

For *0 M CPP (HR? 3; #n AF?C%)$

9he percentage steam contribution from 2,B'( toards poer generation in the +4 ) C-- isderived as belo after folloing the above steps 1 to 5.

PContribution from 2,B'( V 722,B'K 22,B(8/ 729g+4 )8

here:

22,B' V 2eat content of steam from 2,B' V U 2,B'WnetO 22,B'22,B( V 2eat content of steam from 2,B( V U 2,B(WnetO 22,B(29g 0 +4 ) V 2eat content of steam at the inlet to the turbine V U 9g O 29g 0 +4 )



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Ne" ='#n"i" o ee!"ri!i" s'..ie "o "2e 5#n'#!"'rin6 #!ii" 4 "2e .ro/e!" (EG )

>et units of electricity generated 7EGy8 from 2,B V P Contribution from 2,B O 79otal electricitygeneratedAu#iliary Consumption8

Ne" ee!"ri!i" 6ener#"e ro5 HR?1%

EG y 2,B1 % V P Contribution from 2,B1% O >et electricity generated from (4 ) C-- 7EG (4W>et8

EG(4W>etV EG(4WGen0 EG(4WAu#

EG(4WGen 9otal electricity generated from (4 ) C--EG(4WAu#0 Au#iliary consumption at (4 ) C-- in )h

Ne" ee!"ri!i" 6ener#"e ro5 HR?3;

EG y 2,B '( V P Contribution from 2,B'( O >et electricity generated from +4 ) C-- 7EG +4W>et8

EG+4W>etV EG+4WGen0 EG+4WAu#

EG+4WGen 9otal electricity generated from +4 ) C--EG+4WAu#0 Au#iliary consumption at +4 ) C-- in )h

Based on the above EGy 2,B1 % and EG y 2,B ' ( and the corresponding emission factors of the (4 )7E


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CDM Ee!"#i$e %o&r' page %?

E,y V %6%:++1 0 %1+4 V%64:*41 tC;% /yr

?,*,; S'55#r o "2e e+-#n"e es"i5#"ion o e5ission re'!"ions$

:e#r Es"i5#"ion o.ro/e!" #!"ii"e5issions

("ons)

Es"i5#"ion o4#seinee5issions

("ons)

Es"i5#"ion oe#B#6e ("ons)

Es"i5#"ion ooer#e5ission

re'!"ions("ons)

Lear 1 %1+4 %6%:++1 4 %64:*41

Lear % %1+4 %6%:++1 4 %64:*41

Lear ' %1+4 %6%:++1 4 %64:*41

Lear ( %1+4 %6%:++1 4 %64:*41

Lear * %1+4 %6%:++1 4 %64:*41Lear + %1+4 %6%:++1 4 %64:*41

Lear 6 %1+4 %6%:++1 4 %64:*41

Lear 5 %1+4 %6%:++1 4 %64:*41

Lear ? %1+4 %6%:++1 4 %64:*41

Lear 14 %1+4 %6%:++1 4 %64:*41

To"# %1*00 %< @%*


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CDM Ee!"#i$e %o&r' page '4

?,@ A..i!#"ion o "2e 5oni"orin6 5e"2ooo6 #n es!ri."ion o "2e 5oni"orin6 .#n$

?,@,1 D#"# #n .#r#5e"ers 5oni"ore$

$opy this table for each data and parameter

D#"# 7 P#r#5e"er$ EG(4 WGenData unit$ )h/year

Description$ 9otal electricity generated from the (4 ) captive poer plant at B- 7fromboth Aet



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CDM Ee!"#i$e %o&r' page '%

Description$ Au#iliary Consumption by the +4 ) C--

ource of data to beused$

Data records of B-

3alue of data appliedfor the purpose ofcalculating e#pectedemission reductions insection B.*

'*:515.'

Description ofmeasurement methodsand procedures to beapplied$

UA/UC procedures tobe applied$

Any comment$ 9his parameter is calculated using the formulae EG+4WGen EG+4W>et

9his data ill be measured

D#"# 7 P#r#5e"er$ EG +4W>etData unit$ )h/yr

Description$ >et electricity generated from the +4 ) C--


&ndividual distribution energy meters

3alue of data appliedfor the purpose ofcalculating e#pected

emission reductions insection B.*

'%%:'+*


9rivector energy meters of 4.* class accuracy have been installed as individualdistribution meter to measure the net energy consumption.


9he data displayed in the individual distribution energy meters ill be recorded inthe DC. 9he shift engineer ill archive the data in the plant log boo! hich ill

be revieed by the G) 7;)8ho ill in turn report to the 3- -oer on dailybasis. 9his data ill be available up to to years after the crediting periodAll the meters are calibrated annually by the )eter ,elay 9esting division of thestate utility.

Any comment$ 9his parameter is measured

D#"# 7 P#r#5e"er$ SHR?1Data unit$ 9/day

Description$ 9otal steam generation from 2,B1


;nsite instrumentation 7


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CDM Ee!"#i$e %o&r' page ''

section B.*

Description ofmeasurement methods

and procedures to beapplied$


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CDM Ee!"#i$e %o&r' page '(


UA/UC procedures to

be applied$

9he data displayed in the flo meter ill be recorded in the DC. 9he shift

engineer ill archive the data in the plant log boo! hich ill be revieed by theG) 7;)8 ho ill in turn report to the 3- -oer on daily basis. 9his dataill be available up to to years after the crediting periodA detailed calibration system is already in place at B-. 9he flo meter iscalibrated annually.

Any comment$

Data / -arameter$ U2,B(Data unit$ 9/day

Description$ 9otal steam generation from 2,B(ource of data to beused$



35/63


CDM Ee!"#i$e %o&r' page '*


9he data displayed in the flo meter ill be recorded in the DC. 9he shiftengineer ill archive the data in the plant log boo! hich ill be revieed by theG) 7;)8 ho ill in turn report to the 3- -oer on daily basis. 9his data

ill be available up to to years after the crediting period.A detailed calibration system is already in place at B-. 9he flo meter iscalibrated annually.

Any comment$ 9his data ill be measured

D#"# 7 P#r#5e"er$ SAF?C%Data unit$ 9/day

Description$ 9otal steam generation from A


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CDM Ee!"#i$e %o&r' page '+

calibrated annually.


D#"# 7 P#r#5e"er$ STG%Data unit$ 9/day

Description$ 9otal steam inlet to the turbine 79G%8




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CDM Ee!"#i$e %o&r' page '6

Data / -arameter$ Uloss%

Data unit$ 9/day

Description$ 9otal steam lost due to venting: blo don etc at +4 ) C--ource of data to beused$

9he data is calculated


%45.%4


9his data ill be calculated as the difference beteen total steam generated by the2,B '( and A


38/63


39/63


CDM Ee!"#i$e %o&r' page '?


;nsite instrumentation 7temperature gauge of Emerson ma!e ith accuracy of K/4.%4PM 9ag nos$ 99(1*A: (1*B: (1*C8

3alue of data applied

for the purpose ofcalculating e#pectedemission reductions insection B.*

*%4


9emperature gauge of Emerson ma!e ith accuracy of K/4.%4PM 9ag nos$ 99(1*A: (1*B: (1*C has been installed to measure the temperature.


9he data displayed in the temperature gauge ill be recorded in the DC. 9he shiftengineer ill archive the data in the plant log boo! hich ill be revieed by theG) 7;)8 ho ill in turn report to the 3- -oer on daily basis. 9his dataill be available up to to years after the crediting period.

A detailed calibration system is already in place at B-. 9he 9emperature gaugeill be calibrated annually.


D#"# 7 P#r#5e"er$ THR?;Data unit$ 4C

Description$ Average steam temperature from 2,B(


;nsite instrumentation 7temperature gauge of Emerson ma!e ith accuracy of K/4.%4PM 9ag nos$ 99*1*A: *1*B: *1*C8



*%4


9he temperature gauge of Emerson ma!e ith accuracy of K/4.%4PM 9ag nos$ 99*1*A: *1*B: *1*C has been installed to measure the temperature.





D#"# 7 P#r#5e"er$ TAF?C1Data unit$ 4C

Description$ Average steam temperature from A


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CDM Ee!"#i$e %o&r' page (4

for the purpose ofcalculating e#pectedemission reductions in

section B.*Description ofmeasurement methodsand procedures to beapplied$

9emperature gauge of ,osemount ma!e ith accuracy of K/4.%PM 9ag nos$ 99'%1A: '%1B: '%1C has been installed to measure the temperature.





D#"# 7 P#r#5e"er$ TAF?C%Data unit$ 4C

Description$ Average steam temperature from Ao$ 9E14%8

3alue of data appliedfor the purpose ofcalculating e#pectedemission reductions in

*14



41/63



section B.*



9emperature gaugeM 9/C direct to DC module: of accuracy 4.*PM 9ag >o$ 9E14% has been installed to measure the temperature.





D#"# 7 P#r#5e"er$ TTG%Data unit$ 4C

Description$ Average steam temperature at the inlet of 9urbine 79G%8 of +4 ) C--


;nsite instrumentation 7temperature gaugeM 9/C direct to DC module: ofaccuracy 4.*PM 9ag >o$ 9E%4%8


*14



9emperature gaugeM 9/C direct to DC module: of accuracy 4.*PM 9ag >o$ 9E%4% has been installed to measure the temperature.





D#"# 7 P#r#5e"er$ PHR?1Data unit$ @g/cm%

Description$ Average steam pressure from 2,B1


;nsite instrumentation 7-ressure gauge of Emerson ma!e ith accuracy of K/4.1PM 9ag >o$ -9 14+A: 14+B: 14+C8


55


-ressure gauge of Emerson ma!e ith accuracy of K/ 4.1PM 9ag >o$ -914+A: 14+B: 14+C has been installed to measure the pressure



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CDM Ee!"#i$e %o&r' page (%


UA/UC procedures to

be applied$

9he data displayed in the pressure gauge ill be recorded in the DC. 9he shift

engineer ill archive the data in the plant log boo! hich ill be revieed by theG) 7;)8 ho ill in turn report to the 3- -oer on daily basis. 9his dataill be available up to to years after the crediting period.

A detailed calibration system is already in place at B-. 9he -ressure gauge iscalibrated annually.


D#"# 7 P#r#5e"er$ PHR?%Data unit$ @g/cm%

Description$ Average steam pressure from 2,B%


;nsite instrumentation 7-ressure gauge of Emerson ma!e ith accuracy of K/4.1PM 9ag >o$ -9 %4+A: %4+B: %4+C8


55


-ressure gauge of Emerson ma!e ith accuracy of K/ 4.1PM 9ag >o$ -9%4+A: %4+B: %4+C has been installed to measure the pressure.

UA/UC procedures to

be applied$

9he data displayed in the pressure gauge ill be recorded in the DC. 9he shift

engineer ill archive the data in the plant log boo! hich ill be revieed by theG) 7;)8 ho ill in turn report to the 3- -oer on daily basis. 9his dataill be available up to to years after the crediting period.



D#"# 7 P#r#5e"er$ PHR?3Data unit$ @g/cm%

Description$ Average steam pressure from 2,B'


;nsite instrumentation 7-ressure gauge of Emerson ma!e ith accuracy of K/4.4+*PM 9ag >o$ -9 (4+A: (4+B: (4+C8


55


-ressure gauge of Emerson ma!e ith accuracy of K/ 4.4+*PM 9ag >o$ -9(4+A: (4+B: (4+C has already been installed to measure the pressure.

UA/UC procedures to 9he data displayed in the pressure gauge ill be recorded in the DC. 9he shift



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CDM Ee!"#i$e %o&r' page ('

be applied$ engineer ill archive the data in the plant log boo! hich ill be revieed by theG) 7;)8 ho ill in turn report to the 3- -oer on daily basis. 9his dataill be available up to to years after the crediting period.



D#"# 7 P#r#5e"er$ PHR?;Data unit$ @g/cm%

Description$ Average steam pressure from 2,B(


;nsite instrumentation 7-ressure gauge of Emerson ma!e ith accuracy of K/4.4+*PM 9ag >o$ -9 *4+A: *4+B: *4+C8



55


-ressure gauge of Emerson ma!e ith accuracy of K/ 4.4+*PM 9ag >o$ -9*4+A: *4+B: *4+C has been installed to measure the pressure.


9he data displayed in the pressure gauge ill be recorded in the DC. 9he shiftengineer ill archive the data in the plant log boo! hich ill be revieed by theG) 7;)8 ho ill in turn report to the 3- -oer on daily basis. 9his dataill be available up to to years after the crediting period.



D#"# 7 P#r#5e"er$ PAF?C1Data unit$ @g/cm%

Description$ Average steam pressure from Ao$ B-9 '1(A: '1(B:'1(C8



55


-ressure gauge of ,osemount ma!e: ith accuracy of K/ 4.1PM 9ag >o$ B-9'1(A: '1(B:'1(C has been installed to measure the pressure





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CDM Ee!"#i$e %o&r' page ((



D#"# 7 P#r#5e"er$ PAF?C%Data unit$ @g/cm%

Description$ Average steam pressure from Ao$ B-9 +1(A: +1(B: +1(C8


section B.*

55


-ressure gauge of ,osemount ma!e: ith accuracy of K/ 4.1PM 9ag >o$ B-9+1(A: +1(B: +1(C has been installed to measure the pressure.



A detailed calibration system is already in place at B-. 9he -ressure gauge iscalibrated annually


D#"# 7 P#r#5e"er$ PTG1Data unit$ @g/cm%

Description$ Average steam pressure inlet of 9urbine 79G18 of (4 ) C--


;nsite instrumentation 7-ressure gauge of ABB ma!e ith accuracy of K/ 4.1PM9ag no$ -914'8


section B.*

5(


-ressure gauge of ABB ma!e ith accuracy of K/ 4.1PM 9ag no$ -914' hasbeen installed to measure the pressure.






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CDM Ee!"#i$e %o&r' page (*


D#"# 7 P#r#5e"er$ PTG%Data unit$ @g/cm%

Description$ Average steam pressure inlet of 9urbine 79G%8 of +4 ) C--


;nsite instrumentation 7-ressure gauge of ,osemount ma!e ith accuracy of K/4.1PM 9ag no$ -9%4%A: %4%B:%4%C8


5(



-ressure gauge of ,osemount ma!e ith accuracy of K/ 4.1PM 9ag no$ -9%4%A: %4%B:%4%C has been installed to measure the pressure.





D#"# 7 P#r#5e"er$ HHR?1Data unit$ !Cal/!g

Description$ Enthaply of steam generated from 2,B1


team tables


51%.?+



9his data ill be calculated from steam tables based on steam pressure 7- 2,B18and steam temperature 792,B18. 9he data ill be archived either electronically or

in paper and ill be available up to to years after crediting period.


Any comment$ 9his data ill be calculated from the steam table

D#"# 7 P#r#5e"er$ HHR?%Data unit$ !Cal/!g

Description$ Enthaply of steam generated from 2,B%


team tables



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CDM Ee!"#i$e %o&r' page (+



51%.?+


9his data ill be calculated from steam tables based on steam pressure 7- 2,B%8and steam temperature 792,B%8. 9he data ill be archived either electronically orin paper and ill be available upto to years after crediting period.



D#"# 7 P#r#5e"er$ HHR?3Data unit$ !Cal/!g

Description$ Enthaply of steam generated from 2,B'ource of data to beused$

team tables


51%.?+


9his data ill be calculated from steam tables based on steam pressure 7- 2,B'8and steam temperature 792,B'8. 9he data ill be archived either electronically orin paper and ill be available upto to years after crediting period.



D#"# 7 P#r#5e"er$ HHR?;Data unit$ !Cal/!g

Description$ Enthaply of steam generated from 2,B(


team tables



51%.?+


9his data ill be calculated from steam tables based on steam pressure 7- 2,B(8and steam temperature 792,B(8. 9he data ill be archived either electronically orin paper and ill be available upto to years after crediting period.





47/63



D#"# 7 P#r#5e"er$ HAF?C1Data unit$ !Cal/!g

Description$ Enthaply of steam from A


48/63




paper and ill be available upto to years after crediting period.

UA/UC procedures to

be applied$


D#"# 7 P#r#5e"er$ HTG%

Data unit$ !Cal/!g

Description$ Enthaply of steam at turbine inlet 79G%8 of the +4 ) C--


team tables



51%.?+


9his data ill be calculated from steam tables based on steam pressure 7- 9G%8 andsteam temperature 799G%8. 9he data ill be archived either electronically or in

paper and ill be available upto to years after crediting period.



?,@,% Des!ri."ion o "2e 5oni"orin6 .#n$

Or6#nis#"ion s"r'!"'re #n Pro!e're or Moni"orin6 #n Re.or"in6 o #"#$

9he ;rganisation structure for monitoring of parameters for the CD) project activity is provided beloin


49/63


CDM Ee!"#i$e %o&r' page (?

Fi6 ?,%$ Or6#nis#"ion s"r'!"'re #" ?PSL or Moni"orin6 o P#r#5e"ers in "2e CDM .ro/e!"

Procedures for emergency Preparedness

All the parameters measured 7e.g. 9emperature: pressure: flo8 are having %44 P stand by. &n theevent of failure/ malfunctioning of one euipment/ instrument: the value from the standby can beconsidered.



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CDM Ee!"#i$e %o&r' page *4

$alibration of instruments

All the monitoring euipments are calibrated annually as mentioned in section B.6.1 of this document

to ensure the accuracy of all the monitoring parameters.

'odalities and Procedures towards periodic training for the monitoring personnel

1. A yearly internal training schedule is prepared to impart training to the monitoring personnel.

%. All monitoring personnel are trained as per the schedule and training is imparted on themaintenance and calibration of pressure: temperature and flo measuring systems.

'. &n case of any change in the measuring system fe selected engineers are sent to the supplierpremises to be trained on operation: maintenance and calibration of such systems.

$"' internal audit team

A CD) internal audit team ith representative from all the relevant departments ill be responsiblefor data collection and archiving. 9he team ill audit all aspects mentioned in the -DD and ill reportto the Board uarterly. &n case of any deviation: corrective and preventive action ill be ta!en by therespective 2ead of Department 72;D8.

?,& D#"e o !o5.e"ion o "2e #..i!#"ion o "2e 4#seine s"' #n 5oni"orin6 5e"2ooo6 #n"2e n#5e o "2e res.onsi4e .erson(s)7en"i"(ies)

45/14/%446.9he contact detail of the person responsible is given in Anne#1.



51/63


CDM Ee!"#i$e %o&r' page *1

SECTION C, D'r#"ion o "2e .ro/e!" #!"ii" 7 !rei"in6 .erio

C,1 D'r#"ion o "2e .ro/e!" #!"ii"$

C,1,1, S"#r"in6 #"e o "2e .ro/e!" #!"ii"$

%6/4%/%44'

C,1,%, E+.e!"e o.er#"ion# ie"i5e o "2e .ro/e!" #!"ii"$

%* years

C,% C2oi!e o "2e !rei"in6 .erio #n re#"e inor5#"ion$


52/63

PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 03

CDM Ee!"#i$e %o&r' page *%

SECTION D, Eniron5en"# i5.#!"s

QQ

D,1, Do!'5en"#"ion on "2e #n#sis o "2e eniron5en"# i5.#!"s< in!'in6 "r#ns4o'n#r i5.#!"s$

Assessment of Environmental &mpacts due to the project activity as carried out as a part of the Environmental &mpact Assessment 7E&A8 for the integratedsteel plant hich includes the project activity as ell: and submitted to the local pollution control board and )inistry of Environment and


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CDM Ee!"#i$e %o&r' page *'

9he construction phase involved generation of lot of employment: both direct and indirect hich has positively benefitted the socioeconomic environment.

D'rin6 o.er#"ion

8mpacts on air

9he prime impacts on ambient air uality are due to stac! emissions. 2oever all the procedures have been applied to ensure that the stac! emission ismaintained ithin the norms of the ambient air uality.. B- has installed electrostatic precipitators 7E-s8 to reduce the particulate emissions to less than

144 mg/nm

'

.

&n order to reduce the effects of the fugitive emission and hence to maintain the or! =one air uality all the fugitive emission points have been provided ithdust suppression system/ater sprin!lers. As the habitation centres at harsuguda and ambalpur are located about 1+ !m and (* !m aay from the plantrespectively: the impact of air pollutants on these receptors are e#pected to be negligible. 2ence no significant impact is e#pected.

8mpacts on water

9he ater system of the plant has been designed based on ma#imum recirculation and thus effective discharge from the plant to outside ill be almostinsignificant. 9hus no significant impact is e#pected.

9he domestic and sanitary astes e#pected to be generated from the identified facilities ill be treated effectively and hence no adverse impact on ater isenvisaged.

8mpacts on noise level

During normal operations: the ambient noise levels ill increase significantly only close to the turbines and other machinery but this ill be confined only ithinthe shop boundary. 9he noise levels ill be minimi=ed hen the noise reaches the plant boundary and the nearest residential areas beyond the plant boundary: as

elaborate green belt development is envisaged for attenuation of noise. -ersonnel operating close to the noise generating euipments are provided ith personnelprotective euipments 7--E8 in order to reduce the impacts of high noise levels.

All the euipments have been designed as per the reuirement of ;2A 7;ccupational afety and 2ealth Association8 standard and hence no adverse impactdue to the noise levels is envisaged.



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CDM Ee!"#i$e %o&r' page *(

8mpact on ecology#

As the plant is designed for ma#imum recirculation after proper treatment: no effluent ould be alloed to discharge into the ater bodies. 9herefore noadverse impact is e#pected on auatic bodies and therefore the ecology. Greenbelt development ould positively affect the ecology.

Socio-Economic 8mpacts

9he project activity leads to upliftment of s!illed and uns!illed manpoer in the region. 9he project ill be providing employment opportunities not only duringthe construction phase: but also during its operational lifetime. 9he project activity improves employment rate and livelihood of local populace in the vicinity of

the project.

Conclusion

9he net impact under environmental pollution category ould be positive as all necessary abatement measures ould be adopted and periodically monitored.B- monitors the Air and ater uality regularly and the reports are submitted to the local pollution control boards. 9he project act ivity does not have anymajor adverse impacts on environment during its construction or operational phase. 9he socio economic parameters ould sho positive impacts due toincreased job opportunities.

D,%, I eniron5en"# i5.#!"s #re !onsiere si6nii!#n" 4 "2e .ro/e!" .#r"i!i.#n"s or "2e 2os" P#r"< .e#se .roie !on!'sions #n # reeren!es"o s'..or" o!'5en"#"ion o #n eniron5en"# i5.#!" #ssess5en" 'ner"#Ben in #!!or#n!e 9i"2 "2e .ro!e'res #s re='ire 4 "2e 2os" P#r"$

2ost party regulations reuires B- to obtain environmental clearance in the form of I>o objection CertificateJ from ;-CB. 9he local pollution controlboards after revieing the project have accorded Iconsent to establishJ and Iconsent to operateJ.

SECTION E, S"#Be2oers !o55en"s

QQ



55/63


CDM Ee!"#i$e %o&r' page **

E,1, ?rie es!ri."ion 2o9 !o55en"s 4 o!# s"#Be2oers 2#e 4een ini"e #n !o5.ie$

B- published a notice in English 79imes of &ndia8 and local 7Dharitri8 nes daily: inviting vies: comments: objections and suggestions from the sta!eholdersabout the proposed project activity. ubseuent to this the public hearing meeting as conducted on 1+th uly: %44' at 9ahasil office: ,engali. 9hesta!eholders identified for this project are the tate government: tate pollution control board: ,epresentatives of the local panchayat etc. After a detaileddiscussion: an unanimous decision as given in favour of the proposed project.

9he village -anchayat /local elected body of representatives administering the local area have provided their consent / permission to set up the project. 9he noobjection certificate from the local panchayat for setting up this project as obtained: hich ill be provided to the D;E during validation.

E,%, S'55#r o "2e !o55en"s re!eie$

As per the public hearing document conducted for the integrated steel plant 7including the project activity8 of B-: some of the sta!eholders have emphasisedupon creation of local employment opportunities.

9he concerned sta!eholders have given their consent to the project after due e#planation from the project promoter that all the pollution control measures ill beunderta!en by the company to ensure no adverse impact on air : ater: noise and solid astes beyond the stipulated norms due to the project. All the rest of thesta!eholders have supported the project activity considering the potential of the project to generate employment opportunities for unemployed youth in thenearby villages



56/63


CDM Ee!"#i$e %o&r' page *+

E,3, Re.or" on 2o9 'e #!!o'n" 9#s "#Ben o #n !o55en"s re!eie$

B- has provided direct and indirect employment opportunities to local persons. B- has provided for adeuate employment opportunities and infrastructure7ater supply: electricity: sanitation facilities: schools etc81?.

B- has ta!en measures to control air: ater and noise pollution and are complying ith the environmental standards prescribed by the tate -ollutionControl Board%4.

1?,eference$ Document provided to D;E

%4,eference$ Document by ;-CB for air and ater uality report at B- provided to the D;E$This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.


57/63

Anne+ 1

CONTACT INFORMATION ON PARTICIPANTS IN THE PROJECT ACTIVIT:

;rgani=ation$ Bhushan -oer teel imited

treet/-.;.Bo#$ -lot >o. ':

Building$ &ndustrial Area: -hase1City$ Chandigarh

tate/,egion$ Chandigarh

-ostfi#/T&-$ 1+4441

Country$ &ndia

9elephone$ K ?1 16% '?116'5'?


58/63


59/63

Anne+ 3

?ASELINE INFORMATION

9he project activity generates electricity by using aste gases emanating out of the D,& !iln in the productionfacility. 9hus it displaces euivalent uantum of poer hich otherise ould have been generated in a captive

coal: coal ashery rejects and coal char fired plant. 9he emission reduction due to the project activity ill dependupon the net uantity of electricity supplied by the 2,B and the C; %baseline emission factor of the coal:coalashery rejects and coal char based captive poer plant.

Emission ,eduction Estimation from the -roject Activity

Calculation of baseline emission factor 7t C;%/)h8 0 (4 ) baseline plant 72,B1 %M A


60/63

Anne+ - ;

MONITORING PLAN

A, THE METHODOLOG: REUIRES MONITORING OF THE FOLLOING$

1,>et electricity generation%. Au#iliary poer consumption'. team flo at the outlet of 2,B 1: %: '(: Aet Electricity Generated8

No"e$

P Contribution of Enthalpy of team from 2,B is ascertained by dividing the aggregate steam enthalpy at the2,Bs outlet by enthalpy of the steam at the inlet to the turbine. 9his has been discussed in detail ith all therelated algorithms in section B.+.' of this document.

1. team enthalpy 72HR? 2AF?C8 in !Cal/!g is derived by using thermodynamic steam tables: based on thepressure and temperature readings.

%.


61/63

$alibration of instruments

All the monitoring euipments are calibrated annually as mentioned in section B.6.1 of this document toensure the accuracy of all the monitoring parameters.

'odalities and Procedures towards periodic training for the monitoring personnel

A yearly internal training schedule is prepared to impart training to the monitoring personnel.

All monitoring personnel are trained as per the schedule and training is imparted on the maintenance and

calibration of pressure: temperature and flo measuring systems.

&n case of any change in the measuring system fe selected engineers are sent to the supplier premises to

be trained on operation: maintenance and calibration of such systems.$"' internal audit team

A CD) internal audit team ith representative from all the relevant departments ill be responsible for data

collection and archiving. 9he team ill audit all aspects mentioned in the -DD and ill report to the Boarduarterly. &n case of any deviation: corrective and preventive action ill be ta!en by the respective 2ead ofDepartment 72;D8.



62/63

Anne+ -

A44rei#"ions

ABC After Burning Chamber

A


63/63

LIST OF REFERENCES

Sr, No Reeren!es

1,@yoto -rotocol to the Snited >ations

Project Design Document(DRI Kilns)

Documents

Transcript of Project Design Document(DRI Kilns)