Centre for Science and Environment

JSW Energy Vs Top Performers

Topper- No comparison with average performersTopper- Higher benchmarks, higher expectationsProven ability- Move to GLOBAL BEST

Sanjeev K Kanchan

Centre for Science and Environment

Score ComparisonsEnergy

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  Total Weight

JSW Torangallu(% score)

JSW Ratnagiri(% score)

Best in Category JPL Raigarh

Best in parameter

Plant Gross Heat Rate and Trends

7.0 36.8 26.2 34.0 37.6 Tata, Mundra

Design Gross Heat Rate, and Tech

5.0 47.8 49.9 43.8 64.0 Tata, Mundra

Avg. Auxiliary 2.0 45.1 21.0 33.5 80.0 Tata, Trombay

Deviation from Design Heat rate

3.0 57.1 0.0 80.0 80.0 JPL, Raigarh

Availability 3.0 0.0 0.0 56.56 75.00 Dahanu

Total Weight 24.0 9.6 6.2 11.7    

Note- Other parameters: Sec. fuel, avg size, GHG

• Among top performers: < 92% PAF• Ratnagiri- Deviation in GHR >12% , Aux ~9%

Centre for Science and Environment

Score ComparisonsWater

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Total Weight

Torangallu(% score)

Ratnagiri(% score)

Best in Category Ratnagiri

Best in parameter

Water Sources 4 50 75 75 75.0

Sp. Water consumption 5 62 50 50 64.0 GIPCL

Water Stress 3 10 100 100 100

Total Weight 16 or 12 8.39 / 16 8.5 / 12 8.5    

Note- Other parameters: water use in ash handling, COC

• Toranagallu- uses 13% COREX (Bellary – water stressed) Can consumption be further reduced?• Ratnagiri- Sea water based

Centre for Science and Environment

Score ComparisonsAir Pollution

4

 Total

WeightTorangallu(% score)

Ratnagiri(% score)

Best in Category Ratnagiri

Best in parameter(% score)

PM 4 53 56 56 69 Budge Budge

SO2 2 0.0 0.0 0.0 61 Trombay

Pollution Control Tech 2 41 50 50 100 NTPC Singrauli

Coal Storage & Handling

6 25 88 88 88 JSW Ratnagiri

Total Weight 19 5.3 8.5 8.5    

Note- Other parameters: AAQ index

• Estimated SO2 (FGD plant- given value); compared against Chinese norm.

Centre for Science and Environment

Score ComparisonsWater Pollution

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  Total WeightTorangallu(% score)

Ratnagiri(% score)

Best in Category NLC Barsingsar

Best in parameter(% score)

Score for ETP, STP 1 50 100 100100

 

Water Pollution Index 4 100 20 100100

 

Total Weight 7 5/7 3/7 6/7  

Note- Other parameters: coal run-off treatment, CSE lab test

• Ratnagiri- Water pollution related complaints

Centre for Science and Environment

Score ComparisonsSolid Waste

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  Total WeightToranagallu

(% score)Ratnagiri(% score)

Best in Category GIPCL Surat

Best in parameter(% score)

Type of Ash handling 2 100 100 100 100  Many

Ash Utilization 1 0 0 100 >100 Mettur, Torrent

Gainful Ash Utilization 5 8 69 89 >100 Mettur / RRVUNL Kota

Ash Pond Maint. 4 80 40 60 80Torangullu / NLC - Barsingsar

Total Weight 15 7.59 8.27 11.03    

Note- Other parameters: stakeholders observation ash pollution

• Imported coal – at-least 80% ash use criteria (domestic coal at-least- >58%)• Gainful- Imported at-least- 33% (Domestic at-least- 48%)• Ash pond maintenance- Ratnagiri- bund, pipeline

Centre for Science and Environment

JSW- ToranagalluEnergy

• SBU-I (2x130 MW)- in 2000, SBU-II (2x300 MW)- 2009• Avg. GHR - 2,261kCal/kWh (38 %), design GHR 2,162 kCal/kWh,

(BAT- <1,800kCal/kWh, Nordjylland-Denmark)• Deviation - 4.6% (Hissar, Mundra etc.- <1%)• Auxiliary -7.6 % (Maithon/Hissar etc.- ~6%)• PAF- 90.9%; PLF- 94% (PAF- 99%, PLF- >100%)• Sp. Coal consumption at 0.46 kg/KWh (13% energy from COREX)

Water• Water stress area• ZLD, Sp. Water- ~2m3/MWh {Best- 1.6 ; Dry- 0.11(m3/MWh)}• COC of 5-7 (Jojobera- 8, achievable 10)

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Centre for Science and Environment8

Coal handling needs improvement

• Community complaints- Red dust emission (steel), vehicular movement through village (steel, power, mines)• CSR (< 2% of profit)- demand for more access to heath facility•Study of impact (of complex) on Daroji bear sanctuary

Coal handling needs im

provement

Issues to Deal

Centre for Science and Environment

JSW- ToranagalluSolid Waste

• Dry ash handling; Bottom as- Dry/Semi-wet• Ash use-79%; (Budge Budge, Torrent, Mettur, Kota etc.-

>100%)• Gainful use- 51 % (Mettur, Kota- >100%)

Air Pollution• No visible emission• PM- 60-62 mg/Nm3 (norm 100 mg/Nm3)• SO2- 665-934 mg/Nm3

• NOx- 366-429 mg/Nm3

• No mercury emission monitoring(Implication of new pollution norms) ? CEMS ?

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Centre for Science and Environment

JSW- RatnagiriEnergy

• 300 MW x 4 - in 2010/11• Avg. GHR - 2,418kCal/kWh (35.5 %), design GHR- 2,151

kCal/kWh (39.9%), (BAT- <1,800kCal/kWh, Nordjylland-Denmark)

• Deviation - 12% (Hissar, Mundra etc.- <1%)• Auxiliary ~9 % (Maithon/Hissar etc.- ~6%)• PAF- 89%; PLF- 81% (PAF- 99%, PLF- >100%)• Sp. Coal consumption at 0.49 kg/KWh (Imported)• Covered coal storage- only one in India

Water• Sea water with CT- Sea water requirement- 9.7m3/MWh• Issues to deal- Ground water contamination, CT saline mist

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Centre for Science and Environment11

Coal dust e

mission

GW contamination

• Community complaints- Saline mist & leakage from CT, coal dust emission, hot CW discharge - Impact on orchards, fishes•How to convey your work/improvement?

Issues to Deal

Centre for Science and Environment

JSW- RatnagiriSolid Waste

• Dry ash handling• Ash use-77.6%; (Budge Budge, Torrent, Mettur, Kota etc.- >100%)• Gainful use- 83.8 % (Mettur, Kota- >100%)• Issues to deal- ash pond maintenance, ash transport pipeline,

complaints on ash emissionsAir Pollution

• No visible emission• PM- 9-24 mg/Nm3 (norm 50 mg/Nm3)• SO2- 373-405 mg/Nm3

• NOx- not monitored• No mercury emission monitoring(Implication of new pollution norms) ? CEMS ?

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Centre for Science and Environment

Implication of new pollution norms

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Pollutants

Unit size

Installed before Dec 31st, 2003 (shall meet within 2 yrs)

Installed after Dec 31st, 2006(shall meet within 2 yrs)

Installed Jan 1, 2017 onwards(Includes accorded EC, under construction)

PM All 100mg/Nm3 50 mg/Nm3 30 mg/Nm3

SO2<500MW 600 mg/Nm3 -- --

>=500MW 200 mg/Nm3 200 mg/Nm3 100 mg/Nm3

NOx All 600 mg/Nm3 300 mg/Nm3 100 mg/Nm3

Hg >=500MW 0.03 mg/Nm3 0.03 mg/Nm3 0.03 mg/Nm3

Centre for Science and Environment

Implication of CEMS ?

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CEMS- Selection, installation, certification, calibration/re-calibration, daily check, data recording, record keeping, compliance check, publish

• Device health check- daily 10.00 a.m.; zero drift • calibration verification- 3 months • Zero and span drift – every week • >85% data capture • Data verification/ calibration- 6 monthly by empanelled Lab• Compliance

Any exceedance- violation Data spikes (< 1 min)- not for avg Continuous exceedance upto 10% of norms,

o >30 mins- preventive action by industry o >60 mins- to inform SPCB/PCCs about preventive actiono Second time- closure

Frequent exceedance- > 5% of data/day- action by SPCBs/PCCs Industry fails to control emissions- closure as per SOP Start-up/shut down ( batch process for 30 mins)- not for avg