application for extension of validity of ......m/s. hindalco industries ltd renukoot –231217...
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APPLICATION FOR EXTENSION OF VALIDITY OF
ENVIRONMENTAL CLEARANCE
FORM-I for
MODERNISATION & EXPANSION OF
ALUMINA REFINERY & SMELTER PLANT
at
RENUKOOT, SONBHADRA DISTRICT, UTTAR PRADESH
Submitted to:
Ministry of Environment and Forests New Delhi
Submitted by:
M/s. Hindalco Industries Ltd
Renukoot –231217
Dist.Sonbhadra U.P.
September, 2018
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO
900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT,
U.P.
Page 2 of 21
FORM-I (I) BASIC INFORMATION S. No. Item Details
1. Name of the project/s Proposed Modernization and Expansion by
Hindalco Industries Ltd., Alumina Refinery
from 660 KTPA to 900 KTPA and Smelter
Plant from 356 KTPA to 472 KTPA at
Renukoot, Dist. Sonbhadra, Uttar Pradesh
as per the EC vide letter No. F. No. J-
11011/929/2008-IA-II(I) dated December
02,2011.
Through Modernization, we have enhanced
Alumina production from 660 KTPA to 720
KTPA and Aluminium Metal from 356 KTPA
to 420 KTPA by debottlenecking, improving
process, operation & maintenance
efficiency, increasing plant availability
factor and addition of balancing equipment
including 101 pots in the existing 11 pot
lines of smelter plant.
We are now seeking extension of
Environment Clearance for Alumina Plant
from 720 KTPA to 900 KTPA and Smelter
Plant from 420KTPA to 472 KTPA.
2. Sr.No. in the schedule 3 (a) 3. Proposed capacity /area/ length/ tonnage
to be handled/ command area/ lease area/number of wells to be drilled.3(a
Alumina Refinery- 660 KTPA to 900 KTPA
Alumina Smelter- 356 KTPA to 472 KTPA,
area about 9.25 hectare.
4. New/Expansion/Modernization Expansion 5. Existing Capacity/Area etc. Alumina Refinery- 720 KTPA
Alumina Smelter- 420 KTPA 6. Category of Project i.e. ‘A’ or ‘B’ ‘A’ Primary metallurgical industry –All
projects 7. Does it attract the general condition? If
yes, please specify. No
8. Does it attract the specific condition? If yes, please specify.
No
9. Location Plot/Survey/Khasra No. Village Tehsil District State
At Renukoot, Dist. Sonbhadra U.P.
Longitude :83003’ East
Latitude: 240 12’ North
No alternative sites considered, because it
is an expansion project within our existing
plant. 10. Nearest railway station/airport along with
distance in kms Renukoot Railway Station :2 km,SE Varanasi Airport :135km, N
11. Nearest Town, city, District Headquarters Dudhinagar 20km,E
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 3 of 21
S. No. Item Details
along with distance in kms District HeadquartersRobertsgunj49km,N 12. Village Panchayats, ZillaParishad,
Municipal Corporation, Local body (complete postal addresses with telephone nos. to be given)
Project site is located in Renukoot, Sonbhadra District, Uttar Pradesh.
13. Name of the applicant M/s. Hindalco Industries Ltd ,Renukoot
14. Registered Address Shri S.N.Jajoo
Chief Operating Officer(COO)
Hindalco Industries Limited,
P.O. Renukoot,
Dist: Sonbhadra,
Uttar Pradesh – 231217, 15. Address for correspondence:
Name Designation (Owner/ Partner / CEO) Pin code E-mail Telephone No. Fax No.
Shri S.N. Jajoo
Chief Operating Officer (COO)
Hindalco Industries Limited,
P.O. Renukoot,
Dist: Sonbhadra,
Uttar Pradesh – 231217,
Phone: (05446)-252077/79, 254791/96
Fax : (05446)-252107, 252427
Email: [email protected] 16. Details of Alternative Sites examined, if
any. Location of these sites should be shown on a topo-sheet.
No alternative sites considered, because it is
an expansion project within our existing
plant The location map of the project site is enclosed as Annexure-1.
17. Interlinked Projects None
18. Whether separate application of interlinked project has been submitted?
Not applicable
19. If yes, date of submission Not applicable
20. If no, reason Not applicable
21. Whether the proposal involves approval/clearance under: if yes, details of the same and their status to be given. i. The Forest (Conservation) Act, 1980? ii. The Wildlife (Protection) Act, 1972? iii. The C.R.Z. Notification, 1991?
No
22. Whether there is any Government Order/Policy relevant /relating to the site?
No
23. Forest land involved (hectares)
Nil
24. Whether there is any litigation pending against the project and/or land in which the project is propose to be set up? a) Name of the Court b) Case No.
No
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 4 of 21
S. No. Item Details
c) Orders/directions of the Court, if any and its relevance with the proposed project.
(II) ACTIVITY
1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
Sr. No.
Information/Checklist Confirmation
Yes/ No
Details thereof (with approximate quantities/ rates, wherever possible) with source of
information data 1.1 Permanent or temporary change in
land use, land cover or topography including increase in intensity of land use (with respect to local land use plan)
No There will not be any major change in
landuse, land cover or topography.
The land required for the total project is
about 9.25 hectare.
The present land use at the project site is
industrial land.
The general elevation of site is about 330-
m above MSL.
The location map and Study area Map of
the site are enclosed as Annexure-I&
Annexure-II
1.2 Clearance of existing land, vegetation and building?
Yes At present, there is no vegetation and
building at proposed site. 1.3 Creation of new land uses? Yes The proposed Modernization and Expansion
of Alumina Refinery & Smelter Plant will be
established within the premises of the
existing plant. 1.4 Pre-construction investigations,
e.g., bore houses, soil testing? No Not required.
1.5 Construction works ? Yes Construction of Pot Cells, Baking Furnace,
Boiler, Calciner, liquor tanks, Rectifier,
compressor house, turbine, Coal Circuit
etc., will be done. 1.6 Demolition Works ? No Nil. There will not be any demolition works. 1.7 Temporary sites used for
construction works or housing of construction workers?
No The construction workers will be provided
housing with the existing colony
premises.ill be done by our own employees
who reside in colony and through the
contractors who will hired labor from local
area. Thus, there will not be any housing
requirement for the construction workers at
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 5 of 21
Sr. No.
Information/Checklist Confirmation
Yes/ No
Details thereof (with approximate quantities/ rates, wherever possible) with source of
information data
the project site. 1.8 Above ground buildings, structures
or earthworks including linear structures, cut and fill or excavations.
Yes Limited excavation work will be carried out
for construction of the structures. Minimum
cut and fill is required to make the land
suitable for constructions.
Construction of Pot Cells, Baking Furnace,
Boiler, Calciner, liquor tanks, Rectifier,
compressor house, Coal Circuit etc., will be
done. 1.9 Underground works including
mining or tunneling? No Not envisaged
1.10 Reclamation works? No Not Applicable 1.11 Dredging? No Not Applicable 1.12 Offshore structures? No Not Applicable 1.13 Production and manufacturing
Process? Yes Proposed Modernization and Expansion by
Hindalco Industries Ltd., Alumina Refinery
from 660 KTPA to 900 KTPA and Smelter
Plant from 356 KTPA to 472 KTPA at
Renukoot, Dist. Sonbhadra, Uttar Pradesh
as per the EC vide letter No. F. No. J-
11011/929/2008-IA-II(I) dated December
02,2011.
Through Modernization, we have enhanced
Alumina production from 660 KTPA to 720
KTPA and Aluminium Metal from 356 KTPA
to 420 KTPA by debottlenecking, improving
process, operation & maintenance
efficiency, increasing plant availability
factor and addition of balancing equipment
including 101 pots in the existing 11 pot
lines of smelter plant.
The process description of Alumina Refinery
& Smelter plant is enclosed as Annexure-
III, along with the process flow sheet.
1.14 Facilities for storage of goods or
materials? Yes Storage of goods or materials will be stored
in existing storage area.
1.15 Facilities for treatment or disposal of solid waste or liquid effluents?
Yes Red Mud is the solid waste generated from
Bauxite refining. Rotary vacuum drum
filters will be used to convert wet mud
slurry into cake form having a solid content
of about 70%. The well transportable mud
cake (70% solids) with negligible caustic
concentration will be disposed off in area
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 6 of 21
Sr. No.
Information/Checklist Confirmation
Yes/ No
Details thereof (with approximate quantities/ rates, wherever possible) with source of
information data specially earmarked surrounded by a
strong earthen dam.
The fly ash generated in the boiler by the
burning of coal will be dry fly ash and will
be supplied to various cement and cement
based industries.
We have patented process for utilization of
spent pot lining (SPL) by recovering its
fluorine values to produce valuable cryolite,
a raw material used in smelting process. Its
residue is efficiently used in our boilers as
fuel with coal. Thus we will treat & recycle
recycled total additional SPL generated.
We have an efficient Effluent Treatment
Plant and Sewage Treatment Plant which
has sufficient capacity to treat extra
effluent generated through this expansion. 1.16 Facilities for long term housing of
operational workers? No The existing township shall cater the
requirement of Refinery & Smelter. 1.17 New road, rail or sea traffic during
construction of operation? No Existing transport facilities will be used
during construction or operation. 1.18 New road, rail, air waterborne or
other transport infrastructure including new or altered routes and stations, ports, airports etc.?
No The plant is located adjacent to at a
distance of about 0.5 km of N.H. 76 E and
State highway connecting Varanasi and
Shakti Nagar is about 17 km. 1.19 Closure or diversion of existing
transport routes or infrastructure leading to changes in traffic movements?
No Not envisaged.
1.20 New or diverted transmission lines or pipelines?
No Not envisaged.
1.21 Impoundment, damming,
culverting, realignment or other changes to the hydrology of watercourses or aquifers?
No Not required.
1.22 Stream crossings? No Not applicable 1.23 Abstraction or transfers of water
from ground or surface waters? No No additional water will be drawn for
proposed project .The water requirement
for both Refinery and Smelter together will
be about 239.58 m3/hr and will be met
through recycled water from ETP and STP. 1.24 Changes in water bodies or the No No changes in water bodies or land surface
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 7 of 21
Sr. No.
Information/Checklist Confirmation
Yes/ No
Details thereof (with approximate quantities/ rates, wherever possible) with source of
information data land surface affecting drainage or run-off?
is envisaged and hence Existing drainage
network will not be affected.work. 1.25 Transport of personnel or materials
for construction, operation or decommissioning?
Yes Project site is within the existing plant.
Existing facilities will be used for all
activities. 1.26 Long-term dismantling or
decommissioning or restoration works?
No Not envisaged.
1.27 Ongoing activity during decommissioning which could have an impact on the environment?
No Not envisaged.
1.28 Influx of people to an area in either temporarily or permanently?
Yes The construction labor will be hired from
the local area which may lead to temporary
influx of the people. will be done by our
own employees who reside in colony and
through the contractors who will took labor
from local area.
The additional manpower requirement
during operation phase will be around
1200. 1.29 Introduction of alien species? No Not envisaged 1.30 Loss of native species or genetic
diversity? No Not envisaged
1.31 Any other actions? No -
2. Use of Natural resources for construction or operation of Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply).
Sr. No.
Information/ Checklist Confirmation
Yes/ No
Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
2.1 Land specially undeveloped or agricultural land (ha)
No Proposed site is within the existing plant.
So no need to develop the new land.
2.2 Water (expected source &
competing users) unit KLD No No additional water will be drawn from
the source. The water requirement for
both Refinery and Smelter together will
be about 239.58m3/hr that will be met
through recycled water from ETP and STP.
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 8 of 21
2.3 Minerals (MT) Yes
Minerals:
Bauxite –5,15,960MTPA
Lime –9,862 MTPA
Others –
C.P.Coke – 50,000MTPA
Aluminum Fluoride-1,740 MTPA
LDO - 26420 MTPA
Coal –2,00,000MTPA
Caustic Soda –12,869 MTPA
2.4 Construction material – stone,
aggregates, and/ soil (expected source - MT)
Yes Construction material such as sand,
aggregates, soil etc., will be used.
However, the quantification of the
materials will be made during detailed
engineering stage. These materials will be
sourced from surrounding 50-km radius
area. 2.5 Forests and timber (source-MT) No Not envisaged 2.6 Energy including electricity and
fuels (source, competing users) Unit: fuel (MT), energy (MW)
Yes The power requirement for the proposed
expansion will be 169.7 MW that shall be
sourced from the Co – generation unit,
Renukoot and captive power plant at
Renusagar.
LDO – 26, 420 MTPA
Coal – 2,00,000 MTPA 2.7 Any other natural resources
(use appropriate standard units) No Not envisaged
3.0 Use, storage, transport, handling or production of substances or materials, which
could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health
S. No. Information/Checklist
Confirmation Yes/ No
Details thereof (with approximate quantities/ rates, wherever possible) with source of
information data 3.1 Use of substances or
materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies)
No No such material will be used which are
hazardous as per MSIHC rules.
3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases)
No Not envisaged
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 9 of 21
3.3 Affect the welfare of people, e.g., by changing living conditions?
No Not envisaged
3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.
No Not envisaged
3.5 Any other causes No Not envisaged 4.0 Production of solid wastes during construction or operation or decommissioning
(MT/month)
Sr. No. Information/ Checklist Confirmation
Yes/ No
Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
4.1 Spoil, overburden or mine wastes
Yes The spoil and earthwork generated during
construction will be reused for
construction as well as for filling in low
lying ine area. 4.2 Municipal waste (domestic and
or commercial wastes) Yes 10 MT/month domestic solid waste is
being generated which will be vermi-
composted and used within the plant and
colony site for plantation as manure. 4.3 Hazardous wastes (as per
hazardous waste management rules)
Yes Used Oil –37.06 KL/month, ETP Sludge -
72 MT/month and SPL-59 MT/month
will be generated.
4.4 Other industrial process wastes Yes Red Mud is the solid waste generated
from Bauxite refining. Rotary vacuum
drum filters will be used to convert wet
mud slurry into cake form having a solid
content of about 70%. The well
transportable mud cake (70% solids) with
negligible caustic concentration will be
disposed of in an area specially
earmarked surrounded by a strong
earthen dam.
The fly ash generated in the boiler by the
burning of coal will be dry fly ash and will
be supplied to various cement and
cement based industries.
We have patented process for utilization
of spent pot lining (SPL) by recovering its
fluorine values to produce valuable
cryolite, a raw material used in smelting
process. Its residue is efficiently used in
our boilers as fuel with coal. Thus we
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 10 of 21
Sr. No. Information/ Checklist Confirmation
Yes/ No
Details thereof (with approximate quantities/ rates, wherever possible) with source of information data recycled total SPL generated.
We have an efficient Effluent Treatment
Plant and Sewage Treatment Plant, which
have sufficient capacity to treat extra
effluent generated through this
expansion. 4.5 Surplus product No - 4.6 Sewage sludge or other sludge
from effluent treatment Yes Sludge from ETP and STP will be used for
plantation in red mud area. 4.7 Construction or demolition
wastes Yes This will be used internally for filling and
leveling of the sites within the plant site
area. 4.8 Redundant machinery or
equipment No Not envisaged
4.9 Contaminated soils or other materials
No Not envisaged
4.10 Agricultural wastes No Not envisaged 4.11 Other solid wastes No Not envisaged
5.0 Release of pollutants or any hazardous, toxic or noxious substances to air (kg/hr)
Sr. No. Information/Checklist Confirmation
Yes/ No
Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
5.1 Emissions from combustion of fossil fuels from stationary or mobile sources
Yes SPM, SO2 and NOx are the major
emissions from the proposed Expansion of
Refinery and Smelter and will be
controlled through efficient pollution
control equipment.
5.2 Emission from production
processes Yes SO2, PM, Fluoride and NOx emissions will be
from Alumina Refinery and Smelter.
These emissions will be controlled by
installation of efficient Electrostatic
Precipitators, FTP and Advance Dry Scrubbing
System.
Fluoride emissions from pots < 0.8kg/ton
of Aluminium.
5.3 Emissions from material
handling including storage or transport
Yes Fugitive emissions.
5.4 Emissions from construction activities including plant and
Yes The construction activities would result in
an incremental increase in the SPM levels.
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 11 of 21
Sr. No. Information/Checklist Confirmation
Yes/ No
Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
equipment
However, this is restricted to the project
site only and would be marginal and
temporary in nature. 5.5 Dust or odors from handling of
materials including construction materials, sewage and waste
Yes The construction activities may cause
changes in the SPM levels. The impact
would however be marginal, reversible
and temporary in nature.
There will not be any odor generating
substances. 5.6 Emissions from incineration of
waste No Not Envisaged
5.7 Emissions from burning of waste in open air (e.g. slash materials, construction debris)
No Not Envisaged
5.8 Emissions from any other sources
No Not Envisaged
6.0 Generation of Noise and Vibration, and emissions of Light and Heat
Sr. No. Information/ Checklist Confirmation
Yes /No
Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
6.1 From operation of equipment e.g. engines, ventilation plant, crushers
Yes Alumina Refinery - 90-105 dB(A)
Smelter plant- 91-95 dB(A)
Carbon plant- 80-95 dB(A)
Regular maintenance of the equipment
will help in reducing these noise levels.
Necessary PPEs shall be provided to
workers. 6.2 From industrial or similar
processes Yes The expected noise levels will be in the
range of 75-85 dB (A).
Regular maintenance of the equipment
will help in reducing these noise levels.
Necessary PPEs shall be provided to
workers
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 12 of 21
6.3 From construction or demolition
Yes During construction, temporary.
No demolition process.
The range will be 65-80 dB(A). Regular
maintenance of the equipment will help in
reducing these noise levels. 6.4 From blasting or piling No Not envisaged 6.5 From construction or
operational traffic Yes During construction: temporary.
During operation: less to moderate.
The noise levels are expected to be in the
range of about 70-75 dB(A). 6.6 From lighting or cooling
systems No Not envisaged
6.7 From any other sources No Not envisaged
7.0 Risks of contamination of land or water from releases of pollutants into the ground or
into sewers, surface waters, groundwater, coastal waters or the sea
Sr. No Information/Checklist Confirmation
Yes/No Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
7.1 From handling, storage, use or spillage of hazardous materials
No Not envisaged
7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)
No The sewage wastewater will be treated
and used for greenbelt development
The trade effluents will be treated and
recycled for process use. 7.3 By deposition of pollutants
emitted to air into the land or into water
No The incremental ground level
concentrations of air pollutants are likely
to be well within the permissible limits.
Hence, no impact on air is envisaged.
Hence, no risk of contamination of air,
land or water is envisaged. 7.4 From any other sources No Not envisaged 7.5 Is there a risk of long term
build up of pollutants in the environment from these sources?
No Not envisaged
8.0 Risk of accidents during construction or operation of the project, which could affect
human health or the environment
Sr. No Information/Checklist Confirmation
Yes/No Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 13 of 21
Sr. No Information/Checklist Confirmation
Yes/No Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
8.1 From explosions, spillages, fires etc. from storage, handling, use or production of hazardous substances
No No hazardous substance will be used
during construction or operation of the
project, however existing facilities for fire
fighting and to handle any emergency will
be used. 8.2 From any other causes No Not envisaged 8.3 Could the project be affected
by natural disasters causing environmental damage (e.g. floods, earthquakes, landslides, cloud burst etc)?
No There is no record of occurrence of floods,
landslides, cloudbursts etc. The proposed
project site comes under Seismic Zone-III
as per IS 1893 (Part-I):2002
classification. Hence, seismically it is a
stable zone. 9.0 Factors which should be considered (such as consequential development) which could
lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
Sr. No Information/Checklist
Confirmation Yes/No Details thereof (with approximate quantities/
rates, wherever possible) with source of information data
9.1 Lead to development of supporting, utilities, ancillary development or development stimulated by the project which could have impact on the environment e.g.: Supporting infrastructure (roads, power supply, waste or wastewater treatment, etc) Housing development Extractive industries Supply industries Other
No
No
No
Yes
No
Existing infrastructure is sufficient.
Existing township will accommodate all
the employees.
Not envisaged.
Caustic Soda manufacturer, Coal Mines
etc.
Not envisaged. 9.2 Lead to after use of the site,
which could have an impact on the environment
No No Major impacts are envisaged.
9.3 Set a precedent for later developments
No Not envisaged.
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 14 of 21
Sr. No Information/Checklist Confirmation
Yes/No Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
9.4 Have cumulative effects due to proximity to other existing or planned projects with similar effects
No Not falling under critical polluting area
hence no pollution is envisaged.
(III) ENVIRONMENTAL SENSITIVITY
Sr. No Areas Name/ Identity
Aerial distance (with 15-km)
Proposed project location boundary
1 Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value
Nil in 15-km radius area.
N.A.
2 Areas which are important or sensitive of ecological reasons – wetlands, water courses or other water bodies, coastal zone, biospheres, mountains, forests
Reserve Forest near
Dudhi RF.
Muirpur RF
Water bodies:
- RihandReservoir
(4.5-km, E)
(5.0-kms, SE)
(2.5-km, W)
3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration
Detailed Flora and Fauna
Studies will be conducted
and incorporated in EIA
report.
-
4 Inland, coastal, marine or underground waters
Nil in 15-km radius area
5 State, national boundaries Nil in 15-km radius area.
-
6 Routes or facilities used by the public for access to recreation or other tourist, pilgrim areas
Nil in 15-km radius area.
-
7 Defense installations Nil in 15-km radius area. - 8 Densely populated or built-up area Renukoot 0.5-km 9 Areas occupied by sensitive man
made land uses (hospitals, schools, places of worship, community facilities)
Yes Hospitals,
Mandir, Masjid,
Gurudwara,
Community
health centres
and schools exist
in 5 to 10-km
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 15 of 21
Sr. No Areas Name/ Identity
Aerial distance (with 15-km)
Proposed project location boundary radius area
10 Areas containing important, high quality or scarce resources (ground water resource, surface resources, forestry, agriculture, fisheries, tourism, minerals)
Nil in 15-km radius area.
-
11 Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards are exceeded)
Nil in 15-km radius area.
-
12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)
There is no record of
occurrence of floods,
landslides, cloud bursts etc.
The proposed project site
comes under Seismic Zone-
III as per IS 1893 (Part-I):
2002 classification. Hence,
seismically it is a stable
zone.
-
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 16 of 21
ANNEXURE-I
LOCATION MAP OF THE PROJECT SITE
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 17 of 21
ANNEXURE-II
10-KM RADIUS MAP OF THE PROJECT SITE
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 18 of 21
ANNEXURE - III
PROCESS DESCRIPTION OF EXTRACTION OF ALUMINA FROM BAUXITE
Conventional Bayer’s process is used for the extraction of alumina from bauxite. Bauxite
from various mines is received and unloaded with the help of Wagon Tippler. It is
crushed to minus 100 mm lumps and stock piled. Bauxite from different sources get
mixed and blended in the stockpile itself. Occasionally, a dozer is also used for this
purpose. The minus 100 mm lump bauxite in the stock pile is further crushed to minus
12 mm in hammer mills and then again wet grinded in ball mills together with the Test
tank liquor from the process to form a 50% slurry. The slurry is fed into digestors and
the alumina content of bauxite is dissolved in caustic soda at a high temperature of
2480C and 36 Kg/cm2 pressure. The digested slurry is then sent for separation of red
mud from sodium aluminate liquor. After settling, the red mud is washed free from
caustic soda, filtered in drum filters and then dumped into the earmarked low lying areas
within the complex. The areas that have already been reclaimed in this manner have
been partly used for erection of new alumina plant and partly for green belt. The sodium
aluminate liquor is filtered using filter aid as tricalcium aluminate (TCA). The alumina
hydrate from this liquor is precipitated by agitating with seed alumina hydrate in the
precipitator tanks. The precipitated alumina hydrate is classified through Seed & Product
Hydro-cyclones.
The production hydrate from the Product Cyclone underflow is filtered and washed free
of caustic and calcined in gas suspension calciner at a temperature of 1150(C to produce
calcined alumina.
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 19 of 21
ALUMINA PLANT PROCESS FLOW DIAGRAM
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 20 of 21
FUMETREATMENT
SYSTEM
FUMES
BAKING
FURNACE POT ROOM
HANDLINGBUTT & BATH
TREATMENTPLANT
FUME
PLANTGREEN ANODE
CAST HOUSE
FUEL OIL BAKED
FUEL OIL
W ATER
PITCH C.P. COKE
GREEN ANODE
BUTTS (CRUSHED)
RODDING
ROOM
USEDRODS
ANODE
PACKING COKE
RODDED ANODE
BATH (CRUSHED)
ENRICHEDALUMINA
ALUMINAFRESH
ALUMINIUM FLUORIDE
SPENT ANODES
LIQUIDMETAL
DROSSFUEL OIL
ALLOYING ELEMENTS
MAKE UP W ATER
20 K
G IN
GO
T
WIR
E R
OD
S
BIL
LET
S/S
LAB
S
SPL
ALUMINIUM SMELTING PROCESS
Hall – Heroult process of Al. extraction is an extremely energy intensive process where
primary requisite is a source of economical electrical power. Furthermore, the process
uses great quantities of high purity Alumina, Cryolite and also very low ash carbon
electrodes. These source materials have to be prepared by fairly complicated methods.
Primary Aluminium is produced by electrolytic reduction of Alumina, the process is
commonly known as Hall-Heroult Process. Alumina is dissolved in molten cryolite bath
and electrolysis is carried out in specially designed Aluminium electrolysis cells
commonly known as 'pots'. “Faraday Law of Electrolysis” governs the electrolytic
process. Electrolytic cells consist of Anode, Cathode and electrolyte.
Anode (the +ve terminal) – Prebaked, made of CP coke and coal tar pitch Cathode (the –
ve terminal) – made of cathode carbon blocks in which steel collector bars are embedded
to make electrical connection Electrolyte – Medium for carrying out electrolysis,
consisting of mainly, cryolite, aluminium fluoride and calcium fluoride in which alumina is
dissolved for electrolysis
In an electrolytic cell when DC current is passed from anode to cathode through molten
electrolyte, alumina dissolved in electrolyte is dissociated into aluminium& oxygen.
Aluminium being positively charged goes to the cathode while oxygen being negatively
charged goes to anode. Aluminium continues to deposit at cathode, which is tapped out
periodically. The consumed anodes are replaced in certain sequence periodically with
new anode to continue the process.
Hindalco Smelter has its own Carbon Plant to produce prebaked anodes, which comprises
of three sections: Green anode making plant, Bake furnaces & Rodding shop.
Hot metal goes to different casting stations Billet Casting, Slab Casting, Wire Rod, Pig
casting etc.
APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE
PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660
KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA
DISTRICT, U.P.
Page 21 of 21