MONITORING REPORT

Phillips Carbon Black Limited Process Waste Heat Utilization for Power Generation

UNFCCC Ref : 0309

M/s Phillips Carbon Black Limited Palej Plant, Palej-392 220, District: Baruch, Gujarat

Index Description 1. General Information 1.1 Project Activity 1.2 Project Commissioning 1.3 Monitoring Period 1.4 Monitoring Protocol 2. Monitored Results 3. Estimation of Emission Reductions for the monitoring period 3 3 3 3-6 7 8 Page No.

1. General Information 1.1 Project Activity

The project activity involves generation of electricity by utilising process flue gases from carbon black manufacturing, as fuel. The power generation process involves recovery and utilization of the thermal energy of the process waste gas (i.e. tail gas) being produced from carbon black manufacturing process, which was earlier getting lost in the atmosphere in the form of waste heat. This waste heat/ gas is utilized for generation of steam which in turn is used to generate electrical energy. The excess electricity available after meeting the in-house power demand of Phillips Carbon Black Limited (PCBL) plant, is exported to the GEB (Gujarat Electricity Board) grid.

1.2 Project Commissioning

Start date of commercial operation: Dakhin Gujarat Vij Company Limited) Dec 2004. However power export commenced from

30/3/2005 after obtaining due clearance from the Gujarat State Electricity Board subsidiary. (i.e.

1.3 Monitoring Period

The monitoring period is chosen from 30/03/2005 to 01/04/2006.

1.4 Monitoring Protocol

The monitoring protocol requires the following parameters to be monitored for the estimation of emission reductions: Net electricity exported to GEB grid Electricity import from the grid to PCBL Total electricity generated by the CPP Auxiliary electricity consumption of the CPP Net electricity consumed in-house by PCBL LDO usage in in boiler as auxiliary fuel in boiler CBFS usage in boiler as auxiliary fuel in boiler C% in LDO and CBFS

Please refer to the following table for a detail description on the Monitoring Protocol: Serial Monitoring Monitoring Parameters Uncertainty Analysis No. Equipment Record(s) Parameters required to be monitored for the estimation of Emission Reductions 1.4.1 Net electricity The data will GEB monthly 1. This meter is maintained and calibrated by GEB with a pre-calibrated meter. The meter is export/import be measured Statement in the sealed by GEB. to/from GEB by ABT meter form of Grid by the at point of certificate of sale 2. A check on the figures for export in the GEB monthly statement are maintained through a project export to GEB and electricity bill reconciliation with the records from in-house meterings for generation and auxiliary activity Grid. GEB consumption is conducted on a bi-monthly basis. would be responsible for 3. Any major discrepancies in the ABT meter reading (for example, difference between ABT regular meter and the in-house Export Meter readings or extreme deviation in the net export figure calibration. from that reported by the In-house Export Meter of CPP), if identified, will immediately be brought to the notice of GEB.

Serial No.

Parameters

Monitoring Equipment

Monitoring Record(s)

Uncertainty Analysis

Supplementary parameters required to be monitored for checking the operational performance of the power plant 1.4.2 Total In-house Daily reports 1. The In-house Generation Meter (or the Energy Meter) is a micro-processor based metering electrical Generation and Monthly device which is supplied by Enercon (I) Pvt Ltd. It is scheduled to be calibrated by the supplier energy Meter Performance every two years. Calibration is conducted during annual shutdown. generated Report 2. The monthly generation, consumption and export/import figures, are verified with each other on a monthly basis. 3. There is a defined procedure on GHG Performance Monitoring, Measurement and Reporting of Data which ensures that proper corrective actions are undertaken immediately if any discrepancies are identified in the generation, consumption and export figures (like inconsistencies in reported parameters) and/or discrepancies in the operation of the power plant.

Serial No.

Parameters

Monitoring Equipment

Monitoring Record(s)

Uncertainty Analysis

Supplementary parameters required to be monitored for checking the operational performance of the power plant Daily reports 1. The CPP auxiliary consumption will be monitored by 2 Enercon Meters for respective boiler 2 Enercon 1.4.3 Auxiliary feed pumps and a third Enercon Meter for the other auxiliaries. consumption Meters for boiler feed of the power 2. 3 other components contribute to the auxiliary consumption of the CPP borewell pumps, pumps and one plant instrument air compressor, and power loss. These are accounted for through theoretical Enercon meter calculations leading to conservative estimates. However, since CERs depend solely on for CPP authentic export and import billing figures received from GEB, these figures of auxiliary auxiliary consumption are only use as a means of inhouse monitoring. consumption 3. There is a defined procedure on GHG Performance Monitoring, Measurement and Reporting of Data which ensures that proper corrective actions are undertaken immediately if any discrepancies are identified in the generation, consumption and export figures (like inconsistencies in reported parameters) and/or discrepancies in the operation of the power plant. Serial No. Parameters Monitoring Equipment Monitoring Record(s) Uncertainty Analysis

Supplementary parameters required to be monitored for checking the operational performance of the power plant Daily log-sheet 1. LDO consumption in the boiler as start-up fuel is measured with the help of a flow-meter and The data will 1.4.4 Flow rate of recorded in the DCS of CPP and shift-wise data is maintained in the daily log-sheet of the be measured LDO during CPP. by meters at usage of same in boiler plant and 2. There is a defined procedure on GHG Performance Monitoring, Measurement and DCS. Manager as auxiliary Reporting of Data which ensures that proper corrective actions are undertaken immediately if In-charge fuel in boiler any discrepancies are identified in the LDO consumption data. would be responsible for regular calibration.

Serial No.

Parameters

Monitoring Equipment

Monitoring Record(s)

Uncertainty Analysis

Supplementary parameters required to be monitored for checking the operational performance of the power plant Daily log-sheet 1. CBFS consumption in the boiler as auxiliary fuel is measured with the help of a flow-meter The data will 1.4.5 Flow rate of and recorded in the DCS of CPP and shift-wise data is maintained in the daily log-sheet of the be measured CBFS during CPP. by meters at usage of same in boiler plant and 2. CBFS consumption in the boiler can also be cross checked from the CBFS stock register DCS. Manager as auxiliary where the CBFS consumption is recorded through tank level monitoring of CBFS storage tank. In-charge fuel in boiler would be 3. There is a defined procedure on GHG Performance Monitoring, Measurement and responsible for Reporting of Data which ensures that proper corrective actions are undertaken immediately if regular any discrepancies are identified in the CBFS consumption data. calibration.

1.4.6

C% in LDO/ CBFS

Carbon residue analysis

Lab Analysis Report

1. The C% values of CBFS is analysed by independent analyst (presently SGS) for each consignment of CBFS . For LDO, the C% is assumed at a conservative value based on Indian standards. 2. There is a defined procedure on GHG Performance Monitoring, Measurement and Reporting of Data which ensures that proper corrective actions are undertaken immediately if any observations in the C% value of LDO and CBFS (like inconsistencies in reported parameters) are identified.

Monitored Parameters

Electrical Energy
Net export to GEB grid (MkWh) Month Period as per Dakshin Gujarat VIJ Company Limited records Total electricity imported from the grid (MkWh) - measured Net units of electricity substituted in the grid (MkWh) calculated

Auxiliary Fuel consumed in the boiler

LDO consumption in the boiler (tonnes) measured CBFS consumption in the boiler (tonnes) measured C% in LDO measured C%in CBFS measured

Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06 Feb-06 Mar-06

2.699 5.956 3.590 2.387 2.869 2.950 5.617 4.241 5.628 4.071 4.518 5.566

30-3-05(1800 hrs) to 25-4-05 (1500 hrs) 25-5-05 (1500 hrs) to 01-6-05 (1200 hrs) 01-6-05 (1200 hrs) to 01-7-05 (1200 hrs) 01-7-05 (1200 hrs) to 01-8-05 (1200 hrs) 01-8-05 (1200 hrs) to 01-9-05 (1200 hrs) 01-9-05 (1200 hrs) to 01-10-05 (1200 hrs) 01-10-05 (1200 hrs) to 01-11-05 (1200 hrs) 01-11-05 (1200 hrs) to 01-12-05 (1200 hrs) 01-12-05 (1200 hrs) to 01-1-06 (1200 hrs) 01-1-06 (1200 hrs) to 01-2-06 (1200 hrs) 01-2-06 (1200 hrs) to 01-3-06 (1200 hrs) 01-3-06 (1200 hrs) to 01-4-06 (1200 hrs)

0.040 0.197 0.279 0.003 0.007 0.030 0.000 0.284 0.000 0.000 0.000 0.116

2.659 5.759 3.311 2.384 2.862 2.920 5.617 3.957 5.628 4.071 4.518 5.450

0 0.2 2.5 0 0 0 0 3.5 0 0 0 0

8.024 0.723 6.155 8.38 0.628 3.65 2.279 1.225 1.636 3.614 0.766 1.291

86% 86% 86% 86% 86% 86% 86% 86% 86% 86% 86% 86%

89.16% 88.62% 87.98% 87.32% 87.32% 89.31% 88.95% 88.58% 88.52% 88.29% 88.29% 88.24%

Emission Reduction Calculation

Baseline Emissions (BE) Baseline emission Baseline emissions factor of Western (tCO2) Regional Grid (tCO2/MkWh) Project Emissions (PE) Project emissions due to auxiliary fuel firing (tCO2) Emission Reductions (tCO2e) (BE-PE)

Month Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06 Feb-06 Mar-06

Net units of electricity substituted in the grid (MkWh) 2.659 5.759 3.311 2.384 2.862 2.920 5.617 3.957 5.628 4.071 4.518 5.450

Total

49.1354

758.61 758.61 758.61 758.61 758.61 758.61 758.61 758.61 758.61 758.61 758.61 758.61 758.61

2017.144 4368.835 2511.758 1808.526 2171.142 2215.141 4260.885 3001.820 4269.229 3088.301 3427.400 4134.425 37274.606

26.232 2.980 27.739 26.831 2.011 11.953 7.433 15.015 5.310 11.700 2.480 4.177

143.860

1990.912 4365.855 2484.019 1781.696 2169.131 2203.189 4253.452 2986.804 4263.919 3076.602 3424.920 4130.248 37130.746