MUNICIPAL CORPORATION OF GREATER MUMBAI (MCGM)

DEVELOPMENT OF WASTE-TO-ENERGY (WTE) PROJECT AT

DEONAR, MUMBAI

FEASIBILITY & DETAILED PROJECT REPORT

(for 600 TPD Capacity Plant)
Document No. TCE 10176A-2024-DPR-R2

Prepared By:

March, 2019
 REVISION STATUS

Document No. TCE 10176A-2024-DPR-R2

REV. NO. DATE DESCRIPTION

October
R1 DPR for 3000 TPD capacity plant was submitted to MCGM.
2016

DPR for 600 TPD capacity plant is being submitted as per the
R2 March 2019
change in project structure

R2 30-03-2019 SSL AK AK

REV. CHECKED
DATE PREPARED BY CLEARED BY APPROVED BY
NO. BY

FILE NAME: TCE 10176A-2024-DPR-R2

TCE FORM NO. 032 R3
Proprietary rights of the information contained herein belong to TCE.
This information is intended to be used for the mentioned purpose/
project only. In case of misuse of information and any claim arising
thereof, cost and consequence will be on the party misusing the
information.
Contents
Executive Summary ............................................................................................................. i
CHAPTER 1: Introduction ................................................................................................ 1
1.1 Background............................................................................................................. 1
1.2 Objectives of the Project ......................................................................................... 3
1.3 Report Structure ..................................................................................................... 3
CHAPTER 2: Project Site Information &Waste Characteristics ..................................... 5
2.1 Location .................................................................................................................. 5
2.2 Baseline Environmental Data .................................................................................. 8
2.2.1 Geology and Geomorphology of the Region ................................................................. 8
2.2.2 Ambient Air Quality ...................................................................................................... 8
2.2.3 Seismic ........................................................................................................................ 9
2.2.4 Meteorology ................................................................................................................ 9
2.2.5 Groundwater Quality .................................................................................................. 11
2.2.6 Surface Water Quality ................................................................................................ 11
2.3 Waste Characteristics ........................................................................................... 11
2.3.1 Power Plant Capacity: ................................................................................................ 15
2.3.2 Annual Power Generation .......................................................................................... 19
2.4 Review of available data ....................................................................................... 20
2.4.1 Topographical details of the Site ................................................................................ 20
2.4.2 Geotechnical details of the Site .................................................................................. 22
2.4.3 Background on Waste to Energy Project for Mumbai ................................................. 24
2.4.4 Initial Environmental Examination (IEE) Report .......................................................... 25
CHAPTER 3: Technology Screening and Design Basis for WtE ................................. 28
3.1 Approach and Methodology of Technology Screening .......................................... 28
3.2 Biological and Thermal Technologies for Waste Management .............................. 30
3.2.1 Biological Technology ................................................................................................ 30
3.2.2 Bioreactor landfill (BLF) .............................................................................................. 31
3.2.3 Thermal Techniques .................................................................................................. 31
3.3 Climate Change Impact ........................................................................................ 36
3.4 Scenario of Different WtE Plants in National and International .............................. 38
3.5 Lesson learnt from WtE Projects in India .............................................................. 40
3.6 Selection of Technologies ..................................................................................... 41
CHAPTER 4: Regulatory Framework and Clearances ................................................. 45
4.1 Regulatory Framework .......................................................................................... 45
4.1.1 Solid Waste Management (SWM) Rules, 2016........................................................... 45
4.1.2 EIA Notification 2006, and Amendments .................................................................... 47
4.1.3 Coastal Regulation Zone Notification 2011, and amendments ................................... 48
4.2 Statutory Clearances ............................................................................................ 49
4.3 Regulatory Standards ........................................................................................... 50

TCE 10176A-2024-DPR-R2 i
4.3.1 Air Quality Standards ................................................................................................. 50
4.3.2 Water Quality Standards ............................................................................................ 52
4.3.3 Leachate Quality Standards ....................................................................................... 52
4.4 Consent from Airport Authority of India ................................................................. 56
4.4.1 Noise Quality Standards............................................................................................. 57
CHAPTER 5: Project Design Concept ........................................................................... 59
5.1 Technology Description:........................................................................................ 59
5.2 Case Study: Incineration based WtE ..................................................................... 60
5.2.1 Project requirement .................................................................................................... 60
5.2.2 Approach.................................................................................................................... 60
5.2.3 Assessment of Land availability and requirement ....................................................... 60
5.2.4 Assessment of Water availability and requirement ..................................................... 66
5.2.5 Assessment of Power Availability and Requirement ................................................... 67
5.2.6 Components of Waste to Energy Plant ....................................................................... 67
5.2.7 Layout Planning ......................................................................................................... 67
5.2.8 Demarcation of land on the proposed site .................................................................. 67
5.2.9 Weighbridge ............................................................................................................... 68
5.2.10 MSW Receiving Pit/ Platform ................................................................................... 69
5.3 MSW Handling and Pre-processing Plant (MHP) .................................................. 69
5.3.1 Pre-Processing Stages............................................................................................... 70
5.3.2 Storage shed/ Drying area ......................................................................................... 72
5.3.3 Feedstock Feeder System (FFS) ............................................................................... 72
5.3.4 Feedstock .................................................................................................................. 72
5.3.5 Advantage of Pre-processing ..................................................................................... 74
5.4 Incinerator/ Steam Generator for MSW ................................................................. 75
5.4.1 Moving Grate Incinerator ............................................................................................ 75
5.4.2 Fluidized Bed Incinerator ............................................................................................ 77
5.4.3 Rotary Kiln Incinerator ................................................................................................ 78
5.4.4 Steam Turbine Generator and Auxiliaries ................................................................... 80
5.4.5 Water system ............................................................................................................. 82
5.4.6 Water Treatment Plant ............................................................................................... 87
5.4.7 Service and Potable Water System ............................................................................ 89
5.4.8 Fire Protection System ............................................................................................... 89
5.4.9 Effluent Disposal System ........................................................................................... 89
5.4.10 Electrical Systems for Power Plant ........................................................................... 90
5.4.11 Auxiliary Power Supply System ................................................................................ 90
5.4.12 Auxiliary Power Supply system ................................................................................ 94
5.4.13 Control & Instrumentation (C&I) System ................................................................... 99
5.4.14 Fire Fighting ........................................................................................................... 104

TCE 10176A-2024-DPR-R2 ii
5.4.15 Emission Control System (ECS) ............................................................................. 109
5.4.16 Ash Collection and Management System ............................................................... 112
5.4.17 Leachate Collection and Management System....................................................... 116
5.4.18 Treatment of Effluent from Ash Pond ..................................................................... 117
5.4.19 Effluent Treatment Plant ......................................................................................... 118
5.4.20 Sewage Treatment plant ........................................................................................ 118
5.4.21 Process Water Conveyance Pipeline ..................................................................... 118
5.4.22 Storm Water Drainage System ............................................................................... 119
5.4.23 Internal/ Service Road Network .............................................................................. 121
5.4.24 Boundary Wall ........................................................................................................ 122
5.4.25 Administration office ............................................................................................... 123
5.4.26 Worker’s Area ........................................................................................................ 123
5.4.27 Security Cabin ........................................................................................................ 123
5.4.28 Various Plant Buildings/ Structures ........................................................................ 124
5.4.29 Ground Improvement Measures ............................................................................. 125
5.4.30 Field Testing .......................................................................................................... 126
5.4.31 Further Scope ........................................................................................................ 126
5.4.32 Foundations ........................................................................................................... 126
5.4.33 Specification of Materials ....................................................................................... 127
5.4.34 Design Codes and Standards................................................................................. 128
5.4.35 Information Communication Technology (ICT) ....................................................... 131
5.5 Reject Management ............................................................................................ 131
5.5.1 Inert waste: C&D ...................................................................................................... 131
5.5.2 Recyclable Waste .................................................................................................... 132
5.5.3 Leachate .................................................................................................................. 132
5.5.4 Sludge...................................................................................................................... 133
5.5.5 Fly ash ..................................................................................................................... 134
5.5.6 Bottom ash ............................................................................................................... 137
5.5.7 Flue-gas desulfurization (FGD) ................................................................................ 137
5.6 Continuous Emission Monitoring Systems (CEMS) ............................................. 138
5.6.1 Utilities Requirements .............................................................................................. 139
5.6.2 Measuring Principle of SO2, NOx, CO Analyzer Module – Nondispersive Infrared Sensor
(NDIR) .............................................................................................................................. 139
5.6.3 Measuring of Principle of VOC Analyzer Module ...................................................... 140
5.6.4 Bill of Material .......................................................................................................... 140
5.7 Landscape strategy:............................................................................................ 142
5.7.1 Tree Buffer/ Green Belt Development: ..................................................................... 142
5.7.2 Landscape pockets .................................................................................................. 142
5.7.3 Landscape Costing .................................................................................................. 145

TCE 10176A-2024-DPR-R2 iii

5.8 Power Evacuation ............................................................................................... 145
5.8.1 Connectivity ............................................................................................................. 145
5.8.2 Regulatory Process for Connectivity ......................................................................... 146
5.8.3 Evacuation Infrastructure ......................................................................................... 146
5.8.4 Tariff......................................................................................................................... 146
CHAPTER 6: ENVIRONMENTAL & SOCIAL ANALYSIS ............................................. 149
6.1 Environmental Analysis ....................................................................................... 149
6.1.1 Land area requirement ............................................................................................. 149
6.1.2 Adverse Impact due to Industries ............................................................................. 149
6.1.3 Greenhouse Gases and Clean Energy Production ................................................... 152
6.1.4 Impact due to construction activity............................................................................ 152
6.2 Social Structure .................................................................................................. 153
6.2.1 Demography ............................................................................................................ 153
6.2.2 Health and Educational Facilities ............................................................................. 154
6.2.3 Social Factors Influencing the Solid Waste Management ......................................... 154
6.3 Rag – pickers ...................................................................................................... 155
6.4 Health issues ...................................................................................................... 156
6.4.1 Injuries in Form of Cuts and Bruises......................................................................... 157
6.4.2 Injuries Caused by Animals ...................................................................................... 157
6.4.3 Air Borne Diseases .................................................................................................. 157
6.4.4 Chemical poisoning .................................................................................................. 157
6.4.5 Other Diseases ........................................................................................................ 158
6.4.6 Mumbai Ragpickers ................................................................................................. 158
6.5 Aesthetic ............................................................................................................. 158
6.5.1 Direct Impacts .......................................................................................................... 159
6.5.2 Indirect impacts ........................................................................................................ 159
6.5.3 Transport related social issues ................................................................................. 159
6.5.4 Social and Cultural Resources ................................................................................. 160
6.6 Social Impact of WtE Project ............................................................................... 160
6.6.1 Loss of Livelihood .................................................................................................... 160
6.6.2 Health Impact ........................................................................................................... 160
6.6.3 Aesthetic and Overall Environment .......................................................................... 160
6.6.4 Community Health and Safety .................................................................................. 161
6.6.5 Greenhouse gases (GHGs) and clean energy production ........................................ 161
CHAPTER 7: Environmental Management Plan (EMP) .............................................. 163
7.1 Objective ............................................................................................................. 163
7.2 Management of Impacts...................................................................................... 164
7.2.1 Mitigation Measures during Construction and Operation Phases ............................. 164
7.3 Occupational Health and Safety Measures (OHS) .............................................. 164
7.3.1 Mitigation measure for safety of Construction Workers:............................................ 164

TCE 10176A-2024-DPR-R2 iv
7.4 Environmental Monitoring Plan & Implementation Arrangements ........................ 174
7.4.1 Environmental Management Cell ............................................................................. 174
7.4.2 Environmental Monitoring Program .......................................................................... 175
7.4.3 Record Keeping and Reporting ................................................................................ 178
7.4.4 Environmental Audits and Corrective Action Plans ................................................... 178
CHAPTER 8: Project Risk Management ...................................................................... 180
CHAPTER 9: Quantity and Cost Estimation ............................................................... 185
9.1 Quantity Estimates .............................................................................................. 185
9.2 Cost Estimates.................................................................................................... 185
9.3 Financial feasibility of the Project ........................................................................ 186
CHAPTER 10: Funding Scenarios and Financial Model .............................................. 187
10.1 Project Funding Models ...................................................................................... 187
10.2 Levelized Tariff ................................................................................................... 190
CHAPTER 11: 190
11.1 Cost of Generation of Power ............................................................................... 190
11.1.1 In house consumption of power generated ............................................................. 190
11.1.2 Sale of Power Vs Internal Consumption ................................................................. 191
Two option for MCGM ....................................................................................................... 191
CHAPTER 12: Project Implementation Strategy ........................................................... 193
12.1 Maintenance Requirements ............................................................................. 193
12.2 Project Milestone ................................................................................................ 194
12.3 Issues Requiring Attention of MCGM .................................................................. 194
12.4 Interim Plan for Site Management ....................................................................... 196
CHAPTER 13: Literature Review ................................................................................... 199

LIST OF TABLES:
TABLE 2-1:SALIENT FEATURES OF DEONAR DUMPING GROUND ................................................ 5
TABLE 2-2: AIR QUALITY LEVELS FROM APRIL 2010 TO OCTOBER 2015 ..................................... 8
TABLE 2-3: SUMMARY OF WIND PATTERN - IMD COLABA DATA ................................................. 10
TABLE 2-4:PHYSICAL COMPOSITION AND CHEMICAL CHARACTERISTICS OF WASTE IN
INDIAN CITIES.............................................................................................................................. 13
TABLE 2-5: CALORIFIC VALUE RANGE AND THE RELATIVE OCCURRENCE PERCENTAGE .... 14
TABLE 2-6: ANNUAL NET POWER GENERATION (ESTIMATED) .................................................... 19
TABLE 2-7: KEY FINDINGS OF THE TOPOGRAPHIC SURVEY ....................................................... 22
TABLE 2-8 KEY FINDINGS FROM THE GEOTECHNICAL INVESTIGATION REPORT.................... 23
TABLE 2-9: WTE PLANT REFERENCE LIST FROM IDECK REPORT .............................................. 27
TABLE 3-1: ADVANTAGES AND DISADVANTAGES OF BIOMETHANATION TECHNOLOGY ....... 30
TABLE 3-2: ADVANTAGES AND DISADVANTAGES OF GASIFICATION TECHNOLOGY .............. 32
TABLE 3-3:ADVANTAGES AND DISADVANTAGES OF PYROLYSIS TECHNOLOGY..................... 34
TABLE 3-4: ADVANTAGES AND DISADVANTAGES OF PLASMA ARC TECHNOLOGY ................. 35
TABLE 3-5: ADVANTAGES AND DISADVANTAGES OF INCINERATION TECHNOLOGY .............. 36
TABLE 3-6: STATUS OF DIFFERENT WTE PLANTS IN INDIA.......................................................... 38

TCE 10176A-2024-DPR-R2 v
TABLE 3-7: INTERNATIONAL STATUS OF MASS BURNING PLANTS ............................................ 40
TABLE 3-8: LESSON LEARNT FROM WTE PROJECTS IN INDIA .................................................... 40
TABLE 3-9: DETAILS OF WTE TECHNOLOGY OPTIONS ................................................................. 41
TABLE 3-10: DECISION SUPPORT MATRIX FOR SELECTION OF CENTRALIZED APPROACHES
BASED ON EXPERTS’ VALUATION ........................................................................................... 43
TABLE 3-11:WTE RELATIVE RANKING .............................................................................................. 44
TABLE 4-1: ENVIRONMENTAL CLEARANCE REQUIREMENT FOR THERMAL POWER PROJECT
(SO 1533, MODIFIED 25THJUNE 2014) ....................................................................................... 47
TABLE 4-2: PROJECT STAGES AND RESPECTIVE COMPLIANCES .............................................. 50
TABLE 4-3: AIR EMISSION STANDARDS OR INCINERATION FACILITY OF MSW (SWM RULES
2016) ............................................................................................................................................. 51
TABLE 4-4: STANDARDS FOR LEACHATE DISPOSAL AS PER SWM RULE 2016......................... 53
TABLE 4-5: WASTE WATER DISCHARGE STANDARDS BY CPCB (ENVIRONMENT PROTECTION
RULE 1986, SCHEDULE IV) ........................................................................................................ 54
TABLE 4-6: AMBIENT AIR QUALITY STANDARDS WITH RESPECT TO NOISE ............................. 57
TABLE 5-1: COMMON FACILITIES/RESOURCES FOR TECHNOLOGIES ....................................... 59
TABLE 5-2: LAND AVAILABILITY AND DEPTH OF EXISTING MSW................................................. 61
TABLE 5-3: LAND AREA REQUIREMENT .......................................................................................... 64
TABLE 5-4: COMPONENTS OF THE PROPOSED PLANT ................................................................ 67
TABLE 5-5:SPECIFICATIONS OF THE BOILER ................................................................................ 80
TABLE 5-6: RELIABILITY ANALYSIS FOR POWER GENERATED – SEASONAL VARIATION....... 80
TABLE 5-7: STEAM PARAMETERS AT DIFFERENT POINTS IN THE CYCLE ................................ 81
TABLE 5-8: PLANT WATER REQUIREMENT ..................................................................................... 84
TABLE 5-9:CW SYSTEM MAKE-UP REQUIREMENTS ...................................................................... 86
TABLE 5-10: RELAYS & METERING DETAILS ................................................................................... 95
TABLE 5-11: TRANSFORMERS DETAILS .......................................................................................... 95
TABLE 5-12: FAULT CURRENT DETAILS .......................................................................................... 98
TABLE 5-13: REQUIREMENT & SPECIFICATION DETAILS FOR EARTHING SYSTEM ................. 99
TABLE 5-14:PARTICULATE AND EMISSION STANDARD .............................................................. 109
TABLE 5-15:WET FGD SYSTEM (ESTIMATED VALUES) ................................................................ 111
TABLE 5-16: ASH POND CAPACITY (INTERIM PERIOD) ............................................................... 114
TABLE 5-17: ASH DISPOSAL OPTION-1 ......................................................................................... 114
TABLE 5-18: ASH DISPOSAL OPTION-2 ......................................................................................... 114
TABLE 5-19: INERT DISPOSAL OPTION-1....................................................................................... 115
TABLE 5-20: INERT DISPOSAL OPTION-2 ...................................................................................... 115
TABLE 5-21: EFFLUENT POND ........................................................................................................ 118
TABLE 5-22: ELECTRICAL DESIGN CODES ................................................................................... 128
TABLE 5-23: CIVIL DESIGN CODES ................................................................................................. 131
TABLE 5-24: ITEM DESCRIPTION WITH QUANTITY ....................................................................... 140

TCE 10176A-2024-DPR-R2 vi
TABLE 5-25 LANDSCAPE COST SUMMARY ................................................................................... 145
TABLE 6-1NO SIGNIFICANT IMPACTS DUE TO CONSTRUCTION ............................................... 153
TABLE 6-2 RAGPICKERS AILMENTS AND MEDICAL CONDITIONS ............................................. 158
TABLE 7-1:SUMMARY OF POTENTIAL IMPACTS AND MITIGATION MEASURES FOR
CONSTRUCTION PHASE .......................................................................................................... 166
TABLE 7-2:SUMMARY OF POTENTIAL IMPACT AND MITIGATION MEASURES FOR
OPERATIONAL PHASE ............................................................................................................. 171
TABLE 7-3: ENVIRONMENTAL MONITORING PLAN ...................................................................... 176
TABLE 7-4: RECORD KEEPING PARAMETERS WITH PARTICULARS ......................................... 178
TABLE 8-1RISK AND MITIGATION MEASURES .............................................................................. 180
TABLE 9-1: SUMMARY OF BLOCK COST ESTIMATE OF WASTE TO ENERGY PROJECT ........ 185
TABLE 10-1 COMPARISON MATRIX DBO VS PPP MODEL ........................................................... 188
TABLE 10-2: DATA INPUT FOR LEVELIZED TARIFF ...................................................................... 190
TABLE 10-3 COMPARISON BETWEEN SALE OF POWER TO DISCOM VS INTERNAL
CONSUMPTION ......................................................................................................................... 191
TABLE 12-1: COMPLIANCES/REQUIREMENTS AND AGENCY ..................................................... 194
TABLE 12-2: PROJECT MILESTONE FOR DEVELOPMENT OF WASTE TO ENERGY (WTE)
PROJECT AT DEONAR, MCGM, MUMBAI ............................................................................... 197
List of Figures
FIGURE1.1: WASTE HIERARCHY ........................................................................................................ 2
FIGURE 2.1:LOCATION OF THE PROJECT SITE ................................................................................ 7
FIGURE 2.2: THE PROJECT SITE AND SURROUNDINGS ................................................................. 7
FIGURE 2.3:SEISMIC ZONING MAP OF INDIA .................................................................................... 9
FIGURE 2.4: ANNUAL WIND ROSE BASED ON 30 YEARS DATA ................................................... 10
FIGURE 2.5: BELL CURVE SHOWING CALORIFIC VALUE IN KCAL/KG VS. OCCURRENCE
PERCENTAGE.............................................................................................................................. 14
FIGURE 2.6: MUNICIPAL SOLID WASTE FLOW DIAGRAM IN WTE PLANT ................................... 15
FIGURE 2.7: SEASONAL VARIATION IN PLANT EFFICIENCY ......................................................... 16
FIGURE 2.8: TOPOGRAPHIC SURVEY MAP OF THE DEONAR DUMPSITE ................................... 21
FIGURE 2.9: BOREHOLE LOCATIONS AS DEPICTED IN 2005 REPORT ........................................ 22
FIGURE 3.1:OPTIONS AVAILABLE FOR MSW MANAGEMENT/TREATMENT ................................ 29
FIGURE 3.2: COMPARISON BETWEEN LANDFILL AND WTE PLANT ............................................. 37
FIGURE 3.3 NET CO2 REDUCTION OF MSW INCINERATION WHEN REPLACING COAL
COMBUSTION .............................................................................................................................. 37
FIGURE 4.1: GENERAL EIA FRAMEWORK........................................................................................ 48
FIGURE 4.2: CRZ DEMARCATION MAP (1991) ................................................................................. 49
FIGURE 4.3: OVERLAY OF AAI COLOUR CODED ZONING MAP OVER DEONAR DUMPING
GROUND ...................................................................................................................................... 56
FIGURE 5.1: FLOW DIAGRAM FOR TYPICAL WTE .......................................................................... 62

TCE 10176A-2024-DPR-R2 vii

FIGURE 5.2:AVAILABLE LAND PARCEL AT PROPOSED SITE ........................................................ 63
FIGURE: 5.3PROPOSED ALIGNMENT OF WATER CONVEYANCE PIPELINE FROM GHATKOPAR
STP ............................................................................................................................................... 66
FIGURE 5.4: SCHEMATIC REPRESENTATION OF A TROMMEL SCREEN .................................... 71
FIGURE 5.5: SCHEMATIC REPRESENTATION OF EDDY CURRENT SEPARATOR ...................... 72
FIGURE 5.6:RDF MANUFACTURING PROCESS OUTLINE .............................................................. 74
FIGURE 5.7:MOVING GRATE MSW INCINERATION SYSTEM......................................................... 76
FIGURE 5.8:CFB MSW INCINERATION SYSTEM ............................................................................. 77
FIGURE 5.9:ROTARY KILN INCINERATION SYSTEM ...................................................................... 79
FIGURE 5.10: DETAILS OF ASH POND ........................................................................................... 114
FIGURE 5.11:TYPICAL LEACHATE COLLECTION AND RECOVERY SYSTEM ............................ 117
FIGURE 5.12: LINING ARRANGEMENT FOR EFFLUENT POND.................................................... 118
FIGURE 5.13: CROSS SECTION FOR STORM WATER DRAIN FOR AREA PARCEL A ............... 121
FIGURE 5.14: CROSS SECTION FOR STORM WATER DRAIN FOR AREA PARCEL B&C .......... 122
FIGURE 5.15: SECTION OF INTERNAL ROAD ................................................................................ 122
FIGURE 5.16: TYPICAL VIEW OF BOUNDARY WALL ..................................................................... 123
FIGURE 5.17: NDIR ANALYZER ........................................................................................................ 139
FIGURE 5.18: LOCATION OF TATA POWER SUBSTATION ........................................................... 147
FIGURE 6.1:THE SURROUNDING OF PROJECT SITE ................................................................... 151
FIGURE 10.1: PROJECT IN DBO MODE .......................................................................................... 189

List of Annexure:

Sr. No. Annexure Detail

1. Annexure 1 Geotechnical report
2. Annexure 2 Schedules of SWM Rules 2016
3. Annexure 3 Areas & activities under CRZ Zones
4. Annexure 4 List of Documents for Consent Application
5. Annexure 5 Analysis Report of Raw Water Sample
6. Annexure 6 Water Balance Diagram
7. Annexure 7 Key One Line Diagram
8. Annexure 8 Key Single Line Diagram for Pre Processing
9. Annexure 9 Transformer Sizing & Load Description
10. Annexure 10 Exhibit Control System Configuration Diagram
11. Annexure 11 Model FGD System
12. Annexure 12 HDPE Geo-membrane Specification
13. Annexure 13 Nonwoven Geo textiles Specification
14. Annexure 14 Geosynthetic Clay Liners (GCLs) Specification
15. Annexure 15 Landscape layout
16. Annexure 16 Flow Chart for Procedure for Grant of Grid Connectivity
17. Annexure 17 Application format for Grid Connectivity

TCE 10176A-2024-DPR-R2 viii

 Sr. No. Annexure Detail
18 Annexure 18 Suitability of WtE Site

List of Drawings:

Sr. No. Drawing Name Number

1. Plant Layout TCE.10176A-2024-GA-6001
2. Available Land Parcel TCE.10176A-2024-GA-6002
3. Interim Plan TCE.10176A-2024-GA-6003
4. Contour Map Deonar Dumpsite
5. Drawing-5 Drone Mapping Survey for Deonar
Dumping Ground- 2016

TCE 10176A-2024-DPR-R2 ix
TCE 10176A-2024-DPR-R2 x
Abbreviation:

AAI Airport Authority of India

AC Alternate Current
ACB Air Circuit Breaker
ACMS Ash Collection & Management System
ACW Auxiliary cooling water
AMF Auto Mains Failure
BARC Bhabha Atomic Research Centre
BH Bore Hole
BLF Bioreactor Landfill
BOOT Build Own Operate Transfer
BOP Balance of Plant
C&D Construction & Demolition
C & I System Control & Instrumentation System
C/N ratio Carbon to Nitrogen ratio
CBRI Central Building Research Institute
CRRI Central Road Research Institute
CSIR Council of Scientific and Industrial Research
CCZM Colour Coding Zoning Map
CEMS Continuous Emission Monitoring System
CLCS Closed Loop Control System
COC Cycle of Concentration
CPCB Central Pollution Control Board
CPHEEO Central Public Health and Environmental
Engineering Organization
CRZ Costal Regulation Zone
CST Central Sales Tax
CT Cooling Tower
CTE Consent to Establish
CTO Consent to Operate
CW Circulating Water
DBO Design Built and Operate
DC Direct Current
DCS Distributed Control System
DESP Dry Electrostatic Precipitators
DIC District Industries Centre
DM Demineralization
DP Development Planning
DPR Detailed Project Report

TCE 10176A-2024-DPR-R2 xi
 EC Environmental Clearance
ECS Emission Control System
EIA Environmental Impact Assessment
EMP Environmental Management Plan
EPA Environmental Protection Agency
EPABX Electronic Private Automatic Branch Exchange
System
ESP Electro Static Precipitator
ETP Effluent Treatment Plant
EU European Union
FFS Feedstock Feeder System
FGD Flue Gas Desulfurization
FID Flame Ionization Detector
GoM Government of Maharashtra
GT Generator Transformer
HDPE High-density polyethylene
HVAC Heating, Ventilation and Air Conditioning
HVWS High Velocity Water Spray
IBA Incinerator Bottom Ash
ICB International Competitive Bidding

ICT Information Communication Technology

IDCT Induced Draught Cooling Tower
IE Independent Engineer

IS Indian Standards
ISWM Integrated Solid Waste Management
LTP Leachate Treatment Plant
LVS Large Video Screen
MB Mixed Bed
MCCB Module Case Circuit Breaker
MCF Micro Cartridge Filter
MCGM Municipal Corporation of Greater Mumbai
MHP Municipal Handling and Pre Processing Plant
MoEF& CC Ministry of Environment Forest and Climate
Change
MOG Magnetic Oil level Gauge
MPCB Maharashtra Pollution Control Board

MPCS Manufacturer Proprietary Control System

MSL Mean Sea Level

TCE 10176A-2024-DPR-R2 xii

 MSW Municipal Solid Waste
NDIR Non Dispersive Infrared Sensor
NEERI National Environmental Engineering Research
Institute
NFPA National Fire Protection Association
NOC Non Objection Certificate
OLCS Open Loop Control System
OHS Occupational Health & Safety
OSR Oil Surge Relay
PCB Poly Chlorinated Biphenyl
PIL Public Interest Litigation
PLC Programmable Logic Controller
PPA Power Purchase Agreement
PRD Pressure Relief Device
PVC Poly Vinyl Chloride
RCC Reinforced Cement Concrete
RDF Refuse Derived Fuel
RFID Radio Frequency Identification
RO Reverse Osmosis
RQD Rock Quality Designation
SCADA Supervisory Control And Data Acquisition
SCC Submerged Scraper Chain Conveyor
SG Steam Generator
SLF Sanitary Landfill
SNCR Selective Non Catalytic Reduction
SOC Sequence of Events
SoR Schedule of Rates
SPM Suspended Particulate Matter
SPT Standard Penetration Test
SS Stainless Steel
STG Steam Turbine Generator
STP Sewage Treatment Plant
TAC Tariff Advisory Committee
TCE Tata Consulting Engineers
TPD Tonnes Per Day
TPN Triple Pole Neutral
UF Ultra filtration
ULB Urban Local Bodies

TCE 10176A-2024-DPR-R2 xiii

 UPS Uninterrupted Power Supply
USD US Dollars
VAT Value Added Tax
VCM Vacuum Circuit Breaker
VED Volumetric Energy Density
WESP Wet Electrostatic Precipitators
WHO World Health Organization
WtE Waste to Energy
WTP Water Treatment Plant
XLPE Cross Linked Polyethylene

TCE 10176A-2024-DPR-R2 xiv

 Executive Summary

The Municipal Corporation of Greater Mumbai (MCGM), a local authority for

Brihanmumbai area, formed under Mumbai Municipal Corporation Act, 1888 is
responsible for providing municipal and civic services to the citizens of Greater
Mumbai, including collection, transportation, processing and disposal of Municipal
Solid Waste (MSW) generated within their jurisdiction. As part of this endeavour, the
MCGM has planned to install a Waste-to-Energy (WtE) Project in Mumbai which will
have a capacity of approx. 600 Tons per day in modules (the “Project”) and which is
compliant with SWM Rules 2016 and all other applicable rules.
1. Background:
The Municipal Corporation of Greater Mumbai currently generates above 8000 tonnes
of Municipal Solid Waste per day, with an average per capita generation rate of about
540 grams/ capita/ day. Currently, the waste dumpsite at Deonar receives
approximately 5100 TPD of waste from Mumbai which includes approximately 4100
tonnes of MSW and 1,000 TPD of construction and demolition (C&D) waste1. Waste is
being dumped at Deonar dumpsite without any processing.
The present project is for processing of 600TPD waste by way of Waste to Energy
(WtE) project at Deonar. The post processing rejects like ash (Bottom and Fly ash)
would be utilized for useful purposes like making brick, tiles etc. The pre-processing
rejects will also be used for construction purpose to the extent possible.
Project Objective
The objectives of the proposed project are as follows:
• Provide environmentally safe and sustainable solution to implement an
affordable system and technology for the WtE project that is easy to maintain
and in-line with the global standards
• To reduce the MSW burden on landfill
• To improve environmental condition
Project Benefits:

The implementation of WtE project will benefit in many ways as summarized below:

1. Reduction of Implementation of WtE project may reduce the waste volume

Landfill area by 90%2. Considering the lifecycle of 25 years, it will save
requirement Landfill area requirement by more than 80 Hectare.
2. Compliance to SWM Rules 2016 mandates waste processing. Rejects
SWM Rules generated after waste processing can be sent to landfill.
2016

1Initial
Environmental Examination Report for 1000 TPD Waste to Energy Project for MCGM at
Deonar, Mumbai
2Report of the Task Force on Waste to Energy Volume I, 2014

TCE 10176A-2024-DPR-R- Ex. Summary Page i

 3. Environmental There are several environmental benefits from this project like:
Benefits i. Prevention of frequent fire at Deonar site
ii. Spillage of waste to CRZ Areas
iii. Prevention of smoke and fugitive emission to the nearby
areas. The study shows that about 22 diseases can be
prevented by managing solid waste3
iv. Prevention of pollution to surface and ground water
4. Reduction in Using waste for production of energy will save on fossil fuel and
Green House in turn reduce Green House Gas (GHG) emission.
Gas (GHG)
Emissions
5. Safety to Flying Risk due to bird menace can be prevented at Deonar dumpsite
Zone
6. Social Benefit The project may have multiple health benefits to the people of
nearby areas and will improve the overall health benefits to
entire city by way of achieving better air quality.
The rag-picking menace, child labour and other hazardous
recycling activities can also be prevented by implementation of
WtE Project.
7. Resource The project will produce Energy from the plant having a
Conservation minimum capacity of 4 MW. This will help in conserving
resources.

2. Waste Characteristics and Project site Information

A comprehensive study was carried out for waste characterization of Mumbai by
National Environmental Engineering Research Institute (NEERI) in year 2014-15. The
revised final report for this study was submitted in 2016. This report is taken as basis
for project design for WtE in conjunction with several other reports/ studies carried out
in last 4-5 years.
The waste analysis report clearly depicts that it has high moisture content (60-80%).
The calorific value ranges from 530 - 1200 Kcal/Kg. The waste may require pre-
processing (to reduce moisture content and enhance calorific value) to meet the
requisite feedstock quality as mandated in SWM Rules 2016 (Calorific value should be
above 1500 Kcal/Kg). Pre-processing is part of WtE technology. The calorific value
can also be enhanced by pre-stream waste management i.e. during collection and
transportation.
3. Technology Screening and Design Basis for WtE
Various technologies were evaluated for WtE considering the scale of the project,
environmental sensitivities, land area availability etc. Their advantages and dis-
advantages were discussed considering site constraint and meeting the regulatory
requirement, i.e. SWM Rules 2016.

3Report of the Task Force on Waste to Energy Volume I, 2014

TCE 10176A-2024-DPR-R- Ex. Summary Page ii

 Thermal technologies, viz. Incineration (different types of incineration), gasification and
Pyrolysis are better suited for the present scale of the project comparing biological
process such as Bio-methanation. Pyrolysis is also not yet proven for large scale
project for MSW.
4. Regulatory Framework and clearances
The proposed project does not require clearances under Acts and Rules, of Govt. of
India (GoI). The important clearances required for the project are given below:
1. Solid Waste Management Rules (2016)
2. Coastal Regulatory Zone (CRZ) Rules 2011
3. EIA notification, 2006. The project category under EIA Notification is given in
following table:

Category with threshold limit

Project or Activity Conditions if any
A B
(1) (2) (3) (4) (5)
1(d) Thermal 500 MW <500 MW (coal/ General Condition
Power Plants (coal/lignite/ naphta& lignite/ shall apply
gas based); naphtha and gas Note:
based); (i) Power plants upto
15 MW based on
biomass and using
50 MW (Pet coke <50 MW 5MW auxiliary fuel such as
diesel and all other (Petcock diesel coal, lignite, petroleum
fuels including and all other fuels products upto 15% are
refinery residual oil including refinery exempt
waste except residual oil waste (ii) Power plants upto
biomass). except biomass) 15 MW, based on non-
hazardous municipal
waste and using
auxiliary fuel such as
<20 MW>15 MW coal/ lignite/ petroleum
>20 MW (based on (based on products upto 15% are
biomass or non- biomass or non- exempt.
hazardous municipal hazardous (iii) Power plants using
solid waste as fuel). municipal solid waste heat boiler
waste as fuel). without any auxiliary
fuel are exempt.
7(i) Common All projects General Condition
Municipal shall apply
Solid Waste
Management
Facility
(CMSWMF)

TCE 10176A-2024-DPR-R- Ex. Summary Page iii

5. Project Design Concept
The ‘Technology Screening’ study clearly indicates that Incineration is one of the
potential technology which may meet the present project objectives. The feedback
from vendors and case studies of similar scale of projects worldwide has several
examples of successful WtE project based on Incineration technology. Therefore, for
present project, ‘Incineration Technology’ is adopted for feasibility study preparation of
Detailed Project Report (DPR).
The DPR is prepared considering the requirement of SWM Rules 2016. Details of
design consideration are given as below:
1. Land Area Requirement: The area of 12.19 Ha (contagious land) is identified for
the project. In this land area is sufficient for Plant and machinery, all the peripheral
infrastructure, Brick making facility from ash, Ash pond for 1.5 years, Interim
storage of inert for 1.5 years etc. The area statement is given in following table.
Table E1: land Availability and Depth of Existing MSW
Land Availability and Depth of Existing MSW
Land Area Unit Located in MSW above Remark
Parcels Avg. Ground
Level
A 1.39 Ha. Non-CRZ 3-4 m Small Land Parcel
near partial Closure
toe
B 7.5 Ha. Non-CRZ 3-11 m Main Land Parcel
C 3.3 Ha. In CRZ-II & 100 m 3-11 m Add on for Land
away from HT Line Parcel B
Total 12.19 Ha.
Note:
RL of the Average Ground level is 7m.
As per Geotechnical Survey (July-2005), average depth of MSW below average GL is
minimum 10m.
As per Contour map (December-2014), Average depth of MSW above average GL is
undulating from 3m to 11m range.

The available land parcel is also shown in Figure E1.

The available land area as given in Table E-1 above is sufficient only for WtE plant
and for interim storage of rejects (Ash and pre-processing). Ash generated from
process (Fly and bottom ash) needs to be utilized 100% in various ways.
Commonly, the fly ash is utilized in cement industries and making blocks. Bottom
ash can also be utilized for brick making and as sub-grade material for road
construction etc. Area of 2Ha is earmarked for establishing facility for utilization of
rejects.
Other rejects, i.e. pre-processing rejects and some amount of process rejects
needs to be land filled in Sanitary Landfill (SLF).

TCE 10176A-2024-DPR-R- Ex. Summary Page iv

 This land can be developed from the existing dumping site by way of transporting
of waste to other dumping sites, processing and utilization of inert in filling the low
lying areas etc. Developing SLF will require separate project provision considering
the large amount of waste lying at the site and this will also attract Environmental
and CRZ Clearances.
2. Pre-processing: The waste needs to be pre-processed to meet the requirement
of SWM Rules 2016 and also for reducing emission. Pre-processing will also
ensure the homogenisation of the waste and uniform feed quality for seasonal and
daily variation.
3. Water Treatment and other Peripheral Infrastructure: The water requirement
for the plant would be taken from Ghatkopar STP lagoon by 3.5 km pipeline along
the dumpsite. This water to be further treated for use in WtE plant.
Utilization of STP water will help in reducing the burden on fresh water resources
for the city on sustainable basis.
4. Continuous Emission Monitoring System (CEMS): CEMS is one of the
important requirements for WtE plant to monitor the emissions for regulatory
compliance and mitigation which is taken into consideration for project design.
CEMS will help in timely action for mitigation of air emissions and maintaining the
air quality to the required standard.
5. Project Layout Plan: The main objective of the proposed project is to process 600
TPD waste on regular basis. While Power generation is one of the secondary
output. For meeting this objective, the plant would have sufficient redundancy to
cater for 100% waste processing with day to day and seasonal variability in waste
quality.
6. Emission Control: The WtE plant will meet the emission standards specified
under SWM Rules 2016.
7. Reject Management: A facility for rejects management is proposed in the project
in the area of 2Ha. Further to this, additional area is required for SLF, which needs
to be developed separately.
8. Power Evacuation: The power generated from WtE plant will be evacuated
through the nearest grid. This would either be sold to DISCOM or for captive use
of MCGM. In later case, wheeling charges would be applicable.
6. Social & Environmental Analysis
There are many environmental and social benefits by implementation of WtE project.
The major social and environmental benefits of the WtE project are summarized as
below:
1. Emission control: The WtE project implementation will significantly lower the
present un-controlled emission from dump site. It will also prevent the frequent fire
at the site.

TCE 10176A-2024-DPR-R- Ex. Summary Page v

 2. Odor& Noise: The proposed WtE project will comply to the SWM Rules 2016 and
any noise or odour problem is not envisaged.
3. Rag picking: Rag picking and child labour is associated problem. The WtE project
implementation to some extent will able to combat this menace.
4. Health Benefits: The air quality of the area will improve after implementation of
this project. It is expected that many diseases like respiratory, tuberculosis etc will
come down.
5. Aesthetic Environment: The aesthetic environment will improve after project
implementation as it will reduce the dump area. The planned structure with green
belt will significantly improve the aesthetic of Deonar.
6. Employment: There would be generation of employment in formal sector after
WtE plant. This will benefit to large extent the local population.
7. Environmental Management Plan (EMP)
The EMP is prepared for Construction and Operation phase of the project. The EMP
will meet the following specific objectives:

• To adopt construction and operational methods which will limit

environmental degradation
• To protect physical environmental components such as air, water and soil
• To conserve terrestrial and aquatic flora and fauna
• To incorporate the views and perceptions of the local inhabitants on the
project
• To generate employment opportunities wherever possible and feasible
• To provide environmental guidelines and stipulations to the construction
Contractors to minimize the construction related impacts
• To provide adequate safety systems to ensure safety of public at large
• To establish post construction monitoring program to monitor effects of the
project on the environment
Apart from EMP, Risk for the project are also identified.
8. Quantity & Cost Estimate
The block cost summary cost for the project is given in following Table:

TCE 10176A-2024-DPR-R- Ex. Summary Page vi

 Table E2: Summary of Block Cost Estimate of Waste to Energy Project
Component Description Cost (INR
Crores)
Component-A Cost Centre A1.1: Site & Peripheral preparation including 162.10
1.Site Survey,
2.Geotechnical Investigation,
3.Waste Physico-chemical Characterization Study
4.Site Clearance, Excavation, Filling & Compaction
5. Compound Wall
6. Pipeline & Pumping Station
7.Preparation of Eastern Peripheral area slope
8. Landscaping
9. Storm Water Drain
Component-B Cost Centre A1.2: Design including all approvals 28.6
Component-C Cost Centre A1.3: Pre-Processing Plant 69.20
Component-D Cost Centre A1.4: Processing Plant (Electric Power Plant) including 250.00
Civil, Electrical, Mechanical, I&C, Water System, Pollution Control
Equipment, etc.
Component-E Cost Centre A1.5: Allied Infrastructure Construction: 54.5

Internal Road,Storm Water Drainage, Fire Ring main, Weighbridge,

Water Treatment Plant and Storage, Leachate Treatment Plant,
Sewage Treatment Plant, Effluent Treatment Plant, Truck Parking
area, Security Booth, Administration/Laboratory Building, Pile
FoundationCar Parking, Material Entry/Exit Gate, Visitor Entry/Exit
Gate, Workers Area, Canteen, Landscape area with irrigation system
complete, Pile Foundations, Continuous Emission Monitoring System
(CEMS), Information Communication Technology (ICT), Auxiliary
Power Supply System, Laboratory Equipments, Safety and security
arrangement including electronic surveillance, etc.
Component-F Cost Centre A1.6: Power Evacuation Line 21.20
Component-G Cost Centre A1.7: Process by-product Management and Disposal 5.00
(Ash/ Sludge/ Rejects/ other) Plant
Component-H Cost Centre A1.8: Tests on Completion and Training 9.40
Component-I Cost Centre A1.9: Provisional Sums – General 5.00
Total (Rs. Crores) 605.00

Note:
Above estimate is subject to change based on following considerations
1. MCGM Schedule of Rate (SoR): 2014, Standard Manuals, Reports and Market
2. Site clearance, excavation and filling are calculated considering complete removal of legacy waste
from the proposed plant area. There is scope for the Contractor to propose innovative technology
which may lead to reduction in cost and time of site preparation.
3. Some of the sub-components considered for above estimate may not be applicable or
may get replaced depending on the selection of the pre-processing and processing technology.
4. Prices are inclusive of all Taxes and Duties.

TCE 10176A-2024-DPR-R- Ex. Summary Page vii

 Figure E1: Land Parcel for the Proposed WtE Site

TCE 10176A-2024-DPR-R2- Ex. Summary Page viii

Figure E2: Flow Diagram for typical WtE

16% 15% 5% Water

Inert Moisture Metal and glass Requirement Electricit
(@2.5 Cum/MWhr) y

Turbine Continuous
Generator Stack
emission
monitoring
system
• Manual Segregation
Drier Feedstoc
Total Raw • Magnetic Separator WtE Plant of
MSW (600 • Screening k 600 TPD X 1 Air pollution
50 – 70% ID
TPD= 100%) • Shredder or 300 TPD X control fan
2

Air Pollution
control residue
20%
Bottom ash
4%
Fly Ash
Effluent
Treatment
Brick making &
Plant
Extent of pre-processing is as Disposal
per technology requirement To cement
plant &
Treated
Effluent
Disposal

TCE 10176A-2024-DPR-R2- Ex. Summary Page ix

9. Funding Scenario and Financial Model
The WtE project for Mumbai is very important project for efficient waste management.
The important constraints for the project are land availability (carved out from existing
dumpsite) and water (treated waste water from Ghatkopar STP). The project location
has environmental and social sensitivities. Therefore, the project cost is very high
comparing to the similar project elsewhere.
Considering the several constraints and objective of the project, DBO model is more
feasible for project implementation. In this model, the project control would be in hand
of MCGM and its close monitoring is possible. In another model, like PPP, there is a
risk of shifting of objective from waste processing to energy generation. Also, in PPP
mode, the Viability Gap Funding (VGF) would be in tune of about 50%.
Cost of Generation of Power

(i) With the project being financed by MCGM, considering 15 Years Operation Service
period the levelized is arrived at considering:
a. Recovery of only capital investment during the project life
b. Operation Service charges considered @ 2.5% per annum of the Capex Cost
with an annual escalation of 5.72% and
c. Asset Replacement Fund considered at 1% per annum of the Capex cost
The levelized tariff work out to Rs. 18.08/ kWh
(ii) Considering only Operation Service carried out by the Contractor for a period of 15
Years the levelized tariff is arrived at taking:
a. Operation Service charges considered @ 2.5% per annum of the Capex Cost
with an annual escalation of 5.72% and
b. Asset Replacement Fund considered at 1% per annum of the Capex cost
The levelized tariff works out to Rs. 7.04/kWh.
10. Project Implementation Strategy
It is proposed to award a comprehensive contract to Commission Waste to Energy
project and its Operation service, thereafter for a period of 15 years to a pre-qualified
and competitively selected private operator through an International Competitive
Bidding (ICB) process.
The project design and construction period is about 40 months, includes six months of
commissioning. The project is new technology and of very large scale. The Asset
replacement for the project is expected during 8th to 10thyear. The project needs
sufficient time for better yield. Considering all these factors, the Operation service
period for the project is considered as 15 years.

TCE 10176A-2024-DPR-R2- Ex. Summary Page x

11. Literature review
Several documents were reviewed for preparation of the DPR, this includes, IDECK
Report for 1000TPD waste processing and related RFP and RFQ documents for year
2015.
The CPHEEO Manual 2016 and SWM Rules 2016 were also referred.

TCE 10176A-2024-DPR-R2- Ex. Summary Page xi