FOR THE PROPOSED EXPANSION OF ALUMINIUM...

PRE-FEASIBILITY REPORT FOR

THE PROPOSED EXPANSION OF ALUMINIUM SMELTER PRODUCTION

CAPACITY FROM 16 LTPA SMELTER &1215 MW CPP TO 18 LTPA SMELTER

&1215 MW CPP AT

BHURKAMUNDA/BRUNDAMAL VILLAGE, JHARSUGUDA DISTRICT,

ODISHA

Submitted to:

Ministry of Environment, Forest and Climate Change New Delhi

Prepared by:

M/s Vedanta Limited (VL) Jharsuguda, Odisha

November, 2017

Pre-Feasibility Report for the Proposed Expansion of Aluminium

Smelter Production Capacity from 16 LTPA smelter & 1215 MW CPP to

18 LTPA smelter & 1215 MW CPP at Bhurkamunda/Brundamal Village, Jharsuguda District, Odisha

Vedanta Limited PFR-1

1.0 EXECUTIVE SUMMARY

1.1 Introduction

Vedanta Ltd. (VL) is promoted by Vedanta Resources (PLC) UK which is a non-

ferrous metals Conglomerate having mining/metal processing in India & abroad.

Vedanta Jharsuguda Plant has presently capacity of 16 LTPA corresponding to

GP-320 KA prebaked technology from GAMI, China. Vedanta group now desires

to expand Aluminium Smelter of Vedanta– Jharsuguda plants.

Vedanta – Jharsuguda aluminium smelter plant desires to increase the capacity

by 2 LTPA (2,00,000 TPA) i.e. from 16 LTPA smelter & 1215 MW CPP to 18 LTPA

smelter & 1215 MW CPP.

Vedanta is having a total revenue of more than 13 billion US$ sustaining global

leadership of nonferrous metals and optic fibre business. Vedanta has a growing

interest in copper aluminium, zinc, silver lead, iron ore, gold & optical fibre cable

in India, Australia, North America, Zambia and the UK.

1.2 Project at a Glance

The proposed expansion project at a glance is given in Table-1.

TABLE-1

PROJECT AT A GLANCE

General Description

Type of Project Expansion of aluminium smelter capacity from 16

LTPA smelter & 1215 MW CPP to 18 LTPA smelter &

1215 MW CPP

Owner M/s. Vedanta Limited (VL)

Bhurkamunda Village, Jharsuguda District, Odisha

Location of Plant The proposed expansion site is planned within the

existing plant premises of Vedanta at Bhurkamunda

Village, Jharsuguda, Odisha

Technology Energy efficient prebaked technology, state of art

340 kA pot line technology with Pre-baked anodes.

Inputs to Aluminium Smelter

Alumina About 1.93 T of Alumina / Tonne of Metal (or

about 3,86,000 TPA additional

Calcined Petroleum

Coke, cryolite as

Na3AlF6, Aluminium

Fluoride (AlF3), CT Pitch

Additional requirement for expansion:

Calcined Petroleum Coke: 74,000 TPA;

Cryolite: 400 TPA;

Aluminium fluoride: 4000 TPA;

Coal Tar Pitch: 16,000 TPA.

Land requirement Present total plant area: 2061.41 acres. Proposed

Expansion will be within the existing plant.

Power requirement Estimated additional power requirement considering





General Description

auxiliary loads, anode effects etc. would be around

350-400 MW.

Water requirement Around 1 m3 /T (or around 24 m3/hr additional) of

Aluminium. Source: Hirakud Reservoir

Manpower requirement 800 persons additional

2.0 INTRODUCTION OF THE PROJECT/ BACK GROUND INFORMATION

2.1 Identification of Project Proponent and Project

Vedanta is having a total revenue of more than 13 Billion US$ with clear focus on

achieving and sustaining global leadership in non-ferrous metals (with mining also) and

Optic Fiber business. VEDANTA has a growing interest in copper, aluminium, zinc,

silver, lead, iron ore business, Gold and Optic Fiber Cable in India, Australia, North

America, Zambia and the U.K.

Vedanta Ltd. (VL) is proposing for expansion of aluminium smelter capacity from 16

LTPA to 18 LTPA. The proposed expansion will be inside the existing plant

premises. The additional facility will be built up in an identified area of 15 acres in

the existing Vedanta Ltd Aluminium Smelter plant located at Bhurkamunda village,

Jharsuguda District, Odisha.

2.2 Brief Description of Nature of the Project

The existing Vedanta Limited Aluminium Smelter plant has 16 LTPA capacity along

with all auxiliary facilities, Green Anode Plant (GAP) of 4 x 35 TPH, Bake oven plants,

Rodding plants of 1 x 90 RPH, 1 x 160 RPH, Captive Power Plant (CPP) of 9 x 135 MW.

Further 2400 MW TPP is established in the same complex,( 3 x 600 MW CPP1 x 600 MW

TPP).

Now Vedanta intends to expand the aluminium smelter plant by 2 LTPA through

modernization and increase of current efficiency, addition of pots power would be

required for additional smelter capacity as about 13500 kwh/Tonne (DC). Estimated

additional power requirement considering auxiliary loads, anode effects etc. would be

around 350-400 MW.

The estimated project cost is about Rs. 1,240 Crores.

2.3 Need and Justification for the Project

The demand of aluminium in India and worldwide is growing rapidly. To meet the

growing demand of the aluminium, the production capacity in the country needs to

be augmented.





The debottlenecking and additional facility will be taken up in respective location at

Smelter-2 as follows.

Green Anode Plant (GAP)

Basis of calculation are as follows for smelter-2:

Requirement of anode : 1.5 anodes / day/pot

Total Consumption : 2000 anodes/day

Working days : 289

Availability : 85%

Weight of each anode : 1040 kg

Total Consumption /day : 1.04 x 2000 = 2080 T

Existing GAP design capacity: 70 TPH

GAP PRODUCTION : (70 x 24 x 0.85 x 289)/365 = 1150 TPD

Additional requirement : (2080 – 1150) = 930 TPD

New Design Capacity : 930/ (24 x 0.85 x 289/365) = 58 TPH

1 x 60 T/H GAP is recommended.

Rodding Plant :

Production : 80 RPH

Working hours : 2 shifts / day (6.5 hrs/shift)

Total production required : 2080 (in 13hrs) = 160 RPH

Extra production required : 160-80 = 80 RPH

Proposed New Design Capacity = 120 RPH

From the above it is seen that additional GAP and Rodding Plant will be required.

Storage requirement for Calcined Petroleum Coke and coal tar pitch also would require

enhancement. Original proposal for Calcined Petroleum Coke storage capacity was 4 x

7500 T of which 2 have been installed. Balance 2x7500 T Silos along with tie-in

facilities for conveyors will be sufficient for expansion.

As regards coal tar pitch storage, original considerations were 4 x1000 T of which 2

were installed. Balance tanks shall be installed along with tie-in with existing system to

cater for the expansion.

Cast House

The present capacity to cast the desire metal is already installed, whereas further

addition on capacity will be done based on requirement for value added product.

Employment Generation

The proposed expansion project will be operated with skilled and semi-skilled personal.

The total employment for expansion of smelter plant will be 800 persons of direct and

indirect employment.





3.0 PROJECT DESCRIPTION

3.1 Type of the Project

The proposed expansion project is expansion of aluminium smelter capacity from 16

LTPA smelter and 1215 MW CPP to 18 LTPA smelter and 1215 MW CPP through

modernization and additional pots and increasing current efficiency.

3.2 Details of Alternative sites

The proposed expansion of aluminium smelter capacity will be implemented within the

existing plant premises. Hence, there is no alternative sites study for this expansion

project.

3.3 Location of the Project

The proposed expansion project site is within the existing plant premises at

Bhurkamunda village, Jharsuguda district, Odisha. The index map of the project site

is shown in Figure-1. Similarly, the study area showing topographical features

within 10 km radius from the project site boundary is shown in Figure-2. The

Google image of proposed expansion project site and 10 km radius are shown in

Figure-3(A) & 3(B) respectively.

3.4 Size or Magnitude of Operation

The proposed aluminium smelter plant for production of primary aluminium metal is

given in Table-4. The overall layout plan is shown in Figure-4.

TABLE-4

PROJECT DETAILS FOR ADDITIONAL CAPACITY

Sr. No. Description Details

1 Additional Aluminium

production capacity

2 LTPA

2 Land requirement 15 acres (available land inside plant

premises)

3 Water consumption and

source

Around 1 m3 /T (or around 24 m3/hr) of

Aluminium

4 Power consumption Around 350-400 MW

5 Alumina requirement 1.93 T /Tonnes of metal (or about 3,86,000

TPA additional)

6 Fuel requirement (Furnace

Oil)

Around 100 T/day

7 Manpower requirement 800 additional





FIGURE-1

INDEX MAP OF THE PROJECT SITE

Project Site





FIGURE-2

STUDY AREA MAP (10 KM RADIUS)

Pre-Feasibility Report for the Proposed Expansion of Aluminium Smelter Production Capacity from 16 LTPA smelter and 1215 MW CPP

to 18 LTPA smelter and 1215 MW CPP at Bhurkamunda Village,

Jharsuguda District, Odisha


FIGURE-3

GOOGLE IMAGE MAP (10 KM RADIUS)





FIGURE-4

OVERALL LAYOUT PLAN





3.5 Project Description with Process Details

The process adopted for production of aluminium is the process of electrolytic reduction

of alumina to metallic aluminium as being practiced in present age advanced aluminium

smelting plant globally. The aluminium production flow sheet is shown in Figure-5.

3.5.1 Process Description of Aluminium Smelter

The process of reduction is the well-known and commercially established Hall- Héroult

process of electrolysis and will employ state of art specific amperage technology.

Electrolytic operations are proposed to be carried out at cell amperage of 340 kA.

Higher cell amperages are conducive to more economical production & tendency over

time has been to achieve higher current intensities.

The anode system proposed to be used is prebaked centre feed type. Aluminium metal

is deposited in molten form on the cathode under the electrolyte layer and is tapped

under vacuum. As the operation is continuous, alumina is charged at suitable intervals

after breaking the crust that is formed at the top of electrolyte layer.

Fume liberated at the anode during the electrolytic process consists primarily of Oxides

of Carbon & fluorine compounds. The former are obtained by Chemical reaction of the

anode mass whereas the later result from the dissociation of fluorides in the cell bath.

Additionally entrained fluorides, alumina dust are also included in liberated gases. The

gases are vented through dry scrubber type gas cleaning system.





FIGURE-5

ALUMINIUM PRODUCTION FLOW SHEET





3.5.2 Process Related Facilities

Electrolysis

Because of solubility of aluminium oxide in molten Cryolite (Na3AlF6), it is possible to

complete the electrolysis of oxide at a temperature of 950⁰ - 980⁰C. Aluminium oxide

has a melting point of 2050⁰C but is soluble in Cryolite bath upto 10% by weight. The

basic equation describing the Chemical decomposition of aluminium oxide is

2Al2O3 4Al + 3O2

Earlier electrolyte cells were small with current intensities of only several thousand

amperes. With larger sized cells being built, baked anodes started to become popular.

Some of the major factors influencing usage of baked anodes are

It allows higher current densities (presently cells with 500 KA rating or more are

in Vogue)

Distribution of magnetic flux is better & gas flow becomes favourable

Possibility of better thermal balance

Working area is comparatively free of obnoxious fumes

Higher Metal Purity

Electrolytic cell consists of a box shaped steel shell which contains the cathode and

anode assembly. Bottom of steel shell is lined with refractory bricks which support the

cathode assembly. The cathode assembly consists of blocks and cathode bar which

extends over the entire width of the cell & is externally connected to the bus bars with

flexible connectors. Anode assemblies consist of anode block and anode rods. These are

clamped to anode beam. Electrical & mechanical connection between blocks & rods is

made by means of cast iron stubs, which are locked in stub holes of anode blocks.

Pot is placed side by side in the room, completely enclosed by sheet metal hoods,

serviced by multipurpose overhead pot tending machines (PTM), fully controlled by a

process computer, connected though a central hyper dense phase pneumatic transport

system to alumina & fluoride supply & vented through a duct system to the central dry

scrubbing waste gas cleaning installation.

Carbon Plant

Smelter will be self-contained for anode requirement. Anode production facility will

comprise:

Green anode plant;

Baking Furnace; and

Rodding facility.

The process flow sheet of carbon plant is shown in Figure-6.

Green Anode Plant

Major raw material for the manufacture of GAP is Calcined Petroleum Coke & blinder

such as Coal tar pitch.





The following material processing circuits will be encountered in the Green Anode Plant.

Calcined Petroleum Coke : (around 60%)

Butts : (around 25%)

Green Scrap : (around 1%)

Pitch : (around 14%)

Paste mixing & compacting

Through different unit operations in the above circuits, different size fractions of Coarse

butts, medium, and fine coke, mill & dust are weighed, heated and mixed with green

scrap& liquid pitch and paste is made by kneading. Anode us formed by vibrating

forming machine. The process flow sheet of green anode plant is shown in Figure-7.

FIGURE-6

CARBON PLANT FLOW SHEET





FIGURE-7

GREEN ANODE PLANT FLOW SHEET

Baking Furnace

The following processing will be done after the anode is formed

Cooling & Storing

Baking

Baked Anode Clearing & Storage

The above processing requires extensive storage and movement area for materials.

From Green Anode storage area, green anodes are transported by Crane & roller

Conveyor in suitable package to anode baking furnace.

Rodding Plant

Subsequent to baking, anodes are subjected to cleaning operation and the rods which

have been removed from butts are cleaned, inspected and reused. The stub holes of

baked anodes are preheated, rods are positioned & secured in place with molten cast

Iron & used after quality check.

3.6 Requirement and Resources

3.6.1 Land Requirement

Vedanta Aluminium smelter plant along with CPP is spread over an area of 2061.41

acres. The proposed expansion will be implemented in the existing plant premises.

Land breakup of facility is given in Table-7.





TABLE-7

ITEM WISE BREAK-UP OF LAND

Sr. No Plant Unit Area (acres) Area (ha)

1 Total smelter and other areas 1234.81 499.72

2

Captive power plant incl main power plant,

green belt and ash pond area 621.48

251.51

3 Railway sidings 48.93 19.80

4 Township existing 65.19 26.38

5 Township proposed 91.00 36.826

Total 2061.41 834.236

3.6.2 Raw Material Requirement

Major raw material for smelter is smelter grade alumina. Other material will be

cryolite, aluminium fluoride, calcined petroleum coke, coal tar pitch for anode

manufacture.

Alumina will be sourced from captive refinery and also shall be imported. Aluminium

Fluoride will be imported. CP coke will be procured for indigenous or overseas

suppliers. Coal tar pitch will be procured from local sources.

The details of raw material requirement of project are presented in Table-8.

TABLE-8

DETAILS OF RAW MATERIAL REQUIREMENT

Sr. No. Description Quantity

1 Alumina 1.93 T/Tonne of metal or 386,000 TPA

additional

2 Cryolite 2 kg/T or 400 TPA

3 Calcined Petroleum Coke 0.37 T/T (gross anode consumption is around

545 kg/T) or 74000 TPA additional

4 Coal Tar Pitch 0.08 T/T or 16000 TPA additional

5 Aluminum Fluoride 20 Kg/T or 4000 TPA additional

Details of chemical analysis of raw materials is presented in Table-9.

TABLE-9

DETAILS OF CHEMICAL ANALYSIS OF RAW MATERIALS

Sr. No Details of Chemical Constituents Results

I Alumina

a Code AL2O3 Contents >%

Impurities <%

SiO2 Fe2O3 Na2O Loss on Ignition

Al2O3-1 98.6 0.02 0.03 0.50 0.8

Al2O3-2 98.5 0.04 0.04 0.55 0.8

Al2O3-3 98.4 0.06 0.04 0.55 0.8

Al2O3-4 98.3 0.08 0.04 0.60 1.0

Al2O3-5 98.2 0.10 0.05 0.60 1.0






b Other Metal Impurities Limits

TIO2 <0.005 %

V2O5 <0.003 %

P2O5 <0.003 %

ZnO <0.005 %

c Physical Characteristics

Specific surface area >35 m2/g

Α-Alumina Maximum 10%

(-) 325 mesh Maximum 10%

II Calcined Petroleum Coke

1 Moisture (max) 0.3%

2 Volatile matters (max) 0.5%

3 Ash content 0.35%

4 Iron (max) 350 ppm

5 Silicon (max) 350 ppm

6 Nickel (max) 250 ppm

7 Vanadium (max) 300 ppm

8 Sulfur 2.5 – 3.5%

9 Sodium + Calcium (max) 200 ppm

10 Real density 2.05 -2.10 g/cm3

11 Apparent density >1.70 g/cm3

12 Bulk density >0.8 g/cm3

13 Resistivity <600 m

14 Hardness index 32 – 46

III Pitch

1 Softening point (R & B) 105oC – 113oC Coking value

2 (Conardson) 54% (min)

3 QI 6 – 10%

4 TI 30 – 37%

5 Resin 20-26%

6 Density 1.15-1.30 g/cm3

7 Ash content 0.5% (max)

8 Moisture 0.5% (max)

9 Sodium 400 ppm (max)

10 Iron 200 ppm (max)

11 Sulfur 0.7% (max)

12 Viscosity 2x104 cps

13 (1600C) 3x104 cps

IV Aluminium Fluoride Special grade 1 Special grade 2

1 Fluorine as F 61 60

2 Aluminium as Al 30 30

3 Sodium as Na 0.5 0.5

4 Sulphate + Iron as SO3 + Fe2O3 0.38 0.43

5 SO4 0.5 0.8

6 Phosphorus as P2O5 0.04 0.04

7 Loss on ignition at 550oC for 30 Min. 0.5 1.0

V Fuel Oil

Heavy Diesel Oil (HDO)

1 Total Sulphur content 4.5% (Max.)

2 Gross Calorific Value (Kcal/kg) 10,000

3 Flash Point (Min.) 66 oC

4 Water content by Volume (Max.) 1.0%






5 Sediment by weight (Max.) 0.25%

6 Asphaltene content by weight (Max.) 2.5%

7 Kinematic Viscosity in Centistokes at 50o C (Max.)

370

At 98.90 C 20 – 30

8 Ash Content by weight (Max.) 0.1%

9 Acidity (in inorganic) Nil

10 Pour Point (Max .) 50 oC

11 Sodium Content --

12 Vanadium Content 25 ppm

13 Specific heat (kCal/kg. Deg. C) 0.5

14 Relative density at 15oC 0.89 (Approx)

VI Light Diesel Oil (LDO)

1 Pour Point (Max) 12⁰C& 21⁰C for Summer and Winter

respectively

2 Kinematic viscosity in centistokes at 38 Deg.C

2.5 to 15.7

3 Water content, percent by volume (Max.) 0.25

4 Sediment Percent by Mass (Max) 0.10

5 Total Sulphur percent by Mass (Max) 1.8

6 Ash percent by Mass (Max) 0.02

7 Carbon Residue (Rans bottom) percent

by Weight (Max)

1.50

8 Acidity in organic Nil

9 Flash point (Min) (Pensky Martens)

closed cup

66oC

10 Acidity Total, mg of KOH/g (Max) Nil

11 Copper strip corrosion for 3 hours at 100 oC

Not worse than No.2

12 Relative density at 15oC 0.82 – 0.86

3.6.3 Water Requirement

Make up water requirement is not substantial, around 1 m3 /T (or around 24 m3/hr-576

KLD additional) of Aluminium. Requirement would be met from existing facility.

Recirculating cooling water system using wet evaporative cooling towers are deployed

for the existing station. It is used for the condenser and auxiliary equipment cooling in

a semi-open cooling water circuit.

3.6.4 Electrical Power

For smelter, 13,500 kwh (DC)/tonne of metal will be required. Considering auxiliary

units & other factors estimated requirement of Power would be 14,200 kwh/T. Required

amount of power will be taken from 2400 MW TPP/Grid.

As there is no basic change in design of pot room and only modification and current

efficiency improvements with few pots are being added, the existing design cushions in

rectifier & transformer substation will be adequate to take care of the electrolysis

operation.





3.6.5 Fuel Oil

Fuel Oil will be required for baking furnace: 48 kg/T of baked anode would be fuel oil

requirement. Such amount (around 100 T/day) will be available from existing facility.

3.7 Waste Generation and Management

3.7.1 Wastewater Management

The additional waste water generated for Aluminium smelter plant is 576 m3/day.

The major consumptive units and wastewater generation units in the smelter are

cooling towers. The wastewater is treated and reused recycled for fire protection,

dust suppression and gardening.

Major consumption water requirement are cooling towers and domestic water. Waste

water will be treated and recycled to the extent possible. Zero-discharge policy will

be followed.

The existing ETP will be augmented for treating the wastewater generated.

3.7.2 Storm Water Management

Storm water will be collected and utilized in smelter operation.

During first showers in monsoon season, the fugitive emissions of fluorides, which

get deposited on roof top and other areas, is washed out and this rainwater is

collected in storm water guard pond. The necessary drains are constructed within the

plant area to collect the run-off water. Storm water collection pond is constructed

appropriately to prevent contamination of ground water. The stored storm water is

utilized in smelter operation after treatment in ETP.

3.7.3 Solid Waste

With expansion of the plant, the solid wastes will marginally increase which will be

taken care in ongoing solid waste management system. Anode Butts & green scrap

will be recycled in GAP. Solid waste generation details of the existing plant are given

in Table-10.





TABLE-10

ESTIMATED EXISTING SOLID WASTE GENERATION All units in Tonnes

Waste Existing generation (16 LTPA)

Proposed generation (18 LTPA)

Spent Pot lining (Cathode residues)-(T) 40,000 45,000

Used Oil (KL) 530 564

Shot blasting dust (T) 3,000 3,375

ETP Sludge (T) 520 585

Battery (Nos) 150 170

Aluminium Dross (T) 35,000 39,375

Anode Butt (T) 3,00,000 3,37,500

4.0 SITE ANALYSIS

4.1 Connectivity

The proposed expansion project is well connected with road network. Nearest road is

State Highway, SH-10 which is 1.1 km away from the site connecting Jharsuguda and

Sambalpur. The nearest railway station is Jharsuguda Railway Station at a distance of

3.9 km in NNW direction of the proposed expansion project site.

This site is located near Bhurkamunda/ Brundamal villages in Jharsuguda district of

Odisha. Sambalpur town is situated at a distance of 45 km from this area. The

Rourkela-Jharsuguda-Sambalpur broad gauge railway line is passing within a distance

2.5 km from the site. This line is connected to Titlagarh / Rayagada also. The IB Valley

coalfield is very close to this area where from coal can be brought by railway.

Site Selection Background

The basic reasons in favouring Jharsuguda - Sambalpur area for identifying the Smelter

& Captive Power Plant were as follows:

Rourkela - Jharsuguda - Sambalpur – Titlagarh Broad gauge line is passing

adjacent to this area, and this line connects all major bauxite deposits in Odisha.

The State Highway SH -10 connecting Jharsuguda and Sambalpur is also passing

through this area.

Hirakud reservoir, which is considered to be the largest water reservoir in Odisha,

is situated in this area. Availability of large quantum of water from this reservoir is

possible with reasonable pipe length.

The IB Valley area, which is one of the two major coal bearing areas of Odisha, is

spread over a large area within close vicinity.

Social infrastructural facility of Sambalpur and Jharsuguda could be utilized for

plant personnel and thus will minimize the capital investment.

The work culture of the labour force in this area is quite conducive and thus

favourable to any private entrepreneur.





4.2 Land Form, Land Use and Land Ownership

Total land requirement for aluminium smelter expansion plant including greenbelt is

around 15 acres within the existing integrated complex. The overall land for the

proposed expansion is in industrial use, which is under the possession of Vedanta.

The State Highway SH-10 is running within 1.1 km from this site.

Site was selected based on an in-depth study conducted by Vedanta, site was

selected near Brundamal-Bhurkamunda.

4.3 Topography

The land in the plant site fairly flat with a general elevation of about 200 m to 215 m

above MSL and no water streams are present in the site area.

4.4 Existing Land Use Pattern

The existing land use is already under industrial category. The proposed expansion

will be carried out within the existing premises of Vedanta aluminium smelter plant

at Jharsuguda. There is no additional land necessary for the proposed expansion

project.

4.5 Environmental Setting of the Site

The environmental setting of the existing and proposed expansion project site is given

in Table-11.

TABLE-11

ENVIRONMENTAL SETTING OF THE SITE

Sr. No. Particulars Details

1 Latitude & Longitude a) Latitude: 21048’’47”N

b) Longitude: 84002’45”E

2 General elevation above MSL 200m- 215m

3 Present land use at the site Industrial area

4 Nearest highway SH-10 (1.1 km, W), NH-200 (1.9 km, N) NH-200

5 Nearest railway station Jharsuguda Railway Station (3.9 km, NNW)

6 Nearest airport Bhubaneshwar (380 km, NW)

7 Nearest town/City Jharsuguda (3.0 km, NNW)

8 Hills/valleys Nil in 15 km radius

9 Topography Fairly Flat

10 Archaeologically important places

Nil within 15 km radial area

11 National Parks / Wildlife

Sanctuaries

Nil within 15 km radial area

12 Reserved/ Protected Forests Katikela R.F (0.1 km, NE) Shriyapali R.F (2.9 km, NE) Ghichamura R.F (5.8 km, SE) Khait R.F (6.5 km WSW)

Malda R.F (6.8 km, SW) Rampur R.F (7.7 km, SW)





Sr. No. Particulars Details

Patrapali R.F (7.8 km, SW)

13 Seismicity Seismic Zone-II as per IS 1893 (Part I): 2002

14 Streams/Rivers Kharkhari Nala, (within the plant site)

Bhedan River (0.3 km, S ) Ib River (7.6 km, W) Hirakud Reservoir (7.8 km, S)

15 Defence Installations Nil

*all values are aerial distances

Industrial Development in the Study Area

The region is industrially developed with many industries operating in the study area

besides existing aluminium smelter of Vedanta. The list of industries in 10-km radius is

given in Table-12.

TABLE-12

LIST OF INDUSTRIES IN 10-KM RADIUS

Sr. No. Name of Industry Location

(Village) Distance (km) from Plant Site/ Direction

1 L.N. Metallic Sponge Iron

Plant

Sirpura 1.7 km, SW

2 SPS Steel & Power Ltd. Badmal 2.5 km, NW

3 Bhusan Steel Plant Thelkolai 2.7 km, SW

4 Bhagwati Steels Badmal 2.7 km, NW

5 Pawansuit Sponge Iron Plant Badmal 2.9 km, NW

6 Sree Madhar Ispat Ltd.

Sponge Iron Plant

Siripali 3.1 km, NE

7 Singal Sponge Iron Hirma 3.2 km, W

8 SMC Sponge Iron Hirma 3.8 km, WSW

9 Aluminium smelter and

Captive Power Plant (CPP) of

Aditya Aluminum Project

Bamloi 4.0 km, S

10 Action Ispat Sponge Kulitodia 4.7 km, NW

11 Samleswari Sponge Iron Plant Pulcharghai 7.7 km, SSW

*all values are aerial distances

4.6 Climatic Data from the Secondary Sources

The meteorological data is collected from the IMD-Jharsuguda, which is the nearest

IMD station to the existing plant site area. The data collected from IMD includes wind

speed, temperature, relative humidity, atmospheric pressure; rainfall and cloud

cover over a period of 10 years. The monthly maximum, minimum and average

values are collected for all the parameters except wind speed and direction. The

collected data is presented in Table-13.





TABLE-13

CLIMATOLOGICAL DATA-STATION: IMD, JHARSUGUDA (1999-2004)

Month Atmospheric

Pressure (mb)

Temperature (0C) Relative

Humidity (%)

Rainfall

(mm)

0830 1730 Max. Min. 0830 1730

January 992.20 988.17 33.8 6.5 65 42 7.3

February 991.48 986.69 37.6 8.7 58 34 9.6

March 986.90 982.35 42.2 13.1 45 26 15.2

April 984.01 979.04 45.6 19.0 40 20 12.1

May 978.93 974.11 44.4 19.0 44 23 10.92

June 976.86 973.10 46.4 19.0 65 54 161.01

July 976.67 973.68 39.0 19.8 87 79 417.37

August 977.06 974.10 35.2 21.7 86 80 366.2

September 981.95 978.50 37.1 21.0 82 78 217.05

October 988.06 984.05 36.2 16.1 76 64 86.28

November 991.03 986.96 35.6 10.4 65 53 0.7

December 992.94 989.03 32.8 8.0 68 48 5.93

Total 1309.66

Source: India Meteorological Department, Pune

4.7 Infrastructure Facility

Aluminum production of capacity 16 LTPA has been operating for quite few years and

have all infrastructures required for operating such plants. VL already invested for

infrastructural facilities like road access from SH-10 to plant, township its expansion

along with hospital etc.

The proposed expansion will mainly affect GAP & Rodding plant area. Pot line

configuration will remain unchanged with just modification and addition of pots.

Residential Area will be affected to inclusion of additional manpower of around 800

personnel. Green belt was already been considered during preparation of original

layout. Additional power requirement will be sourced from 2400 MW TPP/grid.

Industrial Waste Management, drinking water management, sewage system will be

taken care of from the existing facilities.

Related road/ railway infrastructural requirement is foreseen for the expansion

project to cater the additional volume.

5.0 PLANNING BRIEF

5.1 Existing and Proposed Land Use Details

The existing and proposed plant land use details are given in Table-14.





TABLE-14

EXISTING AND PROPOSED PLANT LAND USE DETAILS

Sr. No Plant Unit Area (acres) Area (ha)

1 Total smelter and other areas 1234.81 499.72

2

Captive power plant including main power

plant, green belt and ash pond area 621.48 251.51

3 Railway sidings 48.93 19.80

4 Existing Township 65.19 26.38

5 Proposed Township 91 36.826

Total 2061.41 834.83

5.2 Brief Description of Main Process and Equipment of Different Anode

Production Facilities

5.2.1 Anode Plant (GAP, Bake Oven, Rodding)

a) Storage and Transportation of calcined petroleum coke

Calcined Petroleum Coke storage capacity of 24 x 7500 T have been installed.

Balance 2 x 7500 T Silos along with tie-in facilities for conveyors proposed.

b) Storage and Transportation of Coal Tar Pitch

2 x 1000 T installed. 2x1000 T proposed along with tie-in with existing system to

cater for the expansion.

c) Recycled Material Treatment

The recycled materials treatment section treats the reject paste, reject green

anode, and reject baked anode from mixing, compacting, anode baking and

anode rodding sections etc., as well as the recycled butts from pot room. The

recycled materials are sent by the bridge crane to suitable crushing equipment

for primary and secondary crushing, and then they are sent respectively to the

green scraps or butts silo bucket elevator and belt conveyor. The pre-crushed

butts from pot room are crushed by suitable crusher and then sent to the butts

silo via conveyors. For the recycled materials treatment, it will be stored in two

butts silos and one green scraps silo. The existing butt storage capacity would

be augmented by installing more butt silos with butt unloading facility

d) Intermediate crushing and screening of petroleum cokes and

recycled materials

The intermediate crushing and screening system of petroleum cokes treats

calcined petroleum cokes, while the intermediate crushing and screening





system of recycled materials treats butts, baked scraps and green scraps. The

main equipment of the two systems are similar, consisting of one speed-

variable impact crusher, two (for the petroleum cokes system) or one (for the

recycled materials system) horizontal vibrating screen(s).

All kinds of calcined petroleum cokes stored in the calcined materials silos are

sent to the impact crusher through volumetric feeder, belt conveyor and electro-

magnetic separator etc. Then they are sent to the two-stage horizontal

vibrating screen by the bucket elevator for being separated as the required four

kinds of grain sizes: 12 - 6mm, 6 - 3mm, 3 – 0.8mm, 0.8- 0mm. Remaining

materials larger than 6mm and cokes larger than 12mm are recycled to the

crusher for re-crushing. For the remaining materials smaller than 6mm, part

are sent to the feeding silo for grinding in the ball mill and part are stored in

the packing materials silo for baking. The packing cokes are sent to the anode

baking furnace by truck.

Green scraps, baked scraps and butts stored in the green scraps and butts silos

enter into the middle crushing and screening system of recycled materials.

Green scraps which are crushed to be smaller than 12mm enter into the green

scraps proportioning silo while those larger than 12mm are recycled to the

crusher for re-crushing. Butts are divided into two grain sizes: 12 - 3mm and 3

- 0mm. They are sent respectively to different proportioning silos while butts

larger than 12mm are recycled to crusher for re-crushing. Butts and green

scraps share one set of system that operates by turns.

e) Grinding

Petroleum cokes stored in the silo are fed into the ball mill. The oversize coarse

particles are recycled to the ball mill for re-grinding while the required fine

materials are collected by the cyclone precipitator and bag filter and then sent to

the fine materials proportioning silo.

f) Pre-heating, mixing, paste cooling, compacting, green anode cooling &

Conveying

Petroleum coke particle materials, fine materials and butts particle materials

stored in different proportioning silos are sent continuously and volumetrically to

the preheating screw by their own continuous proportioning scales as per the

required recipes for being preheated to about 17 oC, then they are sent together

with the green scraps weighed by the continuous proportioning scale according

to the ratio and the liquid pitch from the liquid pitch proportioning system to the

continuous mixer. The paste of required quality from the continuous mixer is

cooled in the paste cooler and then sent to the vibro-compactor. The compacted

green anodes are measured with height, calculated with bulk density and printed

with marks and then enter into the overhead conveyor which transports the green

anodes to the cooling tank. The cooled tested green anodes are sent to be stored

in the carbon transfer station via chain conveyor, while the reject blocks are sent

to the recycled materials treatment section via roller conveyor and fork lifts. The

reject paste is sent by bucket loader to the recycled materials treatment section





g) Anode Baking Facility

In the furnace, the green anode and packing coke will be baked according to the

preset baking curve and the anode baking temperature is about 1100C. The baked

anode is cooled with the fan. When the anode temperature is lower than 200C, it

will be unloaded and sent by the conveyor to the carbon blocks cleaning machine for

removing the packing cokes stuck on the anode. The cleaned anode is sent for

quality inspection. After that, the qualified anode is sent to the carbon blocks

transfer station and stacked by the stacking crane, or sent to the anode rodding

section. The reject block is sent to the recycled materials treatment section.

h) Baking Furnace Fume Treatment

The baking furnace is state-of-art open ring type with auto firing and computerized

temperature control system. The fume from baking furnace contains tar fume and

dust. It is used in the up-to-date open ring type baking furnace and the volatile

matters and tar could be controlled sufficiently and efficiently, so that the fume

amount and pollutants content could be reduced effectively.

It is proposed to use the treatment measure of dry type filter for the tar, dust

contents of the fume. The baking furnace fume goes into the pre-precipitator firstly

for removing the coarse dust, and then it is cooled by the spray cooling device. After

that, it enters into the dry type tar trap for removing the tar and dust the fume. The

purified fume is released through stack. There will be two baking furnaces in the

project, attached with two sets of treatment systems. Both the systems emit treated

fume through the stacks.

i) Rodding

Subsequent to baking, anodes are subjected to cleaning operation and the rods which

have been removed from butts are cleaned, inspected and reused. The stub holes of

baked anodes are preheated, rods are positioned & secured in place with molten cast

Iron & used after quality check.

j) Power Distribution of Anode Production System

The green anode manufacturing unit will be equipped with suitable transformers,

which can meet with the power supply requirements of various sections of green

anode manufacturing, and circulating water system of anode compacting.

The baking plant is equipped with transformers, which can meet with the power

supply requirements of baking unit and various auxiliary systems.

5.2.2 Pot Line & Control Philosophy

Electrolytic cell consists of a box shaped steel shell which contains the cathode and

anode assembly. Bottom of steel shell is lined with refractory bricks which support the

cathode assembly. The cathode assembly consists of blocks and cathode bar which

extends over the entire width of the cell & is externally connected to the bus bars with

flexible connectors. Anode assemblies consist of anode block and anode rods. These are





clamped to anode beam. Electrical & mechanical connection between blocks & rods is

made by means of cast iron stubs, which are locked in stub holes of anode blocks.

Pot is placed side by side in the room, completely enclosed by sheet metal hoods,

serviced by multipurpose overhead pot tending machines (PTM), fully controlled by a

process computer, connected though a central hyper dense phase pneumatic transport

system to alumina & fluoride supply & vented through a duct system to the central dry

scrubbing waste gas cleaning installation.

Operation of pots will be fully automatic and computer controlled. Two level

control is envisaged:-

a) Supervision Level of Potroom: Industrial PCs will be used for the

monitoring and supervision of computer control system of pot lines.

b) Control Level: pot controllers will be used for controlling production

process of pots.

Data communication between supervision level and control level will be through

Local Area Network bus constituted by intelligent communication boards.

Description of Control Functions

a) The following major functions shall be realized by the Pot Control System:-

Data collection & treatment

Pot resistance (voltage) control (lifting anode and lowering anode)

Normal Feed Control

Anode Effect inspection, alarm and treatment control

Anode Effect forecast and feeding control

Bus bar raising tracing

Alumina concentration control

Tapping inspection and control of pot resistance after tapping

Anode changing inspection & control of pot resistance after anode

changing

Voltage fluctuation inspection and control of pot resistance after

voltage fluctuation inspection

Aluminium fluoride feed control

Pot control during start-up

b) Main functions of master computers

Setting & modification of parameters

Preparing & printing of shift-wise, day & month-wise report data and

work order for the next shift

Displaying & printing comprehensive historical curves

Automatic annunciation / alarm of important information





5.3 Existing Facilities within Vedanta Aluminium Smelter Plant

5.3.1 Lightning Protection System

Adequate lightning protection facilities are provided as per the applicable Indian

codes of practice.

5.3.2 Fire Protection System

Adequate fire protection system is provided as per the applicable Indian codes of

practice and Tariff Advisory Committee (TAC) guidelines. Also an appropriate On-site

Disaster Management Plan (DMP) is implementing for the plant which is included in

this report.

5.3.3 Road and Site Drainage

Adequate circular and other roads are provided for smooth operation and effective

emergency response. The drainage network is constructed to prevent water

accumulation in the plant area and to avoid mixing of plant effluent with storm

water.

5.3.4 Communication

Independent telephone exchange is provided to cater the requirement of the smelter

& CPP plant complex. Intercom network is served as the main communication link for

internal communication of the plant & township.

5.3.5 Water Receipt & Storage System

Raw water is received from water reservoir through pipe lines. The drinking water

pumped and stored in overhead tanks. From overhead tank the drinking water is

supplied at various points of smelter. However, for fire water system, separate lines

are to be laid from water reservoir.

For cooling water system, only filtered water as make-up water is provided at the

battery limit of cooling towers. For the distribution of make-up water, one overhead

tank is provided at the smelter and supplied through separate line.

Cooling Water System

From the underground storage tank, filtered water will be pumped to an overhead

tank. The overhead tank will supply make-up water to various cooling towers in

smelter plant and also be an emergency source of water supply to critical units in

case of power failure.

Drinking Water System

Filtered water of underground storage tank will be chlorinated through gravity flow

type chlorinator for dosing of chlorine in water. The distribution of drinking water will

be done by gravity from the overhead storage tank through a network of G.I pipes.





Fire Water System

The system will consist of storage, pumping station and the firewater main ring with

hydrant installed along the road side to fight fire in the off-site areas, and the rising

main will be provided with isolation valves inside the buildings.

Sprinkler Water System

The system consists of storage, pumping station, sprinkler and piping manifolds etc

and will cover the following areas viz., Paste plant, Solid pitch storage and Green

anode storage.

5.3.6 Compressed Air

Compressed air system is used as plant air for the service applications, and as

instrument air for plant instruments. The overall system is consists of 12 High

Pressure compressors and 5 Low pressure compressor. All are power driven. Also Air

dryers are provided to supply dry air to the distribution network.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

The existing aluminium smelter complex and captive power plant area is 2061.41 acres

and the proposed expansion of smelter plant is about 6.0 ha (15 acres). The total

industrial area after proposed expansion will be 2,061.41 acres.

6.2 Residential Area (Non processing Area)

Housing of additional man power will be taken care of by expansion of existing township

or available social infrastructure in the vicinity.

6.3 Greenbelt

The greenbelt in the Smelter and CPP is around 527 acres. The greenbelt and green

coverage will be strengthened.

6.4 Connectivity

The proposed expansion project is well connected with road network. Nearest road is

State Highway, SH-10 which is 1.1 km away from the site connecting Jharsuguda and

Sambalpur. The nearest railway station is Jharsuguda Railway Station at a distance of

3.9 km in NNW direction of the proposed expansion project site.

6.5 Drinking Water Management (Source & Supply of Water)

Water is sourced from Hirakud reservoir. The raw water is treated in clarifier and

filter beds. The total additional water requirement (fresh and recycled) is about 576

m3/day.





6.6 Sewage System and Industrial Waste Management

Expected quality of wastewater generated is given in Table-15. Existing ETP will be

augmented with Reverse Osmosis (RO) proposed to be treated and reused in the

process.

TABLE-15

EXPECTED QUALITY OF WASTEWATER

Sr.

No.

Parameter Unit Raw

wastewater

Treated

Wastewater

Permissible Limits as

per GSR 422 (E) for

On-land Discharge (Irrigation)

1 pH - 5.5 to 9.0 6.0 to 8.5 5.5 to 9.0

2 Suspended Solids mg/l 100 to 500 < 100 200

3 Oil & Grease mg/l 10 to 200 < 5 10

4 Total Dissolved Solids

mg/l 500 to 10000 < 1000 --

5 BOD mg/l 250 to 350 < 30 100

6 COD mg/l 450 to 600 < 100 --

ETP and STP has been designed suitably. Treated sewage is conformed to the standards

for land application. Oil and grease removal system is provided. Regular monitoring of

ground water and surface water as part of the post-project monitoring is carried out.

Oily wastewater generated due to oil spills is collected in separate tanks which is having

skimmers. The skimmed waste oil from each of these areas is sent back to the oil

storage tank and oil free wastewater is pumped to ETP.

6.7 Solid Waste Management

With expansion of the plant, the solid wastes will marginally increase which will be

taken care in ongoing solid waste management system Butts & green scrap will be

recycled in GAP.

7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN

During acquisition of 2061.41 acres of land for Smelter & its infrastructure R & R plan

was duly considered and was utilized for R & R plan for development of necessary R & R

infrastructure.

As the proposed 2 LTPA expansion facility will be within existing plant premises and no

additional land acquisition is contemplated, issues of Rehabilitation & Resettlement do

not arise.

8.0 PROJECT SCHEDULE & COST ESTIMATES

The estimated capital cost is Rs. 1,240 Crores for the additional 2 LTPA Aluminium

smelter capacity.

There is no requirement of land acquisition. 2 nos. CPC silos & 2 nos. of pitch tanks

will be installed.





Pot line refurbishment will be done in the existing pot rooms together with utility tie

in facilities. GAP & Rodding plant will be executed on EPC basis. The estimated

hardware costs are as follows:

Sr.No. Facilities Cost (in Crores)

1 GAP (on EPC basis & the tie in with utilities). 350

2 Rodding Plant (on EPC basis) 250

3 Refurbishment/Construction of new pots along with

utility tie-in facilities

320

4 Infrastructure 220

5 Equipment for Pollution control Inclusive above

6 Contingency, Interest 100

Total Rs. 1240 Crores

The proposed expansion project construction activities will start after obtaining all

necessary statutory clearances from concern authorities and construction will be

completed within the 24 months.

9.0 ANALYSIS OF PROPOSAL

The proposed expansion project is likely to generate direct employment opportunities

during the operation of plant and indirect employment opportunities in the field of

transportation of employees, transportation of raw material & product to nearest port,

development of ancillary units and canteen services and greenbelt development work

etc.

The major advantage in planning the proposed expansion of aluminium smelter plant

is summarized below:

The land available is in possession of Vedanta and within their plant.

Water required will be availed at site from Hirakud Reservoir.

Existing Captive Power Plant (CPP) and other infrastructural facilities are

available.

As part of the Corporate Social Responsibility (CSR), Vedanta is to take steps in

developing education, health, infrastructure development, women empowerment,

sports and vocational training facilities etc.

FOR THE PROPOSED EXPANSION OF ALUMINIUM...

Documents

Transcript of FOR THE PROPOSED EXPANSION OF ALUMINIUM...