REPORT ON ENVIRONMENTAL IMPACTS & ENVIRONMENT MANAGEMENT PLAN FOR INCREMENTAL INCREASE IN PRODUCTION CAPACITY DUE TO PROCESS OPTIMIZATION FROM 359 KTPA to 371 KTPA AUGMENTATION IN ALUMINIUM METAL PRODUCTION at Mahan Aluminium Unit, Orgari Village, Bargawan, Singrauli District, Madhya Pradesh Project Proponent: M/s Hindalco Industries Ltd PO - Bargawan - 486886, District Singrauli, Madhya Pradesh, India Environmental Consultants: Bhagavathi Ana Labs Pvt. Limited (A Bureau Veritas Group Company) 7-2-C14, Industrial Estate, Sanath Nagar, Hyderabad- 500018 NABET Certificate No NABET/EIA/1316/RA008 December, 2016
Report on Environmental Impacts & Environmental Management Plan for Process Optimization at Mahan Aluminium Unit, Orgari Village, Bargawan, Singrauli District, Madhya Pradesh M/s Hindalco Industries Ltd Document Reference : IND.BH.41.16.0108/HSR Revision: Final, Rev01, dated 28/12/2016 Copyright Bureau Veritas India Pvt. Ltd. All rights reserved.
REVIEW AND REVISION HISTORY History of revisions of the present report: Rev Date Modifications 00, Draft 29/07/2016 First issue for Customer review and inputs 01, Final 28/12/2016 Final issue incorporating reviews and comments Table I: History of the Revisions Document No.IND.BH.41.16.0108/HSR, Rev. 01, Final 01, Final 28/12/2016 Final Report PB ESS ESS 00, Draft 29/07/2016 Draft Report PB ESS ESS REV DATE DESCRIPTION REVIEW-1 REVIEW-2 APPROVAL Rev. 01, Final 3/20
TABLE OF CONTENTS REVIEW AND REVISION HISTORY 3 TABLE OF CONTENTS 4 ABBREVIATIONS 5 1.0 INTRODUCTION 7 1.1 PREAMBLE 7 1.2 ABOUT PROJECT PROPONENT 7 1.3 STATUS OF THE PROJECT-STATUTORY CLEARANCES 7 1.4 PROJECT PROPOSAL 9 1.5 PROJECT LOCATION 9 2.0 PROJECT DETAILS 14 2.1 Summary of Project Proposal 14 3.0 IMPACTS DURING OPERATION PHASE 16 3.1 PREAMBLE 16 3.2 PROPOSED PRODUCTION ENHANCEMENT 16 3.2.1 Pollution Load Increase 17 4.0 ENVIRONMENT MANAGEMENT PLAN 18 4.2 Ambient Air Quality 18 6.4 Greenbelt Details 18 5.0 CONCLUSION 21 Rev. 01, Final 4/20
ABBREVIATIONS 1 BALPL Bhagavathi Ana Labs Private Limited 2 BV Bureau Veritas 3 EMP Construction Environmental Management Plan 4 CPCB Central Pollution Control Board 5 CPP Captive Power Plant 6 DG Diesel Generator 7 DSIR Department for Scientific & Industrial Research 8 EC Environmental Clearance 9 EIA Environment Impact Assessment 10 EMP Environmental Management Plan 11 ES Environmental Statement 12 ESP Electro Static Precipitator 13 GoI Government of India 14 HFO Heavy Fuel Oil 15 HIL Hindalco Industries Ltd 16 ISO International Standard Organisation 17 KLD Kilo Litres per Day 18 KTPA Kilo Tonnes Per Annum 19 MoC Ministry of Coal 20 MoEF&CC Ministry of Environment, Forests and Climate Change 21 MSIHCR Manufacture, Storage and Import of Hazardous Chemicals Rules 22 R&D Research & Development 23 TPA Tonnes Per Annum 24 USEPA United States Environmental Protection Agency Rev. 01, Final 5/20
1.0 INTRODUCTION 1.1 PREAMBLE The present Report provides the study on environmental impact and Environmental Management Plan w.r.t. incremental increase in Production Capacity through process optimization at Smelter from 359 to 371 KTPA of Mahan Aluminium Unit, Village Orgari, Tehsil, Deosar, P.O- Bargawan, District Singrauli, Madhya Pradesh by M/s Hindalco Industries Ltd (HIL) hereinafter called Mahan Project. 1.2 ABOUT PROJECT PROPONENT Hindalco Industries Limited (HIL) is a flagship company of the Aditya Birla Group which is one of the largest industrial groups in India. The company is the leading manufacturer of aluminium in India. Mahan Project has an installed smelting capacity of 359 KTPA. HIL has an excellent track record with respect to productivity, energy conservation, quality control and management of environmental pollution control. Details of the Mahan smelter plant capacity, with reference to Captive Power Plant (CPP) are provided in Table-1. S. No 1 Table 1: Details of the Mahan Project of Hindalco Industries Limited Unit Location Mahan Aluminium Unit: Integrated Aluminium Smelter Complex at Village Orgari, Bargawan, District Singrauli (Previously known as District Sidhi) in the State of Madhya Pradesh MoEF&CC File No J-11011/217/2007- I.A. II (I) dated March 18,2009 Smelter Capacity (KTPA) 325 2 EC amendment on February 15, 2012. 359 1.3 STATUS OF THE PROJECT-STATUTORY CLEARANCES CPP Capacity (MW) 750 MW (5x150 MW) 900 MW (6x150 MW including standby unit of 1x150 MW) The permissions and consents for the plant as on date are summarized in Table-2. Rev. 01, Final 7/20
Table 2: Summary of the Statutory Clearances of the Project S. Permission/ Consent No A Mahan Aluminium Unit: Integrated Aluminium Smelter Complex at Village Orgari, Tehsil Bargawan, District Sidhi in the State of Madhya Pradesh Reference Letter Date MoEF&CC File No J-11011/217/2007- I.A. II (I) 1 Public Hearing for the Project 14 March, 2008 2 Original EC letter for Integrated Greenfield Aluminium Smelter Complex for 325 KTPA and CPP of 750 MW at Village Orgari, Tehsil Bargawan, District Singrauli in the State of Madhya Pradesh 18 March, 2009 3 EC amendment letter 15 February, 2012 4 Ministry of Coal, Government of India, allotted Mahan Coal Block to Hindalco Industries Ltd for captive use at Mahan Aluminium Project. 5 THE COAL MINES (SPECIAL PROVISIONS) ACT, 2015 for, coal mines and coal blocks the allocation of which was cancelled by the judgment dated 25th August, 2014 and its order dated 24 September, 2014. 6 Kathautia Coal Mine Block in favour of HIL with effect from 1 April, 2015 (No mining work is being carried out at Kathautia mine as of now by HIL due to land issues which is under litigation at the Hon ble Jharkhand High Court at Ranchi and are subject matter of four writ petitions) 7 Dumri Coal Mine Block in favour of HIL with effect from 22 April, 2015 No mining work is being carried out at Dumri mine as of now by HIL as this is a Schedule III category project, which will likely to commence coal production in FY2018) 8 Latest Consent to Operate under Air (Prevention & Control of Pollution) Act, 1981 and Water (Prevention & Control of Pollution) Act, 1974 12 April, 2006 March 30,2015 Vesting Order No. 104/3/2015/NA dated 23 March, 2015 from the Nominated Authority, MoC, GOI Vesting Order No. 104/24/2015/NA dated 22 April, 2015 from the Nominated Authority, MoC, GOI 01 June 2016 9 MoU letters to take-off fly ash 20 July 2015, 10 August 2015 Rev. 01, Final 8/20
S. Reference Letter Permission/ Consent No Date 10 Hazardous Wastes Authorization 27 April 2015 11 Long Term linkage Coal LOI issued by CIL for Mahan 24.08.2016 1.4 PROJECT PROPOSAL Through Process Optimization, HIL plans to increase the Current Amperage from the existing level of 360 ka to 372 ka. This will be achieved with the existing systems in the Smelter Plant. No installation of additional Pots or Equipment. Enhancement of input amperage will result into marginal increase (3.6 %), to the tune of 12 KTPA, in Aluminium Production Level. Necessary Thermal Balance will be achieved by adjustment of relevant Smelter Pot Room Parameters. Minor improvements will be done in Cast House and Carbon Plants to facilitate this amperage increase. No lining and Busbar changes are required to meet this enhanced amperage. 1.5 PROJECT LOCATION The Mahan Aluminium Unit project site is located at Orgari Village, Bargawan, Singrauli District, Madhya Pradesh. The project location map is given in Figure-1. The Google map is given in Figure-2. The plant layout map is given in Figure-3. The photographs of the existing plant complex are given in Figure-4. Rev. 01, Final 9/20
Process Optimization at Mahan Aluminium Unit, Orgari Village, Bargawan, Figure 1: Location Map - Mahan Plant Rev. 01, Final 10/20
Process Optimization at Mahan Aluminium Unit, Orgari Village, Bargawan, Figure 2: Google Map (10 km radius) - Mahan Plant Rev. 01, Final 11/20
Process Optimization at Mahan Aluminium Unit, Orgari Village, Bargawan, Figure 3: Plant Layout Map - Mahan Plant Rev. 01, Final 12/20
Figure 4: Project Site Photographs - Mahan Plant Rev. 01, Final 13/20
2.0 PROJECT DETAILS 2.1 Summary of Project Proposal HIL is seeking an amendment in EC for incremental increase in Production Capacity of Aluminium Smelter from 359 to 371 KTPA Through Process Optimization, HIL plans to increase the Current Amperage from the existing level of 360 ka to 372 ka. This will be achieved with the existing systems in the Smelter Plant. No installation of additional Pots or Equipment. HIL shall be doing necessary Thermal Balance by adjustment of relevant Smelter Pot Room Parameters. Minor improvements will be done in Cast House and Carbon Plants to facilitate this amperage increase. No lining and Busbar changes are required to meet this enhanced amperage. Enhancement of input amperage will result into marginal increase (3.6 %), to the tune of 12 KTPA, in Aluminium Production Level. Increase in current will lead to increased heat input Will be compensated by: Increased target metal height Reduced cover height Lower target resistance (Low AMD) Increase in current will lead to lower butt height Will be compensated by combination of following: Increased anode height Increased anode density Reduced anode change cycle time Controls through Alpsys Increase metal quantity will be tapped using modified metal tapping table. Feeding will be modified by adjusting feeding parameters Work organization for following major activities will be adjusted as per requirement: Anode change Metal Tapping Beam Raising Measurements and Bath transfer. Rev. 01, Final 14/20
Others Tapping of increased metal will be managed through existing ladles through increased ladle cleaning frequency. Increased PTA engagement will be managed by reducing breakdowns, reducing anode change and tapping time by enhancing skills through training. Metal and anode transfer will be managed by reducing breakdowns and enhancing operator skills through training. Increased metal quantity will be managed in cast house using existing set up, enhanced skill of operators through training and minor improvement jobs. Rev. 01, Final 15/20
3.0 IMPACTS DURING OPERATION PHASE 3.1 PREAMBLE The report presents impacts due to incremental increase in Production Level of Smelter (359 to 371 KTPA) Since the project is already under operation and there has not been any change in the project facilities, the changes in impacts during construction phase will not be there and have not been discussed. The impacts and mitigation w.r.t. the same have been discussed in the report. 3.2 PROPOSED PRODUCTION ENHANCEMENT Following raw materials and other requirements have been envisaged for the proposed production enhancement: Alumina - HIL will require 23500 MT of additional alumina to meet this enhanced volume. This will be sourced from HIL s Captive Alumina Plants and import, if required based on Business decision. Power - Existing installed capacity of 900 MW (5 x 150 MW Units in Operation and 1 x 150 MW Unit as Standby) will be sufficient. Water - No additional requirement. Water consumption will be within the approved limit of 4600 m3/h. Coal - Power Generation will remain within 750 MW and the coal consumption will remain within approved limit of 3.5 MTPA. Aluminium Fluoride Plant s Fluoride Consumption will remain within approved limit of 10 kg/mt of Aluminium (CREP Guidelines) Land - No additional requirement; No Forest Land is involved. Capital Investment - No additional Capital Investment is needed to meet this enhanced production capacity. Manpower - No additional Manpower requirement Addition of New Equipment - None Change in Product Portfolio - None. The Product will be Aluminium Ingot, SOWS, Billet and Wire Rod. Rev. 01, Final 16/20
3.2.1 Pollution Load Increase ETP Since there is no additional requirement of water for this enhanced production capacity, no change in Water Pollution Load. Current ETP capacity: 300 m3/h. Fluoride Level Since the increase in production capacity is very marginal (3.6 %), with the existing Gas Treatment Centre, HIL will be able to maintain the Fluoride Emission within approved limit of 0.67 kg/mt, mentioned in the EC. PAH Level No change. Will remain with the approved limit within the Existing Fume Treatment Centre. Spent Pot Lining No additional generation as there is no increase in number of Pots. Hence, from the above points, it is clear that HIL can achieve proposed additional production capacity without any negative impact to environmental systems. Rev. 01, Final 17/20
4.0 ENVIRONMENT MANAGEMENT PLAN 4.2 Ambient Air Quality Various efforts have been taken to reduce particulate matter levels in ambient air as summarized below: Proper upkeep and maintenance of vehicle, water sprinkling, sweeping on roads and construction site doing regularly for dust Suppression. Internal roads completed. GTC & FTC (Gas treatment center and Fume treatment plant) is in operation to control emission from pot room and baking furnace respectively. Stacks have been constructed with adequate height for wider dispersion of gaseous emissions. Online Continuous monitoring system has been provided for Stacks. Closed conveying system for alumina handling, completed. Bag filters provided at all transfer points to control fugitive emission. Regular water sprinkling done at site to minimize fugitive emission due to vehicle movement. Developing of green belt in and around the plant and colony is in progress. HIL has planted about 4,43,000 plants till date covering land of area 189 ha and Target to cover 33% of total land. Particulate fluoride emissions well within the limit of 0.67 kg/tonne of aluminium produced. Online continuous stack monitoring equipment installed at Gas treatment Centre (GTC) stacks of Pot room for measuring particulates and fluoride emissions. Dedusting systems are in operation at carbon plant. Water sprinklers installed in raw material (coal) handling area. Housekeeping already in place at plant premises. Suitable dust suppression system provided to control fugitive emission during material handling. HIL has already invested more than Rs. 850 Crores for pollution control and appropriate recurring cost has been earmarked for smooth running of the facilities. Control equipment is installed to restrict particulate emission below 50 mg/nm 3. 6.4 Greenbelt Details Photographs depicting greenbelt development at site are given in Figure-5. HIL has taken initiative to develop green belt right from the beginning of project stage in form of in-situ plantation under sustainable development policy. Till date HIL has Rev. 01, Final 18/20
planted more than 4.43 Lacs nos of tree sapling in different location of CPP smelter and township covering about 189 ha area, which are now in well growth with good canopy. HIL has taken a drive to increase the greenery in the premises by in situ method by direct sowing of seed at site of local species mainly Ziziphus mauritiana, Butia monosperma, mangifera indica, Acasia nilotica and acasia catechu etc since early project stage. Which has now become big tree with good canopy and compensating the environment loss. The nos of plants through in situ plantation are more than one lacks in 40 Ha. Rev. 01, Final 19/20
Figure 5: Project Site Photographs depicting Rev. 01, Final 20/20
5.0 CONCLUSION The plant has already obtained EC and is already fully equipped with effective pollution control measure and environmental management action plan. Through Process Optimization, HIL plans to increase the Current Amperage from the existing level of 360 ka to 372 ka with the existing systems in the Smelter Plant. No installation of additional Pots or Equipment has been proposed. Necessary Thermal Balance by adjustment of relevant Smelter Pot Room Parameters will be done. Minor improvements will be done in Cast House and Carbon Plants to facilitate this amperage increase. In view of the need based analysis of the project, the proposed process optimization is most required with no incremental in pollution load and is beneficial. HIL would be grateful for grant of Amendment of Existing Environmental Clearance for proposed enhancement of Aluminium Smelter Capacity from the current level of 359 KTPA to 371 KTPA through Process Optimization without any adverse impact on Environment. Plant s installed Captive Coal Based Power Plant capacity will remain at 900MW (5 x 150 MW in Operation and 1 x 150 MW as Standby). HIL requests for exemption from EIA and Public Hearing and to grant EC amendment based on the submitted detailed environmental impact analysis and EMP report. Rev. 01, Final 21/20