CLEAN DEVELOPMENT MECHANISM PROJECT … - YKK September 2008_V1.pdfCLEAN DEVELOPMENT MECHANISM...

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PROJECT DESIGN DOCUMENT FORM (CDM-SSC-PDD) - Version 03 CDM – Executive Board 1 CLEAN DEVELOPMENT MECHANISM PROJECT DESIGN DOCUMENT FORM (CDM-SSC-PDD) Version 03 - in effect as of: 22 December 2006 CONTENTS A. General description of the small scale project activity B. Application of a baseline and monitoring methodology C. Duration of the project activity / crediting period D. Environmental impacts E. Stakeholders’ comments Annexes Annex 1: Contact information on participants in the proposed small scale project activity Annex 2: Information regarding public funding Annex 3: Baseline information Annex 4: Monitoring Information Appendices Appendix A: Maintenance procedure Appendix B: QA/QC Procedures Appendix C: Abbreviation Appendix D: Calculation for Boiler Rating estimation Appendix E: CO 2 Baseline Database for Northern Grid Appendix F: Copy of Efficiency certificate for Fuel Oil (FO) fired Boiler Appendix G: Calculations for briquette fired boiler efficiency estimation Appendix H: Copy of ISO 14001:2004 certificate for “Environment Management System”

Transcript of CLEAN DEVELOPMENT MECHANISM PROJECT … - YKK September 2008_V1.pdfCLEAN DEVELOPMENT MECHANISM...

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CLEAN DEVELOPMENT MECHANISM PROJECT DESIGN DOCUMENT FORM (CDM-SSC-PDD)

Version 03 - in effect as of: 22 December 2006

CONTENTS A. General description of the small scale project activity B. Application of a baseline and monitoring methodology C. Duration of the project activity / crediting period D. Environmental impacts E. Stakeholders’ comments

Annexes Annex 1: Contact information on participants in the proposed small scale project activity Annex 2: Information regarding public funding Annex 3: Baseline information

Annex 4: Monitoring Information Appendices

Appendix A: Maintenance procedure Appendix B: QA/QC Procedures Appendix C: Abbreviation Appendix D: Calculation for Boiler Rating estimation Appendix E: CO2 Baseline Database for Northern Grid Appendix F: Copy of Efficiency certificate for Fuel Oil (FO) fired Boiler Appendix G: Calculations for briquette fired boiler efficiency estimation Appendix H: Copy of ISO 14001:2004 certificate for “Environment Management System”

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Revision history of this document Version Number

Date Description and reason of revision

01 21 January 2003

Initial adoption

02 8 July 2005 • The Board agreed to revise the CDM SSC PDD to reflect guidance and clarifications provided by the Board since version 01 of this document.

• As a consequence, the guidelines for completing CDM SSC PDD have been revised accordingly to version 2. The latest version can be found at <http://cdm.unfccc.int/Reference/Documents>.

03 22 December 2006

• The Board agreed to revise the CDM project design document for small-scale activities (CDM-SSC-PDD), taking into account CDM-PDD and CDM-NM.

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SECTION A. General description of small-scale project activity A.1 Title of the small-scale project activity: >> “Thermal Energy Generation using Biomass based Briquettes at YKK India Private Limited, Haryana.” Version : 01 Date : 25/09/2008 A.2. Description of the small-scale project activity: >> Purpose of the small scale project activity: The purpose of the project activity is to reduce the greenhouse gas emission in the steam generation process by switching over from the existing Furnace oil /Residual Fuel Oil (FO/RFO) to biomass based briquettes in the boiler. Salient Feature of the project activity M/s. YKK India Private Limited (hereinafter referred to as YKKIPL) was established in the year 1997. YKKIPL is involved in manufacturing, marketing & sales of Metallic and non Metallic zip fasteners and its components on mass scale. The plant comprises of two FO fired boilers of installed capacity 4 TPH and 6 TPH. The 4 TPH boiler remains as standby, while the steam generated from the 6 TPH boiler is used for jacket heating. The plant has proposed a boiler fuel switching project on one of its boiler having capacity 6 TPH, from FO (also referred to as RFO) to biomass based briquette (green fuel) in order to reduce the green house gas emission into the atmosphere as well as to promote the sustainable development in the country. The process flow chart for the exiting scenario is shown in the Figure A.2.1.

Flue Gases to atmosphere

FO

(Fossil Fuel)

Steam @ 10.54 kg/cm2 and temp. 182oC for Jacket Heating

Flue gases to chimney Boiler 6 TPH (Three Pass smoke tube wet back)

Figure A.2.1: Process flow chart before the project implementation

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As YKKIPL’s parent company is based in Japan, it has considered this project very seriously in order to cut down GHG levels in its production process by eliminating the use fossil fuel in the steam generation process. Contribution of the project activity to Sustainable Development

1. Reducing fossil fuel requirement by the use of sustainable energy sources. The project activity encourages the use of biomass based briquettes and displaces the use of fossil fuel in the steam generation process.

2. Owing to the depleting resources of fossil fuel, the use of renewable energy sources is required to reduce the pressure on India’s energy security. Thus, the project activity plays a vital role in preventing the nation’s energy resources.

3. These biomass based briquette are an agro waste product that are not utilized by the farmers for any productive purposes. Therefore, the use of these briquettes by YKKIPL would eventually give an additional source of income to the farmers through the sale of agriculture waste, contributing to their self sustenance.

4. The use of biomass based briquette will promote the other investors to install new briquette manufacturing units. Thus the industrialization near the rural/village areas will bring about the decentralized growth of the country.

5. Social and Economic benefits by generating employment in urban area because of the manual firing of briquettes that need more man power as compared to operators required in FO fired units.

6. The proposed Steam generation using biomass based briquette is environmentally safe and sound technology.

A.3. Project participants: >> Name of Party involved (*) ((host) indicates a host party)

Private and /or public entity(ies) project participants (*) (as applicable)

Kindly indicate if the party involved wishes to be considered as project participant (Yes/No)

Government of India (host)

M/s. YKK India Private Limited, Rewari, Haryana, India

No

A.4. Technical description of the small-scale project activity: >> A.4.1. Location of the small-scale project activity: A.4.1.1. Host Party (ies): >> India A.4.1.2. Region/State/Province etc.: >> Haryana A.4.1.3. City/Town/Community etc: >> Rewari

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A.4.1.4. Details of physical location, including information allowing the unique identification of this small-scale project activity: >> The project activity is located in the Industrial premises of YKK India Private Limited at Tehsil Bawal, District Rewari in Haryana. The latitude and longitude of the Bawal is given as follows: Latitude: 28o5’ N Longitude: 76o35’ E The Physical address of project site: M/s. YKK India Private Limited, Factory Plot No. 699, Sector-2, HSIDC Growth Centre, Bawal, District- Rewari, Haryana – 123 501 (India) A.4.2. Type and category (ies) and technology/measure of the small-scale project activity:

Figure 4.1 Physical location of the project activity (YKKIPL)

Bawal

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>> As per the Appendix B of the simplified modalities and principles (M&P) for small scale CDM project activities given in the CDMUNFCCC website, type and category of the project activity are as follows: Type : I - Renewable energy projects Category : C - Thermal energy for the users with or without electricity Details of Retrofit Technology The project involves investment to convert the 6 TPH fire tube three pass horizontal wet back boiler into biomass based briquette fired boiler by retrofitting the boiler furnace for facilitating the manual briquette firing. The YKKIPL comprises two FO fired boilers of capacity 4 TPH and 6TPH respectively. The one 4TPH FO fired boiler will be kept standby. Before the proposed project activity implementation the boiler fuel consumption was 824.636 kilo litres of FO/year for producing 11,083 MT of steam/year. The project activity has a capacity to reduce the overall GHG emission by 3746 tonnes of CO2 equivalent per year. Since the project activity will be using green fuel, it will not be contributing in the emission of GHGs. The boiler produces saturated steam at saturated pressure 10.54 kg/cm2 and saturation temperature of 182oC. The technology involves retrofit of existing boiler wherein the burner and FO firing system is removed and a well insulated extended surface is constructed for facilitating the manual briquette feeding into the boiler. Biomass based briquettes will be fired at the grate by charging manually and the hot flue gases are allowed to pass over the boiler tubes. However it is to be noted that due to boiler fuel conversion the capacity of the existing boiler will be de-rated from 6 TPH to 3.5 TPH which means 2.39 MWth (Refer Appendix D) for 3.5 TPH. But the total steam generation from the boiler per day will remain the same as the steam requirements remain the same. The schematic diagram of conversion of existing boiler is given in the Figure A.2.2. The exhaust flue gases coming through the boiler will first pass through the air preheater, then entered into the dust collector where the fly ash form the flue gases will be gathered and finally escape out into the atmosphere through the chimney.

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Figure A.2.2: Process flow chart after project implementation

The boiler conversion results in the reduction in the overall efficiency of the boiler. The boiler efficiency will be coming down from 80% (Efficiency of FO fired Boiler) to 61% (Efficiency of briquette fired boiler) due to this conversion (Refer Appendix G). Biomass Briquette Availability The total requirement of biomass briquette to the project activity is very small, to the tune of 2.56KT/year. The agro-waste required for briquette manufacturing is sufficiently available in the District Rewari as well as in adjoining districts. The briquette manufacturer (M/s Stemax Fuel Supplier, New Delhi) therefore, can ensure for the timely supply of briquettes to the project activity.

A.4.3 Estimated amount of emission reductions over the chosen crediting period: >> The YKKIPL has chosen the renewable crediting period for the project activity. The length of first crediting period is 7 years. During 7 years (2009-2016) or first crediting period the overall GHG emission reduction is worked out to be 26224.8 tCO2eq. The crediting period will be renewed twice. Hence total crediting years are 21 years. The average emission reduction is 3746tCO2eq. per year.

Year Estimation of annual emission reductions in tonnes of CO2 e

2009 -2010 3746.4 2010-2011 3746.4 2011-2012 3746.4 2012-2013 3746.4 2013-2014 3746.4

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2014-2015 3746.4 2015-2016 3746.4

Total estimated reductions (tonnes of CO2e ) 3746.4

Total number of Crediting years 7 Annual average of the estimated

reductions over the crediting period 3746

2009-2010 represent the time period between 1st April 2009 (anticipated date of registration) and 31st March 2010. All other years represent the respective financial year spanning between 1st April and 31st March. A.4.4. Public funding of the small-scale project activity: >> There is no national and international public funding involve in the project activity. The investment will be done by the project proponent and there is no subsidy element in the commissioning of the project activity. A.4.5. Confirmation that the small-scale project activity is not a debundled component of a large scale project activity: The proposed CDM project activity is not a bundled component of a large project activity. Thus none of the aspects mentioned in paragraph 2 of Appendix C of the simplified modalities and procedures for the small scale CDM project activities apply to this project. There is no other small scale CDM project activity and will not be applied to register another small scale CDM project activity:

1. With same project participants 2. In the same project category and technology/measure; and 3. Registered within the previous 2 years; 4. Whose project boundary is within 1 km of the project boundary of the proposed project activity at

the closest point. SECTION B. Application of a baseline and monitoring methodology B.1. Title and reference of the approved baseline and monitoring methodology applied to the small-scale project activity: >> Referring to the Appendix B on the UNFCCC website for simplified modalities and principles for small scale CDM project activities, the proposed project activity can be considered under: Sectoral Scope : 01 Type : I - Renewable energy projects Category : C - Thermal energy for the users with or without electricity Version : 13 Date : 28th March, 2008

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Reference: (http://cdm.unfccc.int/methodologies/DB/OJ59EYOQ89A9IPIPFNJPQHBGFJOK8T/view.html) B.2 Justification of the choice of the project category: >> The Approved Methodology (AMS-I C), version 13 is being applied to all CDM project activities which are based on Renewable energy projects that encourages the use of “renewable energy technologies that supply individual households or users with thermal energy that displaces fossil fuels”. The proposed project activity will use renewable energy by means of biomass based briquettes (manufactured by the agro waste products) in lieu of FO (fossil fuel) for generating steam in the boiler. The project activity will use renewable energy technology for producing thermal energy by switching of the fuel from FO to Biomass based briquettes. Thereby the project activity falls under the category AMS IC, version 13, dated 28th March, 2008. Due to the boiler fuel conversion the capacity of the boiler will reduce from 6TPH to 3.5 TPH. This clearly means that the thermal energy generation capacity of the biomass based briquette fired boiler would be less then the existing (3.93 MWth for 6TPH) which is 2.39 MWth (refer Appendix D) for 3.5 TPH. This value is surely less then the limit of 45MWth of maximum output generation capacity as specified in the approved methodology (AMS I C, version 13, dated 28th March, 08) of the Appendix B of the simplified M&P for small scale CDM project activities. Thus, the chosen methodology (AMS I C, Version 13) is applicable for the proposed project activity. Table B.2-1. Relationship between the proposed project activity and the “Technology/measure” of project category-AMS I C. Technology/measure The Proposed project activity YKKIPL 1. This category comprises “renewable energy technologies that supply individual households or users with thermal energy that displaces fossil fuels”. Example include solar thermal water heaters or dryers, solar cookers, energy derived from renewable biomass for water heating, space heating or drying, and other technologies that provide thermal energy that displaces fossil fuel. Biomass based cogeneration systems that produces heat and electricity are included in this category.

1. The project activity displaces the boiler fuel from FO (fossil fuel) to Biomass based briquette (Renewable) for the generation of steam in the process.

2. The thermal generation capacity is specified by the manufacturer, it shall be less than 45 MWth

2. The steam (thermal) generation capacity of the boiler is 2.39 MWth.

B.3. Description of the project boundary: >>

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As per paragraph 5 of “Type AMS I C. Renewable energy projects (Version 13)” of Appendix B of simplified modalities and procedures for small scale CDM project activities the project boundary is the “Physical, geographical site of the renewable energy generation delineates the project boundary.” The proposed project activity involves the reduction of GHG emission in steam generation therefore the project boundary includes the area of steam generation at the plant location.

(Figure B.3.1 Project boundary for the project activity)

B.4. Description of baseline and its development: >> According to the paragraph 6 of the Type I C “Renewable energy projects” of Appendix B of the simplified M&P of small scale CDM Project activities the baseline states that: “For renewable energy technologies that displace technologies using fossil fuels, the simplified baseline is the fuel consumption of the technologies that would have been used in the absence of the project activity times an emission coefficient for the fossil fuel displaced. IPCC default value for emission coefficient may be used.” The coal has been envisaged as the cheapest alternative for steam generation by the project activity. As the coal is readily available to the project proponent and the steam generation cost through the coal will be low as compared to the biomass based briquettes. Thus, the Baseline Emission for the proposed project activity is the GHG emission that would have occurred due to the use of coal in the boiler in the absence of proposed project activity. Key assumption for the baseline methodology in the context of project activity:

1. The efficiency of the steam generating unit, using biomass briquette fuel, is consistent through out the crediting period, which is being monitored.

Biomass based briquette

Project Boundary

Biomass Briquette supplier (Located around 175 KM away form the project activity)

Steam Generation Unit

(Boiler)

Steam @10.54 kg/cm2 and temp 182oC for

Jacket Heating.Smoke + Dust particles (Fly

ash)

To atmosphere

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2. The properties of coal and biomass briquette (monitored data) like calorific value remain consistent before and after the project activity.

Table: B.4.1 Data and parameters for baseline calculations S.No. Data / Parameter Unit Average

value Data Source

Biomass Based Briquette 1. Average Briquette fuel

consumption in the boiler Mt/Day (KT/year)

8 (2.56)

Projected Briquette consumption for completing the constant steam demand of YKKIPL.

2. Net Calorific value of biomass briquette

TJ/KT 15.9 Test reports maintained at the manufacturing site (YKKIPL)

Baseline Fuel (Coal) 1. Average Coal fuel

consumption in the Boiler Mt/Day 4.51 Equivalent Coal consumption based on

the daily briquette consumption.

2 NCV of Coal TJ/KT 28.2 Table 1.2 of Chapter 1 of Volume 2 (energy) of 2006 IPCC Guidelines for National Greenhouse Gas Inventories Programme (IPCC-NGGIP)

Other Data 1 Steam generation Mt/year 11083 Boiler log sheets maintained at

YKKIPL 2 CO2 Emission Factor for

Coal tCO2/TJ 94.6 Table 2.2 of Chapter 2 of Volume 2

(energy) of 2006 IPCC Guidelines for National Greenhouse Gas Inventories Programme (IPCC-NGGIP)

B.5. Description of how the anthropogenic emissions of GHG by sources are reduced below those that would have occurred in the absence of the registered small-scale CDM project activity: Justification for application of simplified methodologies to the project activity The installed capacity of the project is 2.39 MWth which is less than the limiting capacity of 45 MW and is thus eligible to use small-scale simplified methodologies. Further, the project activity is generation of steam, using renewable biomass (briquettes) as fuel source. Hence, the Type and Category of the project activity matches with AMS IC, version 13, as specified in Appendix B of the indicative simplified baseline and monitoring methodologies for small-scale CDM project activities. At present the company is meeting its steam demand through FO fired boiler, which is highly polluting. Therefore, the conversion of boiler fuel form FO to renewable biomass based briquette seams to be a better option for the project activity. The additional revenue generated through the sale of CERs will promote the renewable technology investment for thermal energy generation. Justification for Additionality of the project UNFCCC simplified modalities seek to establish additionality of the project activity as per Attachment A to Appendix B, which listed various barriers, out of which, at least one barrier shall be identified due to

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which the project would not have occurred any way. Project participants identified the following barriers for the proposed project activity: Investment Risk The project activity is one of the initial attempts in YKKIPL in India, where an idea of usage of renewable biomass fuel in the steam generation has been implemented for the first time. Almost all the other zip manufacturers in India are using electricity for production facilities and primary energy (fossil fuel) for process heating. The usage of biomass based steam generation for running the production facility will be experimented for the first time in the company. The cheapest alternative to produce steam for the proposed project activity is coal because the cost of steam generation with coal is approx. Rs. 0.62/kg of steam while it is for Biomass based briquette as per the present survey is Rs. 1.28/kg of steam. If the project activity adopts the coal as alternative fuel, it could have been a profit making project. Also the generation of steam with coal would have led to higher emission as compared to FO. The use of biomass based briquette as a boiler fuel would lead to additional financial burden to the company but it dose not have any contribution in the emission of GHGs into the atmosphere and makes the project activity environmentally friendly. Apart from the boiler conversion, the additional initial investment is also required in the proposed project activity to facilitate the feeding of briquette into the boiler. As such there is no previous case in the similar industry demonstrating the success of such project activity for the entire life term. Thus the project proponent has considered the possible CDM revenue for the project activity as a risk mitigation measure to hedge against the possible changes in biomass briquette prices in the future and possible production interruptions due to non-smooth functioning of the project activity. Other barriers: At present there is no definite market for the available biomass (briquette) in the vicinity of the project. A definite market for biomass (with implementation of project) may result in the change in price of biomass (briquettes) on a higher side (which has been practically observed in other states of India, where biomass based steam generation projects are implemented and the projects have become financially unattractive1). The success of the initiative is therefore dependent upon the biomass price, which is beyond the control of the project proponent. Additionally the biomass briquette (fuel) is required to be stored (inventory) in order to maintaining continues steam generation in the plant. When the biomass briquette is stored, its characteristics change within a period leading to loss of volatile matter and deterioration of biomass quality, which affects the performance of plant equipment. Moreover, the calorific value of biomass also decreases leading to a reduction in efficiency. Biomass briquette procurement is also a risk due to the seasonal availability and also it is subject to seasonal fluctuations due to vagaries of nature. This leads to a hike in the price of biomass briquette in lean months when the biomass availability is less.

1 http://www.thehindubusinessline.com/iw/2007/06/24/stories/2007062401011100.htm

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Apart from theses the briquette loading and unloading is the biggest dilemma before the project proponent. Unlike FO the briquette will have to be fed manually into the boiler. The removal of fly ash is another tedious problem. The project proponent has considered the CDM revenue for the project as a risk mitigation measure related to various risk factors to the project activity. In order to establish that the GHG emission reductions due to the project activity are additional to those that would have occurred in the absence of the current project activity, the “Tool for the demonstration and assessment of Additionality” Version 05, has been used. Step 0 – Preliminary screening based on the starting date of the project activity a) Provide evidence that the starting date of the CDM project activity falls between 1 January 2000 and the date of the registration of a first CDM project activity, bearing in mind that only CDM project activities submitted for registration before 31 December 2005 may claim for a crediting period starting before the date of registration;

This point is not applicable. Carbon Credits are being claimed from the date of registration.

Ok

b) Provide evidence that the incentive from the CDM was seriously considered in the decision to proceed with the project activity.

Incentives from CDM revenue included in the project feasibility report as well as in the board meeting of the company to finalise the project activity2

Ok

Step 1. Identification of alternatives to the project activity consistent with current laws and regulations Define realistic and credible alternatives to the project activity(s) that can be (part of) the baseline scenario through the following sub-steps: Sub-step 1a. Define alternatives to the project activity:

The project activity was essentially conceived to generate clean energy, to meet the plant’s thermal energy needs at YKKIPL. Considering the high upfront investment in unrelated non-core business of briquettes project, YKKIPL would have continued with meeting its thermal energy (steam) needs through following alternatives. 1. Continue with the existing FO fired boiler for meeting the plant thermal energy (steam)

All the alternatives available to the project proponent will provide the same end product (steam) and they are permitted under the prevailing laws of India.

2Excerpts from the minutes of the meeting of the board of directors of the company (YKKIPL) held on 10/01/2008

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needs. 2. Install coal fired boiler for steam generation.

Sub-step 1b. Consistency with mandatory laws and regulations:

1. The candidate CDM project without additional revenue stream of CDM – permitted 2. There is no requirement / mandate given to YKKIPL either from State or Central Government under which the steam generation through biomass (briquette) is required3.

All the available options were open for the project proponents, and none of them has been made mandatory by the State or Union Government of India.

Step 3: Barrier Analysis (Either of Step 2 or Step 3 has to be carried out) Sub-step 3a: Identify the barriers that would prevent the implementation of the proposed project activity

Fuel price fluctuations 1. At present there is no definite market for the available biomass in the vicinity of the project activity. A definite market for biomass (with implementation of project) may result in the change in price of biomass briquettes on a higher side (which has been practically observed in other states of India, where biomass based steam generation projects are implemented and the projects have become financially unattractive4). 2. The major investment barrier to the project is the perceived risk to the project in case of reduced supply of biomass briquettes in future. Fuels prices may raise in case of a few competitors come up within the vicinity of the region. As per information available in the present public domain only few industries in

CDM revenue for the project will offset the additional revenue requirement for biomass based briquette storage during the unavailability of biomass. The success of such an initiative is therefore dependent

3 Central Pollution Control Board. http://www.cpcb.nic.in/Industry-Specific-Standards/Emission/Boiler.pdf 4 http://www.thehindubusinessline.com/iw/2007/06/24/stories/2007062401011100.htm, Dated: 24 June, 2007 5 Trends of briquette price escalation from the previous years 6 As per the briquette price given in the fuel supply agreement with M/s Stemax fuel supplier. 7 8 MT /day x 320 days x INR 4400/MT = INR 112.64Lakh 8 8 MT/day x 320 days x INR 5000/MT = INR 128Lakh 9 3746*15*60 =INR 33.71Lakhs/year 10 Detailed price calculation sheet is attached

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Haryana are already in the process of putting up biomass briquette based plants. But owing to the high GHG emissions and depleting resources of fossil fuel more industries are expected to come up with the demand of biomass briquettes in the coming years. This shows that there is a risk to the investors for the shortage of supply of briquette in future. Shortage in supply of biomass may also lead to price escalation of briquette which might render the project financially unstable. Trends5 based on the escalation in price of biomass briquette for previous years shows that the cost of briquette during the lean months of supply may reach up to INR 5000/tonne. The average price of biomass briquette is of the order of INR 4400/MT6. The average price of the briquette is expected to rise in future if few more industries come up with biomass as a fuel source for steam generation. The average briquette consumption of the plant is about 8MT per day. Considering the average price of briquette @ INR 4400/ MT, the total annual expenditure are of the order of = INR 112.64 Lakh7. If the average price of the briquette is escalated @ INR 5000/ton, to total annual expenditure increase to INR 128Lakh8. The increase in expenditure due to increased cost of briquette is of the order of INR15.36Lakh, which can be off set by the additional CDM revenue9 of the project as the total CERs generated through the project activity will be approximately 3746 tCO2 per year.

The investment analysis conducted at the time of the project development and implementation showed that the project activity is unattractive for YKKIPL in the business-as-usual scenario. The underlying assumptions for the investment analysis have been mentioned below. The project proponent has assumed a steam generation cost as INR 1.28 per kg of steam. The briquette rate for the financial calculations has been assumed as INR 4400 per metric ton

upon the biomass price, which is beyond the control of the investor.

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of biomass briquette. An escalation in the price of briquette has been considered in the calculations. By assuming 100% in-house steam consumption, YKKIPL is replacing the generation of steam from in-house FO fired boiler. An investment comparison analysis for the project activity has been done by the company. The coal has been envisaged as the cheapest alternative for steam generation by the project activity. The investor found that the landed price of the coal is INR 3770/MT10. The steam generation cost with coal is found very low (Rs 0.62/kg of steam) than that of briquette (Rs.1.28/kg of steam) therefore ultimately the use of coal in lieu of briquette in the project activity will be cheaper than that of briquettes. As the objective of the investor to implement this project activity is to eliminate the use of fossil fuel in the steam generation process and the use of coal will not be helpful in the GHG emission reduction as the coal is fossil fuel and emits huge GHGs and therefore the investor has selected biomass based briquette (green fuel) in spite of cheaper fuel i.e., coal. Therefore, the CDM generated revenue has been foreseen as a motivating force in the implementation of the project activity by the investor. As the CDM generated revenue may help the investor during the rise in biomass briquette prices. The assumptions made for the steam generation cost analysis for various fuels in the project activity has been described in the attached excel work sheet.

Technological barriers: 1. YKKIPL has developed the in-house capability to manage and run a Biomass briquette fired boiler. The company is required to develop skills / carry out additional investments for managing a combined steam

There would clearly be a need for more skilled manpower to operate and maintain the power

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generating activity. As the project activity is one of the initial attempts in Zip manufacturing Industry in India, where an idea of usage of Renewable fuel has been implemented for the first time. Almost all the operating Zip manufacturers in India are using electricity for production facilities and primary energy (petroleum products) for process heating. The usage of biomass based steam generation for running the production facility has been experimented for the first time by the company in the state of Haryana without any concrete evidence of its success. Therefore, the company is still trying to develop the technical know how through the plant and machinery suppliers for the project thus the project proponent has considered the possible CDM revenue for the project as a risk mitigation measure to hedge against the change in biomass prices, its availability and success of the project. 2. The price of biomass is very sensitive to the project activity. If the biomass collection cost is too high the project viability may worsen. Due to the low density of biomass the biomass quantity used by the briquette manufacturing plant is very high. Although in the present scenario the biomass availability in the region is abundant, but the cost of biomass collection, storage and transportation may be increased due to uncertainties. Also due to the spiraling prices of fossil fuel the transportation cost of briquette form supplier to project site may ascend which will eventually affect the briquette prices. These entire factors will certainly raise the briquette cost. Therefore, the investor has considered the CDM revenue in offsetting the uncertainty of hiking briquette prices. 3. Biomass Briquette combustion in boiler is relatively new technology. Opting for a relatively new technology for which there is no success story/experience available in the region puts a high technological risk to the project proponents. 4. The critical problem arises with the biomass

plant equipment. The perceived technological risks associated with briquette utilization as primary fuel with boiler are quite high for the project proponent.

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based briquette fired boiler is the removal of fly ash. The investor will have to install a fly ash removal system at the exhaust of briquette fired boiler.

Biomass Briquette availability/ Storage and handling 1. Biomass is available for only 3-6 months in a year, thus the supplier of briquette may face trouble in the consistent supply of briquette to the project activity thus the storage of briquette during the non seasonal period becomes necessary for the project proponent. Further when briquette is stored, its characteristics change within a period leading to loss of volatile matter and deterioration of biomass quality, which affects the performance of plant equipment. Additionally, the calorific value of biomass briquette also decreases leading to a reduction in efficiency. 2. Currently, there is no organized market for procuring the briquettes. The project proponent has to develop an infrastructure in terms of manpower and financial resources, in order to ensure continuous fuel availability. 3. The project proponent also needs to arrange for transportation of briquettes to the project activity site. Although surplus quantity of briquettes are available currently in the region, but in a long run, supply of sufficient briquette is not assured over the life time of the plant. Hence, the constant availability of briquette is the key to the success of the plant. 4. Biomass procurement is also a risk due to the seasonal availability and also it is subject to seasonal fluctuations due to vagaries of nature. This leads to a hike in the price of biomass in lean months. This is a tough task to the project proponent since one single supplier cannot supply the quantity of fuel required for the plant. At a time, negotiations will have to be done with many suppliers for providing sufficient quantity of briquettes.

A large area has to be made available for the storage of briquette, which can’t be used for other productive uses.

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Sub-step 3 b. Show that the identified barriers would not prevent the implementation of at least one of the alternatives (except the proposed project activity):

Due to high capital investment in the steam generation and due to its associated risk of the biomass availability, majority of the industries in Haryana rather generate steam through FO fired boiler.

Step 4. Common practice analysis Sub-step 4a. Analyze other activities similar to the proposed project activity:

Barriers due to prevailing practice: 1. Steam generation through biomass briquette fired boiler is not a common practice in India and more specifically in Haryana. There is only few similar project activities has been envisaged in India.

1) Boiler fuel conversion from RFO to biomass based briquette at Pfizer Limited, Thane, Maharashtra, India 11

2) Boiler fuel conversion at perstrop chemicals India (Pvt.) Limited (PCIPL), Vapi, India12

3) Boiler fuel conversion form RFO to biomass based briquettes Fresenius Kabi India Private Limited, Ranjangaon, Maharashtra, India 13

2. The practice of generating steam by using biomass briquette as primary fuel has not penetrated in the region due to prohibitive barriers to project implementation. The project activity has been experimented for the first time in the Zip manufacturing units in the state.

This shows the low penetration of biomass based power generation and little willingness of entrepreneurs to change the current operating practices. It may, thus, be concluded that the proposed project is not a common practice in the state.

Sub-step 4b. Discuss any similar options that are occurring:

There is only few similar project activities has been envisaged in India.

1) Boiler fuel conversion from RFO to biomass based briquette at Pfizer Limited, Thane, Maharashtra, India

2) Boiler fuel conversion at perstrop chemicals India (Pvt.) Limited (PCIPL), Vapi, India

11 http://cdm.unfccc.int/UserManagement/FileStorage/77NATVYPAP2UA2UH2AXM7SB0PKKMPK 12 http://cdm.unfccc.int/UserManagement/FileStorage/RYOTJFNGO5MX6ZXRVAOYGUF5A2Y0HA 13 http://cdm.unfccc.int/UserManagement/FileStorage/T7GHVQHNZFBX0A9SK09VKVKVGM8RXO

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3) Boiler fuel conversion form RFO to biomass based briquettes Fresenius Kabi India Private Limited, Ranjangaon, Maharashtra, India

B.6. Emission reductions:

B.6.1. Explanation of methodological choices: >> The key parameters for developing baseline methodology for the proposed project activity have been described in B.4. The proposed project activity is basically a boiler fuel conversion activity that involves fuel switching from FO to Biomass based briquette. For this the existing FO fired boiler will be converted to biomass based briquette fired boiler to facilitate the manual feeding of briquettes into the boiler. The conversion of boiler form FO fired to briquette fired will diminish the efficiency of the boiler form from 80% to 61%. So there is more fuel consumes in the case of briquettes to meet the constant steam demand. The coal has been envisaged as the cheapest alternative for steam generation by the project activity. As the coal is readily available to the project proponent and the steam generation cost through the coal will be low as compared to the biomass based briquettes. Thus, the Baseline Emission for the proposed project activity is the GHG emission that would have occurred due to the use of coal in the boiler in the absence of proposed project activity. Thus the baseline emissions can be calculated on the basis of equivalent coal consumption in the boiler in the absence of proposed project activity. The equivalent coal consumption that would have occurred in the absence of project activity has been calculated on the basis of briquette consumption which would have occurred in the steam generation process if the project activity is implemented. The Baseline methodology in the perception of proposed project activity is described below: 1. Baseline Emission (BE Year) The Baseline CO2 emission per year due to the coal (fossil fuel) combustion in the boiler can be calculated as: GHG (BE) Year = Coal Heat, Year x EFCO2, Year ………………………………………………..………… (i) Where BE Year = Baseline CO2 emission due to Coal combustion in Boiler in (tCO2/year) Coal Heat, Year = Net heat generated form Coal combustion in Boiler in TJ per year EFCO2, Year = CO2 Emission factor for Coal in tCO2 /TJ (It is a IPCC default value for emission coefficient for Coal in tCO2 /TJ) The equivalent Coal-e Year consumption can be calculated as follows Coal-e Year = Br Year x FOB....................................................................................................................... (ii)

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Where Coal-e Year = the equivalent Coal consumption in KT / year Br Year = Biomass based briquette consumption in KT/year FOB = Coal to Briquette conversion factor due to difference in their NCVs. It is calculated as the ratio of calorific values of briquette to the Coal. (NCV of Coal is 28.2 TJ/KT and for Briquette is 15.9 TJ/KT, and FOB is 0.564) The average heat generated by the combustion of Coal in the boiler can be obtained as follows: Coal Heat, Year = Coal-e Year x NCVCoal……………………………………………………...………….. (iii) Where Coal Heat, Year = Net heat generated with Coal in TJ per year Coal-e Year = the equivalent Coal consumption in KT / year NCVCoal = Net calorific value of Coal in TJ/KT 2. Leakage (L Year) 2.1 Leakage due to transfer of equipment to / from the project activity Referring to the paragraph 17 of “Type AMS I C, Version 13, Renewable energy project” of Appendix B of the simplified modalities and procedures for small scale CDM project activities, leakage in the project activity is considered as “If the energy generated equipment is transferred from another activity or if the exiting equipment is transferred to another activity, leakage is to be considered”. In the project activity the neither the energy generated equipment is transferred from another activity nor existing equipment is transferred to another activity, therefore the leakage is not considered. GHG (L Year) = 0 ………………………………………………………………………………………. (iv) 3. Project Emission (GHG (P) Year: In this project activity the two fans as shown in Figure A.2.2 (one ID and one FD) will be used for the recycling of the exhaust flue gases. These two fans will be driven by electric motor of capacity 20 HP and 3 HP respectively. The project emission may be calculated as follows: GHG (P Year) = EFD Fan Year x EF Grid Year+ EID Fan Year x EF Grid Year………………………………………(v) Where GHG (P Year) = GHG emission per year due to project activity in tCO2/year EFD Fan Year = Electricity consumption of FD fan motor in MWh per year EID Fan Year = Electricity consumption of ID fan motor in MWh per year EF Grid Year = Grid emission factor of electricity for northern grid in tCO2/MWh There will no other emission take place due to the project activity as this is the renewable energy (green fuel) based project activity. However during emergency period like break down of briquette fired boiler the steam will be generated through the standby FO fired boiler of capacity 4 TPH. The duration and quantity of fuel burnt through the FO fired boiler during break down will be monitored and recorded in the boiler log books. This emission will be very small in quantity and can be neglected. However this emission will be taken in account during monitoring of the project activity.

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4. Baseline Emission Reduction (BER Year) As such the average Baseline emission reduction due to the project activity can be estimated as follows: Baseline Emission Reduction /year = Base line Emission /year – Emission due to leakage /year – Emission due to project activity /year Therefore, Baseline Emission Reduction in tCO2 per year due to the project activity is:

GHG (BER) Year = GHG (BE) Year - GHG (L) Year – GHG (P) Year ……………………….………..… (iv)

B.6.2. Data and parameters that are available at validation: (Copy this table for each data and parameter) EFCO2, Year

Data / Parameter: EFCO2, Year Data unit: tCO2 /TJ Description: CO2 Emission factor for Coal depicts the qty of CO2 emitted in tons per TJ

energy generated by the combustion of Coal. Source of data used: Table 2.2 of Chapter 2 of Volume 2 (energy) IPCC 2006 Guidelines for NGGIP Value applied: 94.6 Justification of the choice of data or description of measurement methods and procedures actually applied :

The (YKKIPL) is a manufacturing unit of Zips and therefore the data for CO2 EF is not available at the plant site. Thereby the IPCC default value for CO2 EF has been employed in the baseline emission calculation.

Any comment: Considering the Table 2.2 of Chapter 2 of Volume 2 (energy) of 2006 IPCC Guidelines for National Greenhouse Gas Inventories Programme (IPCC-NGGIP), the CO2 EF for Coal is 94600 kgCO2/TJ, which is equal to 94.6 tCO2/TJ.

NCVCoal Data / Parameter: NCVCoal Data unit: TJ/KT Description: Net Calorific Value of Coal which is qty. of energy generated in TJ per KT of

Coal combustion. Source of data used: Table 1.2 of Chapter 1 of Volume 2 (energy) IPCC 2006 Guidelines for NGGIP Value applied: 28.2 Justification of the choice of data or description of measurement methods and procedures actually applied :

The applied data has been taken from an official and authentic data source.

Any comment: Considering the Table 1.2 of Chapter 1 of Volume 2 (energy) of 2006 IPCC Guidelines for National Greenhouse Gas Inventories Programme (IPCC-NGGIP), the Default Net Calorific Value for Coal is 28.2 TJ/Gg, which is equal to 28.2 TJ/KT.

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SG Year Data / Parameter: SG Year Data unit: Mt /year Description: Quantity of steam generation by the FO fired boiler in Mt per year Source of data used: Boiler log sheets maintained at the plant site (YKKIPL) Value applied: 11083 Justification of the choice of data or description of measurement methods and procedures actually applied :

The applied data is the average value of steam generation during year 2006, and 2007. This value has been taken from the boiler log sheets maintained at the plant site. Steam meter has been provided which is duly calibrated. The daily steam generation is noted.

Any comment: - EFy Data / Parameter: EFy Data unit: tCO2/MWh Description: CO2 emission factor of the grid Source of data to be used:

Calculated as weighted sum of the OM and BM emission factors. The formulae for this are as per ACM0002

Value applied Details of the data values are given in the baseline calculations in Appendix E Justification of the choice of data or description of measurement methods and procedures actually applied :

- Emission factor is used in the calculation of emission reductions. - The emission factor is calculated. - The data is calculated yearly - 100% of the data is monitored - The data will be archived electronically

Any comment: Calculated as weighted sum of the OM and BM emission factors. EFOM,y Data / Parameter: EFOM,y Data unit: tCO2/MWh Description: CO2 Operating margin emission factor of the grid Source of data to be used:

CEA : ‘The CO2 Baseline Database for the Indian Power Sector’ Version 03, 15th December 2007

Value applied Details of the data values are given in the baseline calculations in Appendix E Justification of the choice of data or description of measurement methods and procedures actually applied :

- This is used in calculation of emission factor Ey - The emission factor is calculated. - The data is calculated yearly - 100% of the data is monitored - The data will be archived electronically

Any comment: Calculated as indicated in the simple OM baseline method EFBM,y Data / Parameter: EFBM,y Data unit: tCO2/MWh Description: CO2 Build margin emission factor of the grid Source of data to be used:

CEA : ‘The CO2 Baseline Database for the Indian Power Sector’ Version 03, 15th December 2007

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Value applied Details of the data values are given in the baseline calculations in Appendix E Justification of the choice of data or description of measurement methods and procedures actually applied :

- This is used in the calculation of emission factor Ey. - The emission factor is calculated. - The data is calculated yearly - 100% of the data is monitored - The data will be archived electronically

Any comment: Calculated as indicated in the simple OM baseline method Specific emissions of all remaining units in the build margin were derived from conservative standard heat rate values. For units falling into the BM, the emissions were taken as equal to that of the respective station.

η FO

Data / Parameter: η FO Data unit: Percentage (%) Description: Ratio of heat output to heat input Source of data used: Boiler log sheets maintained at the plant site (YKKIPL) Value applied: 80.1 Justification of the choice of data or description of measurement methods and procedures actually applied :

The applied data is average value of boiler efficiency measured by the Boiler incharge and recorded in the boiler log sheets. The Boiler efficiency certificate provided by the company has been attached with this PDD in Appendix F.

Any comment: The data has been taken from the boiler log sheets (records) maintained at the plant site.

B.6.3 Ex-ante calculation of emission reductions: >>

1. Baseline Emission (BEYear) Considering the equation (i) of section B.6.1, the baseline emission for the proposed project activity can be calculated as follows: BE Year = Coal Heat, Year x EFCO2, Year ……………………………………….……………………..…… (i) Where BE Year = Baseline CO2 emission due to Coal combustion in Boiler in (tCO2/year) Coal Heat, Year = Net heat generated with Coal in TJ per year EFCO2, Year = CO2 Emission factor for Coal in tCO2 /TJ (It is a IPCC default value for emission coefficient for Coal in tCO2 /TJ) Biomass based briquette consumption in tons per day (Br) = 8 MT per Day (Metric ton /Day) Average number of operating days in a year = 320 Biomass based briquette consumption in kilo tons per year (Br Year) = 8 x 320 Br Year = 2.56 KT/year

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Equivalent Coal consumption will be calculated by referring the equation (ii) of the section B.6.1 as shown below: Coal-e Year = Br Year x FOB …………………........................................................................................ (ii) Where Coal-e Year = the equivalent Coal consumption in KT / year Br Year = Biomass based briquette consumption in KT/year FOB = Coal to Briquette conversion factor due to difference in their NCVs. It is calculated as the ratio of calorific values of briquette to the Coal. (NCV of Coal is 28.2 TJ/KT and for Briquette is 15.9 TJ/KT, and FOB is 0.564) Coal-e Year = 2.56 KT/year x 0.564 = 1.44.KT/Year The average heat generated in TJ by the combustion of Coal per year will be found by using the equation (iii) of the section B.6.1 as given below: Coal Heat, Year = Coal-e Year x NCVCoal ….……………………………………………………………. (iii) Where Coal Heat, Year = Net heat generated with Coal in TJ per year Coal-e Year = the equivalent Coal consumption in KT / year NCVCoal = Net calorific value of Coal in TJ/KT (IPCC default NCV for Coal is 28.2 TJ/KT) Substituting the value of Coal-e Year from equation (ii) into equation (iii) gives Coal Heat, Year = 1.44 KT/year x 28.2 TJ/KT = 40.7TJ/Year EFCO2, Year = 94.6 tCO2/year……………………………………………………………………………(iv) Now, substituting the values from equation (iii), (vi) in to equation (i) gives: BE Year = Coal Heat, Year x EFCO2, Year

= 40.731TJ/Year x 94.6 tCO2/year

BE Year = 3853.1 tCO2 /Year 2. Leakage (L Year) 2.1 Leakage due to transfer of equipment to / from the project activity Referring to the paragraph 17 of “Type AMS I C, Version 13, Renewable energy project” of Appendix B of the simplified modalities and procedures for small scale CDM project activities, leakage in the project activity is considered as “If the energy generated equipment is transferred from another activity or if the exiting equipment is transferred to another activity, leakage is to be considered”.

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In the project activity the neither the energy generated equipment is transferred from another activity nor existing equipment is transferred to another activity, therefore the leakage is not considered GHG (L Year) = 0 ………………………………………………………………………………………. (v) 3. Project Emission (P Year) In this project activity the two fans as shown in Figure A.2.2 (one ID and one FD) will be used for the recycling of the exhaust flue gases. These two fans will be driven by electric motor of capacity 20 HP and 3 HP respectively. The project emission may be calculated as follows: GHG (P Year) = EFD Fan Year x EF Grid Year+ EID Fan Year x EF Grid Year………………………………………………..………..(vi) Where GHG (P Year) = GHG emission per year due to project activity in tCO2/year EFD Fan Year = Electricity consumption of FD fan in MWh per year EID Fan Year = Electricity consumption of ID fan in MWh per year EF Grid Year = CO2 Baseline emission factor of electricity for northern grid in tCO2/MWh GHG (P Year) = EFD Fan Year x EF Grid Year+ EID Fan Year x EF Grid Year EFD Fan Year = 17.18 MWh/ year (FD Fan will be driven by a motor of capacity 3 HP) EID Fan Year = 114.58 MWh/year (ID Fan will be driven by a motor of capacity 20 HP) Calculation of Baseline emission factor for northern grid (EF) Grid Year The approved small scale methodology AMS ID, version 13 mandates using methodology specified in ACM0002 (version 07, Dated 14, December, 07) for calculation of baseline emission factor due to displacement of grid electricity. The CEA database has been calculated on the basis of the methodology given in ACM0002, version 07. The baseline emission factor is calculated using the combined margin approach. Step 1: Calculation of Operating Margin Emission Factor The operating margin emission factor has been calculated using a 3 year data vintage: The EFOM,Y for Northern grid is estimated to be: For the year 2004-2005 the EFOM,Y is 0.98010 tCO2/MWh For the year 2005-2006 the EFOM, Y is 0.99919 tCO2/MWh For the year 2006-2007 the EFOM, Y is 0.99846 tCO2/MWh (Data Source: CO2 Baseline Database for Indian Power Sector, Version 03) Thus the final EFOM,Y based on three years average is estimated to be 0.99256 tCO2/MWh.

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Step 2: Calculation of the Build Margin Emission Factor EFBM,Y The EFBM,y is estimated as 0.6283 tCO2/MWh, Data Source: CO2 Baseline Database for Indian Power Sector, Version 03,(with sample group m constituting most recent capacity additions to the grid comprising 20% of the system generation). Step 3: Calculation of Baseline Emission Factor EFy The baseline emission factor EFy is calculated as the weighted average of the Operating Margin emission factor (EFOM, y) and the Build Margin emission factor (EFBM,y): EFy = wOM EFOM,y + wBM .EFBM,y Where the weights wOM and wBM, are 50% and 50% respectively, and EFOM,y and EFBM,y are calculated as described in Steps 1 and 2 above and are expressed in tCO2/MWh. Baseline Emission factor: 0.813 tCO2/MWh Therefore Baseline Emission Factor for northern grid is EF Grid Year = 0.813 tCO2/MWh GHG (P Year) = EFD Fan Year x EF Grid Year+ EID Fan Year x EF Grid Year GHG (P Year) = 17.18*0.81 + 114.58*0.81 GHG (P Year) = 13.9 + 92.8 = 106.7 tCO2 / year There will no other emission be taking place due to the project activity as this is the renewable energy (green fuel) based project activity. However during emergency period like break down of briquette fired boiler the steam will be generated through the standby FO fired boiler of capacity 4 TPH. The duration and quantity of fuel burnt through the FO fired boiler during emergency will be monitored and recorded in the boiler log books. This emission will be very small in quantity and can be neglected. However this emission will be taken in account during monitoring of the project activity. 4. Baseline Emission Reduction (BER Year) As such the average Baseline emission reduction due to the project activity can be estimated as follows: Baseline Emission Reduction /year = Base line Emission /year – Emission due to leakage /year – Emission due to project activity /year GHG (BER) Year = GHG (BE) Year – GHG (L) Year -GHG (P) Year ……………………………….. (vii) Since GHG (L) Year = 0 and GHG (P) Year = 106.7 tCO2/year Therefore, Baseline Emission Reduction per year for the project activity is: GHG (BER) Year = 3853.1 tCO2/ Year – 0 – 106.7 tCO2/ year………………………. ………….(viii) GHG (BER) Year = 3746.42 tCO2/year

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The estimated emission reduction due to the project activity is = 3746 tCO2/Year

B.6.4 Summary of the ex-ante estimation of emission reductions: >>

It is noted that the operating conditions of the plant would remain same throughout the crediting period. The fuel consumption in the project activity will be consistent throughout the crediting period. Therefore, the estimated emission reduction per year will also be remaining same throughout the crediting period. On applying the formulae, the values obtained are as follows: Year Estimation of

project activity emissions (tCO2 e)

Estimation of baseline

emissions (tCO2 e)

Estimation of leakage (tCO2 e)

Estimation of overall emission

reductions (tCO2 e)

2009 -2010 106.7 3853.1 0 3746.4 2010-2011 106.7 3853.1 0 3746.4 2011-2012 106.7 3853.1 0 3746.4 2012-2013 106.7 3853.1 0 3746.4 2013-2014 106.7 3853.1 0 3746.4 2014-2015 106.7 3853.1 0 3746.4 2015-2016 106.7 3853.1 0 3746.4

Total (tonnes of CO2e)

746.9 26971.7 0 26224.8

2009-2010 represent the time period between 1st April 2009 (anticipated date of registration) and 31st March 2010. All other years represent the respective financial year spanning between 1st April and 31st March. B.7 Application of a monitoring methodology and description of the monitoring plan:

B.7.1 Data and parameters monitored: (Copy this table for each data and parameter) NCV of Biomass based briquette Data / Parameter: NCV of Biomass based briquette Data unit: TJ/KT Description: Net Calorific Value of briquette which is qty. of energy generated in TJ per KT

of biomass based briquette combustion. Source of data to be used:

Test records maintained at the plant site or supplier site

Value of data 15.9 Description of measurement methods and procedures to be applied:

The applied data has been obtained from test records from accredited laboratory and verified from the briquette purchase invoices.

QA/QC procedures to be applied:

The sample of briquette will be sent periodically in the accredited laboratory for measurement of NCV of briquettes and verification should be done from briquette purchase invoice.

Any comment: The data monitored will be recorded in the boiler log sheets for 3 years

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Br Day (Copy this table for each data and parameter) Data / Parameter: Br Day

Data unit: Mt/Day (Metric ton/Day) Description: The average consumption of the biomass based briquettes in KT per Day Source of data to be used:

Boiler log sheets maintained at YKKIPL, Rewari (Haryana).

Value of data 8 Description of measurement methods and procedures to be applied:

Manual weighing balance may be used to measure the briquette quantity in truck load. Daily briquette consumption will be measured by tipper loads. Record of receipt of briquette quantity in truckloads through external weighing balance & also daily record of number of tipper loads carrying briquettes to the furnace is maintained at the plant.

QA/QC procedures to be applied:

Quantity of briquette consumed will be measured by calibrated weighing scale.

Any comment: The data monitored will be archived in the boiler log books for 3 years. SGDay

(Copy this table for each data and parameter) Data / Parameter: SGDay

Data unit: Mt/Day Description: Steam generation in Mt in briquette fired boiler per Day Source of data to be used:

Boiler log sheets maintained at the plant (YKKIPL) site

Value of data 34.6 Description of measurement methods and procedures to be applied:

Steam meter has been provided which is duly calibrated. The daily steam generation is noted by qualified and trained operator.

QA/QC procedures to be applied:

Quantity of steam generated will be metered on continues basis and monitored daily with the help of steam flow meter which is already installed

Any comment: The data monitored will be archived in boiler log books for 3 years. EFD Fan (Copy this table for each data and parameter) Data / Parameter: EFD Fan

Data unit: MWh/year Description: Net electricity consumption through the FD fan in MWh/year. Source of data to be used:

Rating of motor mentioned on the plate in HP or kW. The rated capacity of FD fan motor is 3 HP.

Value of data 17.18 Description of measurement methods and procedures to be applied:

The applied data has been obtained on the basis of rated capacity of the motor

QA/QC procedures to be applied:

The electricity consumption of the FD fan motor will be measured periodically

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Any comment: The data monitored will be recorded in the boiler log sheets for 3 years EID Fan (Copy this table for each data and parameter) Data / Parameter: EID Fan

Data unit: MWh/year Description: Net electricity consumption through the ID fan in MWh/year. Source of data to be used:

Rating of motor mentioned on the plate in HP or kW. The rated capacity of ID fan motor is 20 HP.

Value of data 114.58 Description of measurement methods and procedures to be applied:

The applied data has been obtained on the basis of rated capacity of the motor

QA/QC procedures to be applied:

The electricity consumption of the ID fan motor will be measured periodically

Any comment: The data monitored will be recorded in the boiler log sheets for 3 years η Briquette (Copy this table for each data and parameter) Data / Parameter: η Briquette

Data unit: Percentage (%) Description: Efficiency of briquette fired boiler i.e., Ratio of heat output to the heat input Source of data to be used:

Applied data has been obtained through energy balance of FO fired boiler and Briquette fired boiler. Calculations are given in Appendix G

Value of data 61.0 Description of measurement methods and procedures to be applied:

Direct efficiency of the boiler that will be evaluated by plant’s boiler incharge.

QA/QC procedures to be applied:

The briquette fired boiler efficiency will be evaluated by plant’s boiler incharge and record will be maintained.

Any comment: The data monitored will be archived in boiler log sheets for 3 years.

TS (Copy this table for each data and parameter) Data / Parameter: TS

Data unit: oC Description: Temperature of the steam generated Source of data to be used:

Boiler log sheets

Value of data 182 Description of measurement methods and procedures to be applied:

The temperature of the steam generated will be monitored daily with the help of temperature gauge.

QA/QC procedures to be applied:

Temperature gauge will be calibrated once in a year for checking its degree of accuracy.

Any comment: The data monitored will be archived in boiler log sheets for 3 years

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PS (Copy this table for each data and parameter) Data / Parameter: PS

Data unit: kg/cm2

Description: Pressure of the steam generated Source of data to be used:

Boiler log sheets

Value of data 10.54 Description of measurement methods and procedures to be applied:

The pressure of the steam generated will be monitored daily with the help of pressure gauge.

QA/QC procedures to be applied:

The pressure gauge will be calibrated once in a year for maintaining its degree of accuracy.

Any comment: The recorded data will be archived in boiler log sheets for 3 years. B.7.2 Description of the monitoring plan:

>> According to the paragraph 19 of methodology AMS IC, Thermal energy for the users with or without electricity (version 13, dated 28th March, 2008), the monitoring shall consist of: “For projects where only biomass or biomass and fossil fuel are used the amount of biomass and fossil fuel shall be monitored”. In the project activity the biomass based briquettes will be used in lieu of FO in the boiler for steam generation. The investor has prepared a separate operation and maintenance structure for monitoring the CDM project activity. The various activities of the O&M structure of the project activity are as follows: 1 Routine Maintenance Services

Routine Maintenance Labour Work involves making available suitable manpower for operation and maintenance of the Equipment and covers periodic preventive maintenance, cleaning and upkeep of the Equipment including -

a) Steam boiler b) Biomass Briquette handling equipments c) Water treatment plant d) Control Panel Maintenance

A detailed maintenance plan for the plant is described in Appendix A.

2 Management Services a) Steam generation b) Preparation and submission of monthly performance report in agreed format. c) Taking monthly meter reading of steam generated by the biomass briquette fired boiler.

3 Technical Services a) Visual inspection of the boiler plant and accessories

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b) Technical Assistance including checking of various technical, safety and operational parameters of the Equipment, trouble shooting and relevant technical services.

4 Project Monitoring

a) The project activity has placed order to procure a steam flow metre for the measurements of generated steam from plant. In the current scenario the company measures water quantity for measuring steam generation.

b) The quantity of biomass (briquettes) combusted in the project plant is recorded equal as the quantity of biomass purchased.

c) NCV of biomass briquettes utilized in the plant will be measured based on reliable authorized data nationally or locally on annual basis.

d) Surplus availability of biomass in the region will be estimated from the available official data from the local government agencies.

e) The main, check, and auxiliary consumption meters are tested and calibrated for accuracy at regular intervals. Periodical testing, sealing and maintenance of meters in the presence of authorized representatives will be carried out. Copies of test reports shall be available for evidence.

f) Project performance will be evaluated in terms of the specific fuel consumption i.e. kWh/kg of biomass consumption. This data will be estimated on monthly basis. If the plant performance degrades, the specific fuel consumption value will also go down.

g) In order to maintain a consistent performance of the plant the regular maintenance of the plant will be carried out as per the maintenance schedule proposed in the Appendix A.

5 Responsibilities a) Head-Utility:

1. Over all responsibility of environment, health and safety of the plant and the project activity.

2. Associating with GA (General Affairs) and HR towards implementing of the legal compliance. 3. Project Conformance Review on regular basis 4. Organizing the internal audits for checking the data record. 5. Implementing all monitoring control procedure 6. Organizing and conduct training programs on CDM to the relevant staff 7. Has the overall responsibility for closing the project non conformances and implementing corrective action before the verification 8. Reviewing of records and dealing with monitoring data. 9. Ensuring implementation of legal compliances b) Dy. Manager- Boiler and Utility will have the following responsibilities:

1. Supervising and training the boiler operators, firemen and maintaining training records. 2. Responsible for monitoring measurement and reporting. 3. Responsible for record handling and maintenance 4. Assist the Head-Utility in checking and review of records and during internal audit. 5. Ensure that the operators in boiler house record the data appropriately. 6. Monitoring the biomass briquette quantity and steam generation at the plant site.

c) Dy. Manager-Electrical and Utility: Responsible for proper operation of electrical equipment and taking meter reading for steam generation, calibration of the monitoring instruments and reporting, reviewing of records and detailing the data.

1. Responsible for the calibration of monitoring instruments and reporting

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2. Reviewing of records and detailing the data. 3. Assist the Head-Utility while internal audit 4. Associating with the Head-Utility towards maintenance and calibration of equipments using for data.

6 Emergency Preparedness

Emergency preparedness is an important part of YKKIPL's operation of power plant. The plant is designed and constructed for safe, reliable operation with safety systems and highly qualified employees. To control all the possible aspects of emergencies, the YKKIPL has to evolve an emergency management system or plan as required by international standard ISO 14001: 1996. This emergency plan is referred as EMSP09 (Emergency preparedness and response) in YKKIPL. This plan identifies possible emergency situations and suggests recommendation for preventing and mitigating the associated environmental impacts. The company has got the ISO 14001:2004 certificate for establishing “Environment Management System” in the plant. (Certificate is enclosed with this PDD in Appendix H). YKKIPL comprises an advance effluent treatment plant (ETP) in factory premises since from the beginning. Recently the company has initiated the effluent dyeing water re-cycling through the latest available techniques to minimize the extract ground water and for reduction of green house gases like Carbon di-oxide through changing the Agro waste biomass to generate the steam. A disaster management plan (referred as IUTS 01 in YKKIPL) already exists in the company, which includes the fire safety, electrical safety, etc provisions. A regular awareness is created for the different safety procedures. The biomass storage will be incorporated in the existing plan. The objectives are further classified as: 1. Rescue operation and First aid of persons affected during emergency 2. Safeguard other persons during emergency 3. Minimize the damage to property and to the environment 4. Initially contain the incident impact and then bring the incident under control 5. Provide authentic information to external interested parties. 6. Rehabilitation of affected persons 7. Preservation of relevant records 8. Inquiry and analysis of the causes of emergency situations that led to the incident and take

suitable corrective action.

7 Training procedures a. Regular training of the plant persons will be arranged by YKKIPL every year by calling the

external experts. b. Engineers/ technicians recruited will have experience of working in the similar fields. c. Equipment supplier’s sill deputes their commissioning engineers to train the engineers/

technicians and supporting operating manuals will be provided by them. B.8 Date of completion of the application of the baseline and monitoring methodology and the name of the responsible person(s)/entity(ies) >> Date of Completion: 01/06/2008

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Contact person: Mr. Alok Goyal Head - Carbon Credits, Senergy Global Limited Ground Floor, Eros Corporate Tower, Nehru Place, New Delhi – 110019, India. Tel: +91- 11- 4650 5500 Fax: +91- 11- 4650 5555 E,mail : [email protected] URL: www.senergyglobal.com

SECTION C. Duration of the project activity / crediting period C.1 Duration of the project activity: C.1.1. Starting date of the project activity: >> 03/06/2008, Date of contract order for the project activity. C.1.2. Expected operational lifetime of the project activity: >> 25 Years C.2 Choice of the crediting period and related information: C.2.1. Renewable crediting period >> Renewable Crediting Period C.2.1.1. Starting date of the first crediting period: >> 01/04/2009 (Expected date of registration of the project with CDM EB) C.2.1.2. Length of the first crediting period: >> 7 Years C.2.2. Fixed crediting period: C.2.2.1. Starting date: >> Not Applicable C.2.2.2. Length: >> Not Applicable

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SECTION D. Environmental impacts >> The environmental emissions after implementation of the project activity arise from the combustion of biomass (briquette) in the boiler. The project activity, which is a ‘carbon neutral fuel’ based steam generation plant, generates steam in addition to meet YKKIPL steam demand thereby displacing an equivalent amount of steam the plant would have drawn from the FO fired boiler. The biomass is green fuel and the CO2 released is very less as compared to the amount of CO2 taken up by the biomass during growing, therefore no net emissions occur. The fly ash produced due to biomass combustion is collected manually by using trolleys. The possible sources of fly ash consumption have been envisaged by the project proponent in the nearby cement manufacturing units. D.1. If required by the host Party, documentation on the analysis of the environmental impacts of the project activity: >> According to the Notification S.O.1533, Published in the Gazette of India, Extraordinary, Part-II, and Section 3; Sub-section (ii) Ministry of Environment and Forest, Government of India, dated 14th September, 2006 the project being a renewable energy biomass based project does not fall under the purview of Environmental Impact Assessment (EIA). However the design and philosophy of this project activity is driven by the concept of providing low cost –low emission energy with acceptable impact on the environment hence the environment and safety aspects of the project activity are discussed below: Particulate matter and the gases: Since the project activity is based on carbon neutral fuel therefore the net emission through the combustion of biomass briquettes is nullify. However the environmental emissions arising due to project activity is Dust particulate from fly ash in the flue gas. The fly ash will be collected manually by using trolleys. This fly ash may be used in the nearby cement manufacturing unit as the investor has envisaged the possible sources of fly ash of fly ash consumption in the region. The project activity has been implemented in the industrial premises on the YKK India Private Limited. The industry is located at Tehsil Bawal in the District Rewari, Haryana. The CDM project has been implemented within the premises of establishment, which is operating from 1997 with all the necessary permissions and consents of statuary bodies of governing the industries within the state. D.2. If environmental impacts are considered significant by the project participants or the host Party, please provide conclusions and all references to support documentation of an environmental impact assessment undertaken in accordance with the procedures as required by the host Party: >> The project activity provides thermal energy with acceptable impacts on the environment. There are no significant environmental impacts of the project activity. The project dose not fall under the purview of environment impact assessment (EIA) notification (S.O. 1533) of the Ministry of Environment and Forest (MoEF), Government of India (GOI).

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SECTION E. Stakeholders’ comments >> The project activity has been installed within the industrial premises of YKKIPL and there has no land been procured for the proposed project activity. The local stake holders, who have been immediately affected by the project activity, will eventually get benefited due to project activity. Since the local environment will be cleaner by using biomass based briquette fired boiler plant in lieu of FO. E.1. Brief description how comments by local stakeholders have been invited and compiled: >> YKKIPL organised stakeholder consultation meetings with individual industrial associates, plant employees and local elected representatives with the objectives on inform the interested stakeholders on the environmental and social impacts of the project activity. Personal invitation letters has been sent to the villager public representatives. A notice on the plant main gate was put to inform the workers and local public. YKKIPL identifies the following stakeholders to keep the transparency in the operational activity to the project promoters and thereby Local Authority of the village- Bawal Apart from these all the statutory clearances pertaining to the implementation of the boiler retrofitting have been carried out. The statutory bodies both at the state and central government level have approved the operation of the project activity and no comments have been made. YKKIPL representatives presented the salient features of the project activity to the stakeholders and requested their suggestions/objections. The opinions expressed by them were recorded and are available for validation. E.2. Summary of the comments received: >> The project proponent has been received comments form its employees, supplier, and the areas representatives, who have communicated their appreciation for such an effort on YKKIPL’s part. They have no objections to the installation of the proposed boiler fuel switching project. The copies of the comments received form the stake holders are available for validation. Some of the comments made during the stake holder consultation are as follows: Since the project activity will provide direct and indirect employment opportunities to the local peoples thus encouraging the project activity. The project activity will not cause any displacement or adverse social impacts on the local population rather improving their quality of life. The project will provide an additional source of income to the local villagers engaged in trading, procurement, transportation, and handling of biomass. Possible employment opportunities during construction, operation and maintenance During the operation of boiler a contract with the labour contractor will be made. According to this contract unloading of the briquettes at the project site, feeding into the boiler, collecting the fly ash and disposal of the ash will be arranged by the contractor too. He will supply approximately 4 labours per shift of boiler operation and extra labour of other jobs.

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E.3. Report on how due account was taken of any comments received: >> YKKIPL will ensure the involvement of local manpower in handling of biomass based briquettes in the premises of project activity. The briquettes will be fed manually in the boiler that will also create the opportunities of employment for the local villager.

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Annex 1

CONTACT INFORMATION ON PARTICIPANTS IN THE PROJECT ACTIVITY Organization: M/s. YKK India Private Limited Street/P.O.Box: Sector-2, HSIDC Growth Center Building: Plot No. 699, City: Bawal Village, Rewari District, State/Region: Haryana Postfix/ZIP: 123 501 Country: India Telephone: +91- 1284- 264 353 FAX: +91- 1284- 264 369 E-Mail: [email protected] URL: www.ykkindia.com Represented by: Title: Asst. General Manager Salutation: Mr. Last Name: Prasad Middle Name: - First Name: Ajay Department: Utility and Engineering Mobile: +91- 9812009307 Direct FAX: +91- 1284- 264 369 Direct tel: +91- 1284- 264 353 Personal E-Mail: [email protected]

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Annex 2

INFORMATION REGARDING PUBLIC FUNDING

There is no public funding involved in the project activity and the project participants hereby confirm that there is no diversion of overseas development assistance

.

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Annex 3

BASELINE INFORMATION

The project activity involves the boiler fuel conversion form fossil fuel to renewable energy source i.e., form FO to biomass based briquettes. According to the paragraph 6 of the Type AMS I C, version 13, dated 28th March, 08, “Renewable energy projects” of Appendix B of the simplified M&P of small scale CDM Project activities the baseline states that: “6. For renewable energy technologies that displace technologies using fossil fuels, the simplified baseline is the fuel consumption of the technologies that would have been used in the absence of the project activity times an emission coefficient for the fossil fuel displaced. IPCC default value for emission coefficient may be used.” Thus, the Baseline Emission for the proposed project activity is the GHG emission that would have occurred due to the use of FO in boiler in the absence of proposed project activity. The conversion of boiler form FO fired to briquette fired will diminish the efficiency of the boiler form from 80% to 61%. So there is more fuel consumes in the case of briquettes to meet the constant steam demand. The baseline emissions can be calculated on the basis of equivalent FO consumption in the boiler in the absence of project activity. The equivalent FO consumption that would have occurred in the absence of project activity is calculated on the basis of briquette consumption which would have occurred in the steam generation process if the project activity is implemented. Key assumption for the baseline methodology in the context of project activity:

1. The efficiency of the steam generating unit, using biomass briquette fuel, is consistent through out the crediting period, which is being monitored.

2. The properties of FO and biomass briquette (monitored data) like calorific value remain consistent before and after the project activity.

The Baseline emissions are estimated as follows: 1. Baseline Emission (BE Year) The Baseline CO2 emission per year due to the coal (fossil fuel) combustion in the boiler can be calculated as: GHG (BE) Year = Coal Heat, Year x EFCO2, Year ………………………………………………..………… (i) Where BE Year = Baseline CO2 emission due to Coal combustion in Boiler in (tCO2/year) Coal Heat, Year = Net heat generated form Coal combustion in Boiler in TJ per year EFCO2, Year = CO2 Emission factor for Coal in tCO2 /TJ (It is a IPCC default value for emission coefficient for Coal in tCO2 /TJ) The equivalent Coal-e Year consumption can be calculated as follows Coal-e Year = Br Year x FOB...................................................................................................................... (ii)

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Where Coal-e Year = the equivalent Coal consumption in KT / year Br Year = Biomass based briquette consumption in KT/year FOB = Coal to Briquette conversion factor due to difference in their NCVs. It is calculated as the ratio of calorific values of briquette to the Coal. (NCV of Coal is 28.2 TJ/KT and for Briquette is 15.9 TJ/KT, and FOB is 0.564) The average heat generated by the combustion of Coal in the boiler can be obtained as follows: Coal Heat, Year = Coal-e Year x NCVCoal……………………………………………………...………….. (iii) Where Coal Heat, Year = Net heat generated with Coal in TJ per year Coal-e Year = the equivalent Coal consumption in KT / year NCVCoal = Net calorific value of Coal in TJ/KT Reference: CO2 Emission Factor of Coal: Table 2.2 of Chapter 2 of Volume 2 (energy) of 2006 IPCC Guidelines for National Greenhouse Gas Inventories Programme (IPCC-NGGIP) in tCO2/TJ. The applied value is 94.6 tCO2/TJ. NCV of Coal: Table 1.2 of Chapter 1 of Volume 2 (energy) of 2006 IPCC Guidelines for National Greenhouse Gas Inventories Programme (IPCC-NGGIP) in TJ/KT. The applied value is 28.2 TJ/KT NCV of Briquette: Test records maintained by the project proponent or the briquette supplier in Kcal/kg. The applied value is 3800 kcal/kg or 15.9 TJ/KT. Briquette Consumption/year: Boiler log sheets maintained at the project site in MT/day. The applied value is 8MT/day Efficiency of FO fired boiler: Test records maintained by the project proponent. The applied value is 80%. Efficiency of Briquette fired boiler: Test records will be maintained by the project proponent. The applied value is 61%.

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Annex 4

MONITORING INFORMATION According to the paragraph 19 of methodology AMS IC, Thermal energy for the users with or without electricity (version 13, dated 28th March, 2008), the monitoring shall consist of: “19. For projects where only biomass or biomass and fossil fuel are used the amount of biomass and fossil fuel shall be monitored”. In the project activity the biomass based briquettes will be used in lieu of FO in the boiler for steam generation. The investor has prepared a separate operation and maintenance structure for monitoring the CDM project activity. The various activities of the O&M structure of the project activity are as follows: 1 Routine Maintenance Services

Routine Maintenance Labour Work involves making available suitable manpower for operation and maintenance of the Equipment and covers periodic preventive maintenance, cleaning and upkeep of the Equipment including -

e) Steam boiler f) Biomass Briquette handling equipments g) Water treatment plant h) Control Panel Maintenance

A detailed maintenance plan for the plant is described in Appendix A. 2 Management Services

d) Steam generation e) Preparation and submission of monthly performance report in agreed format. f) Taking monthly meter reading of steam generated by the biomass briquette fired boiler.

3 Technical Services c) Visual inspection of the boiler plant and accessories d) Technical Assistance including checking of various technical, safety and operational

parameters of the Equipment, trouble shooting and relevant technical services. 4 Project Monitoring

h) The project activity has placed order to procure a steam flow metre for the measurements of generated steam from plant. In the current scenario the company measures water quantity for measuring steam generation.

i) The quantity of biomass (briquettes) combusted in the project plant is recorded equal as the quantity of biomass purchased.

j) NCV of biomass briquettes utilized in the plant will be measured based on reliable authorized data nationally or locally on annual basis.

k) Surplus availability of biomass in the region will be estimated from the available official data from the local government agencies.

l) The main, check, and auxiliary consumption meters are tested and calibrated for accuracy at regular intervals. Periodical testing, sealing and maintenance of meters in the presence of authorized representatives will be carried out. Copies of test reports shall be available for evidence.

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m) Project performance will be evaluated in terms of the specific fuel consumption i.e. kWh/kg of biomass consumption. This data will be estimated on monthly basis. If the plant performance degrades, the specific fuel consumption value will also go down.

n) In order to maintain a consistent performance of the plant the regular maintenance of the plant will be carried out as per the maintenance schedule proposed in the Appendix A.

5 Responsibilities

d) Head-Utility: 1. Overall responsibilities of environment, health and safety of the plant and the project activity.

2. Associating with GA (General Affairs) and HR towards implementing of the legal compliance. 3. Project Conformance Review on regular basis 4. Organizing the internal audits for checking the data record. 5. Implementing all monitoring control procedure 6. Organizing and conduct training programs on CDM to the relevant staff 7. Has the overall responsibility for closing the project non conformances and implementing corrective action before the verification 8. Reviewing of records and dealing with monitoring data. 9. Ensuring implementation of legal compliances e) Dy. Manager- Boiler and Utility will have the following responsibilities:

1. Supervising and training the boiler operators, firemen and maintaining training records. 2. Responsible for monitoring measurement and reporting. 3. Responsible for record handling and maintenance 4. Assist the Head-Utility in checking and review of records and during internal audit. 5. Ensure that the operators in boiler house record the data appropriately. 6. Monitoring the biomass briquette quantity and steam generation at the plant site.

f) Dy. Manager-Electrical and Utility: Responsible for proper operation of electrical equipment and taking meter reading for steam generation, calibration of the monitoring instruments and reporting, reviewing of records and detailing the data.

1. Responsible for the calibration of monitoring instruments and reporting 2. Reviewing of records and detailing the data. 3. Assist the Head-Utility while internal audit 4. Associating with the Head-Utility towards maintenance and calibration of equipments using for data.

6 Emergency Preparedness

Emergency preparedness is an important part of YKKIPL's operation of power plant. The plant is designed and constructed for safe, reliable operation with safety systems and highly qualified employees. To control all the possible aspects of emergencies, the YKKIPL has to evolve an emergency management system or plan as required by international standard ISO 14001: 1996. This emergency plan is referred as EMSP09 (Emergency preparedness and response) in YKKIPL. This plan identifies possible emergency situations and suggests recommendation for preventing and mitigating the associated environmental impacts. The company has established “Environment Management System” in the plant which is ISO 14001:2004 certified. (Certificate is enclosed with this PDD in Appendix H).

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YKKIPL comprises an advance effluent treatment plant (ETP) in factory premises since from the beginning. Recently the company has initiated the effluent dyeing water re-cycling through the latest available techniques to minimize the extract ground water and for reduction of green house gases like Carbon di-oxide through changing the Agro waste biomass to generate the steam. A disaster management plan (referred as IUTS 01 in YKKIPL) already exists in the company, which includes the fire safety, electrical safety, etc provisions. A regular awareness is created for the different safety procedures. The biomass storage will be incorporated in the existing plan. The objectives are further classified as: 9. Rescue operation and First aid of persons affected during emergency 10. Safeguard other persons during emergency 11. Minimize the damage to property and to the environment 12. Initially contain the incident impact and then bring the incident under control 13. Provide authentic information to external interested parties. 14. Rehabilitation of affected persons 15. Preservation of relevant records 16. Inquiry and analysis of the causes of emergency situations that led to the incident and take

suitable corrective action.

7 Training procedures d. Regular training of the plant persons will be arranged by YKKIPL every year by calling the

external experts. e. Engineers/ technicians recruited will have experience of working in the similar fields. f. Equipment supplier’s sill deputes their commissioning engineers to train the engineers/

technicians and supporting operating manuals will be provided by them.

Appendix-A

Head-Utility & Engineering

Dy. Manager- Boiler and Utility

Dy. Manger- Electrical and Utility

Boiler Operators

Operation and Maintenance plan for the project activity

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Appendix A: Maintenance Procedure

DESCRIPTION COMMENT Check temperature of exhaust

gases

Compare temperatures with tests performed after annual

cleaning.

Check Steam Pressure or Water

Pressure/Temperature

Is Variation in steam pressure or water

pressure/temperature under different loads?

Wet steam may be produced if the pressure drops too fast

(caused by excessive loading on the boiler).

Common causes of unstable water level are:

a. Contaminates in boiler such as oil, excessive solids,

excessive feed water treatment, etc.

b. Overload on boiler Check for Unstable Water Level

c. Malfunctions in equipment such as feed water pump,

water level control, etc.

Check Motors and Auxiliary

Equipment

Check to see that motors and auxiliary equipment are

functioning properly.

Check Air Temperature In Boiler

Room

The air temperature in the boiler room should not exceed

or drop below recommended limits.

Check Blow down

The frequency and amount of blow down will depend

upon the amount and condition of the feed water. Check

to see that the blow down valve does not leak.

Clean Waterside Surfaces Follow manufacturer's recommended procedure in

cleaning and preparing waterside surfaces

Clean Fireside Follow manufacturer's recommended procedure in

cleaning and preparing fireside surfaces

Repair Refractories on Fireside Use recommended materials and procedure to repair

refractory

a. Clean condensate receivers, and deaeration system Feed-water System

b. Clean and recondition feed water pumps

a. Clean all electrical terminals Electrical Systems

b. Check electronic controls and replace any defected

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parts

c. Check mercury switches and replace if deterioration

has occurred

Hydraulic and Pneumatic Valves Check operation and repair any leaks

Start-up and Operation Follow start-up and operation procedures

a. Make adjustments to give desired exhaust gas

composition Exhaust Gases

b. Record composition, firing position and temperature

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Appendix B QA/QC Procedures

Parameter Data Type Data variable Data unit

Measured (m), calculated (c) or estimated (e) Comments QA/QC Procedures

1.Biomass Briquette quantity

Mass or volume

Quantity of biomass fuel combusted in the boiler

Metric tonne m and c

The quantity of biomass briquettes combusted in the boiler will be measured by weighing m/c. The data will be kept for 3 years after the end of the last crediting period.

Any direct measurement with mass or volume meters at the plant site should be crosschecked with an annual energy balance that is based on purchased quantities and stock changes.

2.SGy Steam generation quantity

Total quantity of steam generated in the plant during the year y

Metric ton/year m

Data may be recorded from the steam flow meters provided at the boiler location at YKKIPL

Data will be recorded through onsite installed main and check meters. The plant operator is responsible for recording this set of data. The data will be cross checked based on the monthly/ annual fuel consumption by the briquette fired boiler.

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Appendix C Abbreviations BER Baseline Emission reduction CDM Clean Development Mechanism CPCB Central Pollution Control Board CERs Certified Emission Reductions EIA Environment Impact Assessment GHG Greenhouse Gases FO Furnace Oil INR Indian National Rupees IPCC Inter Governmental Panel on Climate Change kg Kilogram km Kilometer kV Kilo volt kW Kilo watt kWh Kilo watt hour MNES Ministry of Non-Conventional Energy Sources MoEF Ministry of Environment & Forests MoP Ministry of Power MT Metric Tonnes MW Mega Watt NCV Net Calorific Value NGGIP National Greenhouse Gas Inventories Programme NOC No Objections Certificate O&M Operations & Maintenance RFO Residual Fuel Oil TPA Tonne per Annum TPH Tonne per hour HSEB Haryana State Electricity Board HSPCB Haryana State Pollution Control Board UNFCCC United Nations Framework Convention on Climate Change YKKIPL YKK India Private Limited

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Appendix D Estimation of Boiler rating Due to fuel conversion the boiler capacity is de-rated from 6 TPH to 3.5 TPH. Boiler Type = Fire tube three pass horizontal wet back boiler FO fired Boiler Capacity = 3.5 TPH = 0.972 kg/sec (3.5*1000/3600) Working Pressure and Temperature of the FO fired boiler = 10.54 kg/cm2, 182oC. Energy at 10.54 kg/cm2, 182oC = 2778 kJ/kg or 2.778 MJ/kg Energy at 100oC temperature = 0.419 MJ/kg Boiler Rating = 0.9722*(2.778-0.419) = 2.39 MWth

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Appendix E CENTRAL ELECTRICITY AUTHORITY: CO2 BASELINE DATABASE VERSION 3.0

DATE

15 December

2007 BASELINE METHODOLOGY

ACM0002 / Ver 07

EMISSION FACTORS Weighted Average Emission Rate (tCO2/MWh) (excl. Imports) Weighted Average Emission Rate (tCO2/MWh) (incl. Imports)

2000-

01 2001-

02 2002-03 2003-

04 2004-

05 2005-

06 2006-

07 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 North 0.72 0.73 0.74 0.71 0.71 0.71 0.72 North 0.72 0.73 0.74 0.71 0.72 0.73 0.74 East 1.09 1.06 1.11 1.10 1.08 1.08 1.03 East 1.06 1.03 1.09 1.08 1.05 1.05 1.00 South 0.73 0.75 0.82 0.84 0.78 0.74 0.72 South 0.74 0.75 0.82 0.84 0.79 0.74 0.72 West 0.90 0.92 0.90 0.90 0.92 0.87 0.85 West 0.90 0.92 0.90 0.90 0.92 0.89 0.86 North-East 0.42 0.41 0.40 0.43 0.32 0.33 0.39

North-East 0.42 0.41 0.40 0.43 0.52 0.33 0.40

India 0.82 0.83 0.85 0.85 0.84 0.82 0.80 India 0.82 0.83 0.85 0.85 0.84 0.81 0.80 Simple Operating Margin (tCO2/MWh) (excl. Imports)

Simple Operating Margin (tCO2/MWh) (incl. Imports)

2000-

01 2001-

02 2002-03 2003-

04 2004-

05 2005-

06 2006-

07 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 North 0.98 0.98 1.00 0.99 0.97 0.99 0.99 North 0.98 0.98 1.00 0.99 0.98 1.00 1.00 East 1.22 1.22 1.20 1.23 1.20 1.16 1.13 East 1.22 1.19 1.17 1.20 1.17 1.13 1.09 South 1.02 1.00 1.01 1.00 1.00 1.01 1.00 South 1.02 1.00 1.01 1.00 1.00 1.01 1.00 West 0.98 1.01 0.98 0.99 1.01 0.99 0.99 West 0.98 1.01 0.99 0.99 1.01 1.00 0.99 North-East 0.74 0.71 0.74 0.74 0.71 0.70 0.69

North-East 0.74 0.71 0.74 0.74 0.90 0.70 0.70

India 1.02 1.02 1.02 1.03 1.03 1.02 1.01 India 1.01 1.02 1.02 1.02 1.02 1.02 1.01 Build Margin (tCO2/MWh) Build Margin (tCO2/MWh) (not adjusted for imports)

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(excl. Imports)

2000-

01 2001-

02 2002-03 2003-

04 2004-

05 2005-

06 2006-

07 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 North 0.53 0.60 0.63 North 0.53 0.60 0.63 East 0.90 0.97 0.93 East 0.90 0.97 0.93 South 0.70 0.71 0.71 South 0.70 0.71 0.71 West 0.77 0.63 0.59 West 0.77 0.63 0.59 North-East 0.15 0.15 0.23

North-East 0.15 0.15 0.23

India 0.69 0.68 0.68 India 0.69 0.68 0.68 Combined Margin (tCO2/MWh) (excl. Imports) Combined Margin in tCO2/MWh (incl. Imports)

2000-

01 2001-

02 2002-03 2003-

04 2004-

05 2005-

06 2006-

07 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 North 0.76 0.76 0.77 0.76 0.75 0.80 0.81 North 0.76 0.76 0.77 0.76 0.76 0.80 0.81 East 1.06 1.06 1.05 1.07 1.05 1.06 1.03 East 1.06 1.05 1.04 1.05 1.04 1.05 1.01 South 0.86 0.85 0.86 0.85 0.85 0.86 0.85 South 0.86 0.85 0.86 0.85 0.85 0.86 0.85 West 0.87 0.89 0.88 0.88 0.89 0.81 0.79 West 0.87 0.89 0.88 0.88 0.89 0.82 0.79 North-East 0.44 0.43 0.44 0.44 0.43 0.42 0.46

North-East 0.44 0.43 0.44 0.44 0.52 0.42 0.46

India 0.86 0.86 0.86 0.86 0.86 0.85 0.85 India 0.85 0.86 0.86 0.86 0.86 0.85 0.84 GENERATION DATA EMISSION DATA Gross Generation Total (GWh) Absolute Emissions Total (tCO2)

2000-

01 2001-

02 2002-03 2003-

04 2004-

05 2005-

06 2006-

07 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 North 144,292 151,185 155,385 165,735 168,438 179,751 191,104 North 97,866,565 102,743,113 106,808,582 109,996,544 112,212,597 120,102,148 129,554,682 East 58,936 64,048 66,257 75,374 85,776 93,902 101,959 East 58,026,488 61,427,499 66,593,200 75,512,010 83,956,860 92,517,515 96,360,317 South 129,035 131,902 136,916 138,517 144,086 147,355 161,897 South 89,019,263 92,178,116 105,239,700 108,123,211 105,603,624 101,760,966 109,251,806 West 162,329 165,805 177,399 172,682 183,955 188,606 199,346 West 135,192,153 141,597,621 148,557,341 144,127,175 157,781,065 153,933,199 157,722,686 North-East 5,319 5,332 5,808 5,867 7,883 7,778 6,970

North-East 2,207,396 2,159,969 2,285,724 2,462,796 2,468,463 2,532,819 2,645,856

India 499,911 518,272 541,764 558,175 590,138 617,392 661,277 India 382,311,864 400,106,317 429,484,546 440,221,736 462,022,608 470,846,647 495,535,347 Net Generation Absolute Emissions OM (tCO2)

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Total (GWh)

2000-

01 2001-

02 2002-03 2003-

04 2004-

05 2005-

06 2006-

07 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 North 135,230 141,415 144,743 155,043 157,291 168,206 179,223 North 97,866,565 102,743,113 106,808,582 109,996,544 112,212,597 120,102,148 129,554,682 East 53,350 58,097 59,841 68,428 77,968 86,014 93,818 East 58,026,488 61,427,499 66,593,200 75,512,010 83,956,860 92,517,515 96,360,317 South 121,158 123,630 127,789 128,373 134,676 138,329 152,206 South 89,019,263 92,178,116 105,239,700 108,123,211 105,603,624 101,760,966 109,251,806 West 150,412 153,125 164,448 159,780 170,726 176,003 185,493 West 135,192,153 141,597,621 148,557,341 144,127,175 157,781,065 153,933,199 157,722,686 North-East 5,195 5,213 5,671 5,752 7,762 7,655 6,828

North-East 2,207,396 2,159,969 2,285,724 2,462,796 2,468,463 2,532,819 2,645,856

India 465,345 481,479 502,492 517,376 548,423 576,206 617,567 India 382,311,864 400,106,317 429,484,546 440,221,736 462,022,608 470,846,647 495,535,347 Share of Must-Run (Hydro/Nuclear) (% of Net Generation) Absolute Emissions BM (tCO2)

2000-

01 2001-

02 2002-03 2003-

04 2004-

05 2005-

06 2006-

07 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 North 25.9% 25.7% 26.1% 28.1% 26.8% 28.1% 27.1% North 17,108,583 20,625,908 22,941,127 East 10.8% 13.4% 7.5% 10.3% 10.5% 7.2% 9.0% East 14,303,611 16,990,438 17,547,736 South 28.1% 25.5% 18.3% 16.2% 21.6% 27.0% 28.3% South 20,092,752 20,045,639 21,475,360 West 8.2% 8.5% 8.2% 9.1% 8.8% 12.0% 13.9% West 27,148,870 22,318,133 22,707,948 North-East 42.2% 41.7% 45.8% 41.9% 55.5% 52.7% 44.1%

North-East 299,124 267,051 325,491

India 19.2% 18.9% 16.3% 17.1% 18.0% 20.1% 20.9% India 78,952,941 80,247,168 84,997,662 Net Generation in Operating Margin (GWh)

2000-

01 2001-

02 2002-03 2003-

04 2004-

05 2005-

06 2006-

07 North 100,189 105,076 106,942 111,450 115,151 120,869 130,597 East 47,570 50,308 55,377 61,378 69,746 79,863 85,375 South 87,114 92,103 104,449 107,603 105,568 100,978 109,116 West 138,071 140,173 150,889 145,264 155,731 154,918 159,681 North-East 3,002 3,039 3,074 3,343 3,456 3,621 3,819

India 375,947 390,700 420,730 429,040 449,653 460,249 488,587 IMPORT DATA

20% of Net Generation (GWh) Net Imports (GWh) - Net exporting grids are set to zero

2000-

01 2001-

02 2002-03 2003-

04 2004-

05 2005-

06 2006-

07 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07

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North 27,046 28,283 28,949 31,009 31,458 33,641 35,845 North 0 0 0 0 3,616 5,748 6,612 East 10,670 11,619 11,968 13,686 15,594 17,203 18,764 East 489 555 357 1,689 0 0 0 South 24,232 24,726 25,558 25,675 26,935 27,666 30,441 South 1,162 1,357 518 0 0 0 0 West 30,082 30,625 32,890 31,956 34,145 35,201 37,099 West 321 0 797 962 285 11,982 10,473 North-East 1,039 1,043 1,134 1,150 1,552 1,531 1,366

North-East 0 0 0 0 2,099 0 92

India 93,069 96,296 100,498 103,475 109,685 115,241 123,513 Net Generation in Build Margin (GWh)

Share of Net Imports (% of Net Generation)

2000-

01 2001-

02 2002-03 2003-

04 2004-

05 2005-

06 2006-

07 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 North 32,064 34,340 36,511 North 0.0% 0.0% 0.0% 0.0% 2.3% 3.4% 3.7% East 15,818 17,567 18,907 East 0.9% 1.0% 0.6% 2.5% 0.0% 0.0% 0.0% South 28,513 28,228 30,442 South 1.0% 1.1% 0.4% 0.0% 0.0% 0.0% 0.0% West 35,257 35,425 38,242 West 0.2% 0.0% 0.5% 0.6% 0.2% 6.8% 5.6% North-East 2,055 1,793 1,437

North-East 0.0% 0.0% 0.0% 0.0% 27.0% 0.0% 1.3%

India 113,707 117,353 125,538

Appendix F

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Appendix G

Briquette fired boiler efficiency estimation

The efficiency of briquette fired can be calculated by energy balance of both the two cases

Case I: FO fired boiler (Existing)

Net Heat generated /day = Qty of FO x NCV of FO x Efficiency of FO fired boiler

= 2.42 KT/day/1000*40.4 TJ/KT*0.8 = 0.0782 TJ/day……………………..………1

Case II: Briquette fired boiler (Project Activity)

Net Heat generated /day = Qty of Br x NCV of Br x Efficiency of Br fired boiler

= 8 KT/day/1000*15.9 TJ/KT*Eff. = (0.1272*Eff.) TJ/day…………..………..2

Equating equation 1 & 2 for energy balance:

0.0782 TJ/day = 0.1272*Eff. TJ/day

Efficiency of briquette fired boiler = 0.614 =61.4%

For Conservative side 61% has been assumed as Briquette fired boiler efficiency.

Appendix H

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