PRE-FEASIBILITY REPORT...Pre-Feasibility Report for the Expansion of Aluminium Smelter Production...

PRE-FEASIBILITY REPORT FOR

THE EXPANSION OF ALUMINIUM SMELTER PRODUCTION

CAPACITY FROM 5.75 LTPA TO 10.85 LTPA AT VILLAGE

RISDA, TEHSIL - KORBA, DISTRICT - KORBA, CHHATTISGARH

Submitted to:

Ministry of Environment, Forest and Climate Change New Delhi

Prepared by:

M/s Bharat Aluminium Company (BALCO) Korba, Chhattisgarh

August 2017

Pre-Feasibility Report for the Expansion of Aluminium Smelter

Production Capacity from 5.75 LTPA to 10.85 LTPA at Village

Risda, Tehsil Korba, District Korba, Chhattisgarh

Bharat Aluminium Company Limited (BALCO) PFR-1

1.0 EXECUTIVE SUMMARY

1.1 Introduction

Bharat Aluminium Company (BALCO) was established at Korba, Madhya Pradesh

(presently Chhattisgarh) as a Government of India undertaking with integrated

smelter capacity of 1 LTPA (1,00,000 tonnes per annum) with Soder berg

technology employing 100 kA cells and Alumina Refinery capacity of 2 LTPA. The

plant started in 1973. BALCO was taken over in 2001 by Sterlite Industries, an

associate of Vedanta Resources, PLC.

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.

Since 2001, BALCO modernized & expanded the plant in the following manner:

(i) Setting up a 2,50,000 TPA pre-baked technology smelter and 540 MW

captive power plant employing GAMI – China 320 KA technology;

(ii) Expanding further by installation of 3.25 LTPA aluminium and 1,200 MW

(4X300 MW) captive power plant employing GAMI China 340 KA) pre baked

anode technology. While installing 3.25 LTPA smelter, original 1 LTPA

Soderberg smelter was dismantled favoring environmental friendly pre

baked technology. 3.25 LTPA smelter included 336 no 340 KA pots and

ingot casting capacity of 1.50 LTPA & wire rod of 2.00 LTPA capacity.

(iii) The previous expansion was undertaken based on the EC which was granted

by MOEF vide Lr J-11011/123/2007-IA-II(1), Dated 16.09.2008 for the

expansion of aluminium smelter plant from 3.5 LTPA to 9.0 LTPA. Under the

said EC smelter plant of 3.25 LTPA was constructed and 1 LTPA Soderberg

smelter was dismantled. However the remaining capacity of 3.25 LTPA was not

constructed due to prevailing economic scenario at that point of time. The said

EC expired in September, 2015. Now Balco is expanding its existing aluminium

production capacity by 5.1 LTPA in the area earmarked for balance 3.25 LTPA

smelter capacity by incorporating advanced state of the art environment

friendly technology.

BALCO is presently contemplating to undertake brown field expansion of the

smelter by installing 5.10 LTPA (5,10,000 TPA) by employing 500 KA cell

technology. It is proposed that the said smelter shall be constructed at the

designated area, earlier proposed for 3.25 LTPA aluminium smelter.

1.2 Project at a Glance

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





TABLE-1

PROJECT AT A GLANCE DETAILS

General Description

Type of Project Expansion of aluminium smelter capacity from 5.75

LTPA to 10.85 LTPA by addition of 5.10 LTPA capacity

Owner M/s. Bharat Aluminium Company Limited

BALCO Nagar, village Risda, tehsil Korba, district

Korba, Chhattisgarh

Location of Plant The site is located within existing BALCO Complex at,

village Risda, tehsil Korba, district Korba,

Chhattisgarh

Technology Energy efficient prebaked technology, state of art

500 KA pot line technology with Pre-baked anodes.

Inputs to Aluminium Smelter

Alumina About 1.94 T of Alumina / Tonne of Metal (or

about 9,89,400 TPA)

Calcined Petroleum

Coke, cryolite as

Na3AlF6 Aluminium

Fluoride (AlF3), CT

Pitch

Calcined Petroleum Coke: 2,04,000 TPA;

Cryolite: 1,020 TPA;

Aluminium fluoride: 7650 TPA

CT Pitch: 39,500 TPA

Land requirement 39.66 ha (98 acres). The land is already available

Power requirement About 850 MW (including auxiliary power) based

on average 12,500 Kwh/tonne (DC Power) for Pot

Line from the Captive Power Plant of BALCO

Water requirement About 2,400 m3/day (100 m3/hr) from Hasdeo

Barrage around 10 km from plant.

Manpower requirement 1,050 persons

2.0 INTRODUCTION OF THE PROJECT/ BACK GROUND INFORMATION

2.1 Identification of Project Proponent and Project

BALCO is a group company of M/s. Vedanta Aluminium Limited and Sterlite Industries

India Ltd. 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 Fibre business. VEDANTA has a growing interest in copper, aluminium,

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

America, Zambia and the U.K.

BALCO is proposing for expansion of aluminium smelter capacity from 5.75 LTPA to

10.85 LTPA by addition of 5.10 LTPA capacity in an area of 39.66 ha (98 acres) in

the existing BALCO integrated aluminium complex, which is located at village Risda,

tehsil Korba, district Korba, Chhattisgarh.





2.2 Brief Description of Nature of the Project

The existing BALCO integrated aluminium complex comprise 2 smelter units totaling

5.75 LTPA (5,75,000 TPA) smelter (2,50,000 TPA + 3,25,000 TPA) along with all

auxiliary facilities, captive power plants totaling 4 x 67.5 MW (270 MW near in

NTPC Jamanipali, Korba) , 4 x 135 MW (540 MW) and 4 x 300 MW (1200 MW) .

Now BALCO intends to install 5.10 LTPA (5,10,000 TPA) aluminium smelter and

associated facilities in the factory premises at Balco plant where in the general plant

layout, it is designated as “Brownfield Smelter” with associated facilities. Power

requirement for smelter expansion shall be met from the existing power plants.

The estimated project cost of aluminium smelter is about Rs. 7,927.04 Crores.

2.3 Need and Justification for the Project

BALCO has been the first in the Indian Aluminium Industry to produce the Alloy

Rods, which is a Feedstock for all Aluminium Alloy Conductors, needed for today’s

power transmission lines. BALCO contributes to about 20% of the country's

aluminium production. BALCO has the distinction of being the sole provider of

aluminum for Indian Defense Missiles like Prithvi, Akaash, Agni, Agni-II.

BALCO was the first major Public Sector Organization which went through the

economic reforms and disinvested to Sterlite Group in 2001. BALCO is a partially

integrated aluminium company with captive bauxite mines, captive power plants,

refineries and smelters.

In the last 44 years, BALCO has built-up a production capacity of 2,50,000 TPA of

alumina production capacity; 5,75,000 TPA of smelting capacity and expanded its

fabrication facility to include three Properzi Rod Mills, three pig casting machines,

integrated hot and cold rolling mills, and captive power plants of 270 MW + 540 MW

+ 1200 MW capacity. BALCO has received ISO-9001:2000 certification for

manufacture and supply of calcined alumina, aluminium ingots/billets, aluminium

rods and aluminium rolled products.

Present day power demand and supply scenario for BALCO plant is given in following

Table-2 & 3.

TABLE-2

EXISTING POWER GENERATION DETAILS

Sr. No Power Plant Capacity

(MW)

Total Capacity

(MW)

Net output after

Aux Consumption

(MW)

1 CPP-1 4X67.5 270 240

2 CPP-2 4X135 540 486

3 CPP-3 4X300 1200 1100

4 Total 2010 1826 Source: DPR





TABLE-3

EXISTING SMELTER PLANT POWER REQUIREMENT DETAILS

Bauxite ore requirements are being met from Mainpat mine is about 53 lakh tonnes

(5.3 million tonnes) of Bauxite reserves and Bodai-Daldali mine is about 63 lakh

tonnes (6.3 million tonnes) of Bauxite reserves.

BALCO is interested in further expansion of their aluminium production capacity by

5.10 LTPA with the available surplus power from the existing captive power plant for

meeting power demand. The power requirement for the proposed smelter plant shall

be about 850 MW.

2.4 Employment Generation

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

The total employment for smelter complex will be 1,050 persons, direct employment of

400 persons and indirect employment of 650 persons.

3.0 PROJECT DESCRIPTION

3.1 Type of the Project

The proposed expansion project deals with the expansion of aluminium smelter

capacity from 5.75 LTPA to 10.85 LTPA by addition of 5.10 LTPA capacity to the

existing capacity in an area of 39.66 ha (98 acres) in the existing BALCO integrated

aluminium complex.

3.2 Details of Alternative sites

There is no alternative sites examined for installation of aluminium smelter plant as it is

an expansion project and will be implemented within the existing land.

3.3 Location of the Project

The proposed expansion project site is within the premises of BALCO integrated

aluminium complex at village Risda, which falls in tehsil Korba, district Korba in

Chhattisgarh state. 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.

Sr. No. Smelter Plant Requirement in Smelter Plant

1 Potline-1 420 MW

2 Potline-2 530 MW

3 Proposed Expansion 850 MW

4 Total 1,800 MW





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 ALUMINIUM SMELTER

Sr. No. Description Details

1 Aluminium production

capacity

5.10 LTPA Aluminium Ingots

2 Land requirement 39.66 ha (98 acres)

3 Water consumption and

source

2,400 m3/day

Water is drawn from Hasdeo river.

4 Power consumption About 850 MW (including auxiliary power)

based on average 12,500 Kwh/tonne (DC

Power) for Pot Line from the Captive Power

Plant (CPP) of BALCO

5 Alumina requirement About 1.94 T of Alumina / Tonne of Metal

(or about 9,89,400 TPA)

6 Fuel requirement

Furnace Oil

15,000 KLPA

7 Manpower requirement 1,050 persons





FIGURE-1

INDEX MAP OF THE PROJECT SITE

Balco Project Site





FIGURE-2

STUDY AREA MAP (10 KM RADIUS)

Pre-Feasibility Report for the Expansion of Aluminium Smelter Production Capacity from 5.75 LTPA

to 10.85 LTPA at Village Risda, Tehsil Korba, District Korba, Chhattisgarh


FIGURE-3(A)

GOOGLE IMAGE MAP OF PROPOSED EXPANSION PROJECT SITE





FIGURE-3(B)

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 – Heroult

process of electrolysis and will employ State of Art 500 KA cell technology. Electrolytic

operations are proposed to be carried out at a cell amperage of 500 KA. Generally

speaking, 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, it is possible to complete the

electrolysis of oxide at a temperature of 9500C – 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. Prebaked anodes made of pitch and Calcined Petroleum Coke weighing

approximately 100 kg were used. Cathodes were mostly monolithic rammed

construction. With larger sized cells being built, self baking soderberg anodes started to

become popular. Horizontal stud & vertical stud soderberg reduction cells became more

common. Main advantage of continuous Soderberg Electrode was that the plant is very

simple affair with no provision of anode forming, baking & rodding. Soderberg

technology necessitated change to meet new demands of improved working conditions,

emission control both inside & outside pot lines and higher degree of automation.

Prebaked anode in place of Soderberg technology became the trend. 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; and

Higher Metal Purity.

The original BALCO Plant was designed based on 100 KA technology employing

continuously self-baked soderberg technology. Because of inherent suitability prebaked

anode was selected for 2,50,000 TPA expansion. The same was also envisaged for

325000 TPA expansion carried out by BALCO.

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.

A total of 376 electrolyte cells, or pots are envisaged. Cells are arranged in four pot

rooms in one pot line.

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 hyperdense phase pneumatic transport





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

scrubbing waste gas cleaning installation.

Process and Plant Characteristics of High Amperage Cells (500 KA and above)

BALCO, in their proposed expansion is planning to set up 5.10 LTPA smelter 500 KA cell

technology. Besides expansion by 5.10 LTPA by 500 KA cells, there will be billet & rolled

products together with saleable “Sow ingot’ and liquid metal.

BALCO shall be partnering with suitable technology provider and EPC Contractor for 500

KA smelter technology.

As per published information, the following KA cells are operating in India.

Hindalco: Mahan 3,60,000 TPA (AP36 Technology 360 KA)

Lapanga 3,60,000 TPA (AP36 Technology 360 KA)

NALCO : 4,75,000 TPA (180 KA to 220 KA)

2,45,000TPA (GP-320 KA, 320 KA)

Vedanta: VAL, Jharsuguda – 5,00,000 TPA (GP-320 KA, 320 KA) & (1,250,000 TPA

(GP – 340 KA, 340 KA)

BALCO – 2,50,000 TPA (GP-320 KA, 320 KA) & 3,25,000 TPA (GP – 340,

340 KA)

The above shows that maximum cell amperage operating in India is of the range of 360

KA.

The higher KA cell ratings will have the following advantages:

(i) Lowers specific energy consumption;

(ii) It reduces capital expenditure;

(iii) Requires lesser man power;

(iv) Less cell maintenance costs, control, fume treatment facilities; and

(v) Assists in faster recovery of investment.

As per published records, there are presently four (4) different super high amperage

cell technologies operating at 550-660 KA in worldwide aluminium industry.

The following Table-5 and Table-6 highlight pertinent details of 500 KA cells

technology being contemplated by BALCO.

TABLE-5

PERTINENT TECHNICAL DETAILS OF 500 KA CELLS

Sr. No. Items Units GP500-376

1 Anode Size mm 1770x770x645

2 No. of anodes piece 48

3 Operating current kA 500

4 Current density of A/cm2 0.764





Sr. No. Items Units GP500-376

anode

5 Avg current efficiency % 94.5

6 Avg voltage V 3.950

7 Stable and efficient ACD mm 44.00

8 Bath type CaF2%6.8 + MgF2%0.4 + CR2.2

9 Alumina quality India and Australia

10 Cathode resource 50% semi graphitic cathode

11 Avg. DC consumption Kwh/t.Al 12553

12 Installed nos. of pots in potline

Pots 376

13 Nos. of operating pots Pots 370

14 Daily tapping volume

per pot

Kg/p.d 3804

15 Annual tapping volume per pot

t/a 1388

16 Annual tapping volume per potline

t/a 513560

17 No. of potline 1.00

18 Total capacity t/a 513560

19 Anode requirement 24 groups/48 pieces/32 days

TABLE-6

PERTINENT TECHNICAL DETAILS OF CARBON PLANT ANODE SIX (MM)

Sr. No. Items Units GP-500-376

1 No. of anodes piece 48

2 Operating current kA 500

3 Anode requirement 24 groups/48 pieces/32 weeks

4 Daily quantity demand of anode in Potline pieces/day 564

5 Annual quantity demand of anode in Potline

pieces/day 205860

6 Annual anode rodding capacity pieces/day 207939

7 Capacity of anode rodding line piece/hour 51.27

8 Annual anode baking capacity piece/year 210040

9 Capacity of each firing system for baking furnace

piece/year 52560

10 Nos. of firing system for baking furnace

- 4.00

11 Capacity compaction of anode vibrating pieces/year 213238

12 Capacity of anode vibrating compaction by

hour

piece/hour 33.50

13 Unit weight of green anode kg/piece 1366.91

14 Capacity of mixing kneader by hour

t/h 46.49

15 Unit weight of baking anode kg/piece 1271

16 Gross volume of anode Kg/t.Al 498.42

Carbon Plant

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

comprise:





Green anode plant comprising paste preparation, green anode formation;

Baking; and

Rodding facility.

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

Green Anode Plant

Raw material used in the manufacture of anode is calcined petroleum coke and the

binder such as coal tar pitch.

The following material processing circuits will be encountered in the paste plant:

Calcined petroleum coke;

Butts and green scrap;

Ball milling of coke;

Pitch; and

Paste preparation.

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

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

scrap & liquid pitch & paste is made by kneading. Anode is 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

The following processing will be done after the anode is formed:

Cooling & storing;

Baking; and

Baked anode cleaning & storage.

The above processing requires extensive storage & movement area for materials. From

the green anode storage area, green anodes are transported by crane and roller

conveyor in suitable package to anode baking furnace.

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 rods are

positioned & secured in place with molten cast iron & used after quality check. The

anode rodding and cleaning process flow sheet is shown in Figure-8.

Casting and subsequent Operation

A casting house is envisaged to produce “Value Added Products (VAP)” by installations

of suitable furnaces and casting machines.





Anode Production Process

As the 500 KA cell technology will have different anode formation, a complete new

dedicated plant shall be installed to cater the expansion project.

Raw materials for anode manufacturing are calcined petroleum coke and liquid coal

pitch plus recycled materials (butts and green scraps) reclaimed from the process. They

are crushed, screened, ground, proportioned, preheated, mixed, compacted and baked

etc. until they are made into qualified prebake anodes.

Heavy Fuel Oil (HFO) will be utilized for baking purpose.

In the anode production process, the baked anode manufacturing is divided into the

three production sections. Raw materials preparation, Green anode manufacturing and

Anode baking. The raw materials preparation section includes storage and

transportation of calcined petroleum coke and liquid coal pitch and treatment of

recycled materials etc.; The green anode manufacturing section includes intermediate

crushing and screening of calcined petroleum coke & recycled materials, grinding,

mixing, compacting, green anode cooling and conveying and heat transfer oil heating

station etc.; and the anode baking section includes storage and transportation of

carbon blocks, anode baking, and baking fume treatment etc.

FIGURE-8

ANODE RODDING AND CLEANING FLOW SHEET





GIS Vs AIS Switchyard

Space required for per bay (Bus 1 & Bus 2 arrangement scheme) 220 kV Air

Insulated switchyard is around 17 meters per bay, 220 kV AIS is considered.

Further, the power from the proposed 220 kV AIS is evacuated to GRID through

220/400 kV rated Interconnecting Transformer (ICT). Necessary 400 kV transmission

line shall be considered for evacuating the power to grid.

3.6 Requirement and Resources

3.6.1 Land Requirement

The aluminium smelter plant and captive power plant including greenbelt is around

39.66 (98 Acres). 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 Smelter Plant 98 39.66

2 Greenbelt 35 14.17

Total for Aluminium Smelter Plant (A) 133 53.83

3.6.2 Raw Material Requirement

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

TABLE-8

DETAILS OF RAW MATERIAL REQUIREMENT

Sr. No. Description Quantity

1 Alumina 9.89 LTPA

2 Calcined Petroleum Coke 2,04,000 TPA

3 Coal Tar Pitch 39,500 TPA

4 Aluminum Fluoride 7,650 TPA

5 Heavy Diesel Oil (HDO) 40,000 KLPA

Details of raw materials chemical analysis 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

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) 12 Deg.C & 21 Deg.C 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

The total water requirement (fresh and recycled) of the smelter is about 2,400 m3/day

(100 m3/hr). Out of this, the fresh water requirement is 1400 m3/day and balance

quantity of 1000 m3/day is treated wastewater from effluent treatment plant.

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.





3.7 Waste Generation and Management

3.7.1 Wastewater Management

The total water requirement for aluminium smelter plant is 2,400 m3/day. The major

consumptive units and wastewater generation units in the smelter are cooling towers

and domestic waste from canteen and toilets is generated in the plant. The

wastewater is treated and reused for fire protection, dust suppression and gardening.

The water system flow diagram of smelter plant is given in Figure-9.

3.7.2 Storm Water Management

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 pond. The necessary drains are constructed within the plant

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

appropriate lining to prevent contamination of ground water. The stored storm water

is utilized in smelter operation. This is help to conserve the fresh water sources to

comply our zero discharge policy before reusing, water is treated in ETP to bring

back in the process.

3.7.3 Solid Waste

Solid Waste Generation in Aluminium Smelter Plant

The major categories of solid waste expected during aluminium smelter operation is

from Spent Pot Lining (SPL) and impregnation from electrolysis unit, coke fines

(burnt) and refractories from bake oven, sundry waste from plant, ladle cleaning

refractories, cast house refractory’s, effluent treatment plant sludge and domestic

solid waste etc.

In pots, solid waste is generated in the form of butts. Butts are cleared from the

various waste material attached to it and utilized in anode plant. The waste material

from the butts is reused in bath preparation in pot. The major solid waste generated

in the smelter plant is Spent Pot Lining in reduction plant, used oil from various units

and dross from cast house. Quantitative estimation of solid waste generation from

the above units is presented in Table-10. The cathode consists of carbon blocks with

refractory material lining for insulation. The life of these cathodes is approximately

72 month (1800 days working days). Over this period of time, the carbon in blocks

gets graphised and impregnated with fluoride salts resulting in reduction of pot

efficiency.





TABLE-10

SOLID WASTE DETAILS FROM SMELTER

Name of the

Residue / Waste

Brief Composition

[of major chemical

(metal etc.) constituents

in %]

Current rate of

generation per annum

Generation rate post current

expansion (if any)-

Altogether

Current Stocks (as on 31.07.2017)

Current disposal strategy

(Disposal on land, in SLF,

sold to registered recyclers,

etc.)

Potential Values

(for reuse,

recovery of metal,

etc.)

Spent Pot Lining

Carbon, Ammonia, Sodium Fluoride

12,000 T 22,000 T 53,600 T Co Processing/

SLF/ DeToxification

NIL

Used oil/Spent oil

Hydro Carbon 300 KL 500 KL 30 KL Authorized recyclers

-

ETP Sludge

Oil, Soil 17 T 30 T 0 SLF -

Anode Butt

Carbon 1,00,000 T 2,00,000 T 8,000 T Internally recycled

-

Dross Aluminium 10,000 T 20,000 T 1,200 T Authorized recyclers

0.7 Lac/T

These spent linings contain 5% to 6% fluoride. These are designated as hazardous

wastes as per the schedule of Hazardous Wastes Rules. The quantity of SPL

generated depends upon number of pot failures and hence is a function of smelter

operation. The failure of one pot generates approximately 120 tonnes of SPL.

Disposal Mechanism

Spent Pot Lining is temporarily stored under covered sheds on concrete floor to prevent

any contamination with water or land. BALCO is also promoted the use of SPL in

cement / steel industries by supplying SPL to authorised parties. A secured landfill is

constructed for the disposal of any unused SPL.

Pre-Feasibility Report for the Expansion of Aluminium Smelter Production Capacity from 5.75 LTPA

to 10.85 LTPA at Village Risda, Tehsil Korba, District Korba, Chhattisgarh


FIGURE-9

WATER BALANCE DIAGRAM FOR SMELTER PLANT





4.0 SITE ANALYSIS

4.1 Connectivity

The proposed expansion project is well connected with road network, the nearest road

is National Highway-149B (connecting Champa to Katghora) in a distance of 1 km in

west direction from the proposed expansion project site. The nearest railway station is

Korba Railway Station in a distance of 6 km in South West direction from the proposed

expansion project site.

4.2 Land Form, Land Use and Land Ownership

The total land requirement for the aluminium smelter plant including greenbelt is

around 53.83 ha (133 acres) within the existing BALCO integrated aluminium

complex. The overall land for proposed expansion project is in industrial use, which

is under the possession of BALCO.

4.3 Topography

The land in the plant site is plain with gentle slopes with a general elevation of about

250 m to 300 m above MSL and no water streams present in the site area.

The plant site comprises of industrial area and no agriculture land is involved in the

plant site. The plant area is under possession of BALCO and displacement of population

and Rehabilitation and Resettlement issues are not involved in the proposed expansion

project.

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 BALCO integrated aluminium

complex.

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: 22°23'24.5"N to 22°23'49.73"N

b) Longitude: 18°43'32.4"N to 18°44'09.5"N

2 General elevation above MSL 300 m

3 Present land use at the site Industrial land

4 Nearest highway NH-149B (1.0 km, W)

5 Nearest railway station Korba (6.0 km, SSW)

6 Nearest airport Raipur (220 km, SW)

7 Nearest town/City Korba (5.2 km, SSW)

8 Hills/valleys Nil in 15 km radius

9 Topography Plain





Sr. No. Particulars Details

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 Dense mixed Jungle, Risda (1.3 km, ESE) Protected Forest near Bhalumara (6.5 km, SSE) Protected Forest near Naktikhar (6.6 km, SE)

Protected Forest near Rampakharra (7.2 km, S) Protected Forest near Bhargaon (7.2 km, N) Protected Forest near Bundeli (9.7 km, SE)

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

14 Streams/Rivers Belgari nala (0.1 km, NW) Dhengu nala (0.1 km, S) Hasdeo river (1.5 km, W)

15 Defence Installations Nil

Industrial Development in the Study Area

The region is industrially developed with many major power plants and coal mines

operating in the study area besides existing aluminium smelter of BALCO. 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 Aluminium Smelter of BALCO 5.75

LTPA

Adjacent -

2 Captive Power Plant of 540 MW & 1200 MW BALCO

Adjacent -

3 2x250 MW Power Plant of Chhattisgarh State Electricity Board – Korba (East)

Korba 0.2 km, SSW

4 Dr. SPM Thermal Power Plant (2x250 MW)

- 1.0 km, SSW

5 2600 MW (200x3 + 500x4) MW Power Plant of National Thermal

Power Corporation

Gerwan 3.2 km, W

6 2x250 MW Power Plant of Chhattisgarh State Electricity Board – Korba (West)

Darri 4.0 km, NW

7 500 MW Power Plant of

Chhattisgarh State Electricity Board – Korba (West)

Darri 4.0 km, NW

8 Existing Coal Fields of South Eastern Coal Fields (SECL)

- 6.0 km, SW

9 Captive Power Plant of 270 MW of BALCO

Balghikhar 4.4 km, WSW

10 Industrial explosives plant of IOCL Gopalpur 8.2 km, NW





4.6 Climatic Data from the Secondary Sources

The meteorological data is collected from the IMD-Ambikapur, 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, AMBIKAPUR

Month Atmospheric

Pressure (mb) Temperature (0C) Relative

Humidity (%) Rainfall (mm)

0830 1730 Max. Min. 0830 1730

January 947.9 945.2 27.6 4.4 75 48 26.1

February 946.3 943.5 31.4 6.7 66 39 22.8

March 944.7 941.2 36.9 11.1 49 26 18.5

April 941.8 937.9 40.7 16.5 39 22 13.3

May 938.4 934.6 42.7 20.7 41 26 24.2

June 934.7 931.7 41.5 21.6 66 55 251.1

July 934.6 932.2 33.9 21.4 86 81 460.9

August 935.4 933.1 32.4 21.4 88 83 389.9

September 939.5 936.7 32.4 19.8 85 78 230.5

October 944.2 941.5 32.3 13.4 78 63 62.4

November 947.2 944.5 29.5 8.6 73 54 15.6

December 948.7 945.9 26.5 5.5 75 51 11.6

Total 1,526.9

Source: India Meteorological Department, Pune

4.7 Infrastructure Facility

Infrastructure facilities near the site are available for the transportation of material

and equipments. The fresh water requirement of the plant is meeting from the

Hasdeo river, which is located at 1.5 km NW from the project site. The nearest town

is Korba, which is well connected by road and rail and all the basic facilities are

available.

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. Land description Area

Acres Hectares

A Integrated aluminium smelter complex 948 383.63

1 Proposed smelter (old plant / brownfield /area) 98 39.66

2 Existing smelters, power plant and ancillary plant 585 236.73

3 Old Alumina plant 85 34.40





Sr. No. Land description Area

Acres Hectares

4 Road & open space 55 22.26

5 Green belt inside plant boundary 125 50.58

B Ash pond (outside plant complex) 375 151.75

C Township land (outside plant complex) 650 263.04

D Balance other land (outside plant complex

boundary, encroachment etc.

745 301.49

Grand Total ( A+B+C+D) 2,718 1099.91

The greenbelt area or green coverage in township, ash dyke and other areas is

161.87 ha (400 acres).

5.2 Brief Description of Main Process and Equipment of Different Anode

Production Facilities

5.2.1 Raw Materials Preparation

a) Storage and Transportation of Calcined petroleum coke

Calcined petroleum coke will be transported to the plant by truck or by Railway

Wagon. The coke is transferred to calcined petroleum coke silos by conveying

and lifting devices. Each existing silo has a storage capacity of 4,000 t. 2 nos.

additional silos are envisaged for the increased requirement.

b) Storage and Transportation of Liquid Coal Pitch

Liquid coal pitch transported to the plant by truck is sent to the two liquid pitch

storage tanks via pitch pump with jacket. Each storage tank has a storage

capacity of 1,000 t. 2 nos of tanks of same capacity shall be added along with

heating arrangements.

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 – 6 mm, 6 – 3 mm, 3 – 0.8 mm, 0.8 - 0 mm.

Remaining materials larger than 6mm and cokes larger than 12 mm 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 12 mm enter into the green

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

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

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

larger than 12 mm 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 17oC, 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

The green anodes sent from the green anode manufacturing shop are collated by

the collating conveyor in the carbon blocks transportation station, and stacked by





the tacking crane. In addition, the stacking crane is equipped with single anode

clamp for handling single anode. According to the baking requirement, the green

anodes stored in the station are sent by the chain conveyor to the anode baking

shop.

h) Baking Furnace Fume Treatment

The baking furnace fume contains tar, dust, and small amount of fluoride. Dry

type pollution control measure to contain tar, dust and fluoride contents of the

fume will be considered. The baking furnace fumes are conditioned, cooled and

subjected to dust collection system by bag dust collectors. The purified fume is

sent by the exhaust fan to the stack for emitting to the atmosphere.

i) 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 Room Control

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 Balco Integrated Aluminium Complex

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 to the requirement of the

smelter 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 tank located at smelter. 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 CPP and water is pumped from CPP.

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 this is filled from CPP through separate line.

Cooling Water System





The cooling system is provided for the station is natural draft type cooling towers.

Circulating cooling water flow including dissipation of the heat load of auxiliary

equipment. As per the water quality of Hasdeo water reservoir, the Total Dissolved

Solid (TDS) in water is reasonably low. Hence softening process is not considered in

the designing. Based on the source water quality the cooling tower is designed for

five Cycles of Concentration (COC), which is attainable in the cooling circuit. The

blow down from the cooling towers is utilized for ash disposal, water spray in coal

handling system, miscellaneous requirement etc.

Among chemical dozing requirements in the water system, shot chlorination in CW

circuit to contain algae growth, lime and alum dozing in pre-treatment section for

effecting coagulation and use of acid and alkali for regeneration of resin in

demineralization plant and condensate polishers are considered.

Drinking Water System

Filtered water in underground storage tank is chlorinated through gravity feed type

chlorinator to directly dose chlorine into the water. This is done at CPP. The

distribution of drinking water is done by gravity from the overhead storage tank

through a network of G.I. pipe lines laid underground/over ground to cater the

requirement of all units, plant and non-plant buildings.

Fire Water System

The basic philosophy of the fire protection system design is centred on water as the

main fire extinguishing medium, although other types of firefighting devices are

provided. The system is designed to provide adequate quantity of water at a

specified pressure. The clarified and filtered water received from power plant is used

for fire water and sprinkler system.

However, since the process for the aluminium smelter plant is based on the

electrolytic reduction, the use of water for extinguishing fire in the following

sections/units of the plant is absolutely prohibited for safety reasons:

Pot rooms including all buildings in that area;

Cathode assembly area (cast iron furnace area);

Cast house;

Baking furnace;

Rodding shop (cast iron furnace and spraying furnace area); and

Sub-stations and control rooms.

The system consists of storage, pump station and the fire water main ring with

hydrants installed along the road side at regular intervals in the off-site areas, and

rising main is provided with landing valves inside the buildings. There are two fire

water pumps, one electric driven and one diesel driven. In addition there is a jockey

pump to maintain the pressure in the fire hydrant.

Sprinkler Water System

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

and it covers following areas:





Paste Plant;

Solid pitch storage & handling building; 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 system is consists of four compressors out

of which three are power driven and one is diesel driven. Three air dryers are

provided to supply dry air to the distribution network.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

The existing BALCO aluminium smelter and captive power plant area is 271.13 ha (670

acres) and proposed expansion of smelter plant area is about 39.66 ha (98 acres). The

total industrial area after proposed expansion will be 310.79 ha (768 acres).

6.2 Residential Area (Non processing Area)

The existing township caters to the proposed expansion project employment

requirement. It is developed with a state of art combined township for employees

including security personnel and supporting staff of smelter and thermal power plant. It

have other amenities such as schools, community centre, guest house, health centre,

hospital, shopping complex, post office, bank etc.

6.3 Greenbelt

The greenbelt area in the integrated complex is 50.58 ha (125 acres). The greenbelt

area or green coverage in township, ash dyke and other areas is 161.87 ha (400 acres).

6.4 Connectivity

The proposed expansion project is well connected with network, the nearest road

network is National Highway-149B (connecting Champa to Katghora) in a distance of 1

km in west direction from the proposed expansion project site. The nearest railway

station is Korba railway station in a distance of 6 km in South South West direction from

the proposed expansion project site.

6.5 Drinking Water Management (Source & Supply of Water)

The total water requirement (fresh and recycled) of the smelter is about 2,400 m3/day

(100 m3/hr). Out of this, the fresh water requirement is 1,400 m3/day and balance

quantity of 1,000 m3/day is treated wastewater from effluent treatment plant. The

water is sourced from Hasdeo barrage. The raw water is treated in clarifier and filter

beds.

6.6 Sewage System and Industrial Waste Management

Expected quality of wastewater generated is given in Table-15.





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 capacity. Treated sewage is conformed to the

standards for land application. Oil and Grease removal system is provided. Regular

monitoring of ground water (one sample at the solid waste dump) and surface water as

part of the post-project monitoring is carried out.

Oily waste water 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 the oil free waste water is pumped to ETP.

6.7 Solid Waste Management

The major categories of solid waste expected during aluminium smelter operation is

from Spent Pot Lining (SPL) and impregnation from electrolysis unit, coke fines

(burnt) and refractories from bake oven, sundry waste from plant, ladle cleaning

refractories, cast house refractory’s, ash from captive power plant, effluent

treatment plant sludge and domestic solid waste etc.

Spent Pot Lining is temporarily stored under covered sheds on concrete floor to prevent

any contamination with water or land. BALCO is also promoted the use of SPL in

cement / steel industries by supplying SPL to authorised parties. A secured landfill is

constructed for the disposal of any unused SPL.

6.8 Power Requirement & Supply/Source

The power requirement of the proposed smelter plant is about 850 MW (including

auxiliary power) based on average 12,500 Kwh/tonne (DC Power) for Pot Line.

The power requirement is met from Captive Power Plant (CPP).

The 2 nos. of additional power evacuation line at 400 kV level is considered. Necessary

space is considered for location of additional lines and further connecting it to the

nearest Grid in smelter switch yard design.

7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN

The land allocated for the proposed expansion project is within the existing BALCO

intergraded complex. Hence, no R&R issues involved in the proposed expansion project.





8.0 PROJECT SCHEDULE & COST ESTIMATES

The estimated capital cost is Rs. 7,927.04 Crores for 5.10 LTPA aluminium smelter.

The proposed expansion project construction activities 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 BALCO and within their plant.

Water required will be availed at site from Barrage on Hasdeo river.

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

available.

As part of the Corporate Social Responsibility (CSR), BALCO is taken steps in

developing education, health, infrastructure development, women empowerment,

sports and vocational training facilities actively seeks opportunities to share its success

with the communities in areas where it operates. The Company has a long way to go in

this area and is determined to make a difference in the lives of the less fortunate.

The fields of its activities are:

Women and child care;

Direct and indirect employment of the people particularly the downtrodden;

Promotion of education;

Relief and rehabilitation;

Rural development;

Promotion and preservation of culture;

Water harvesting;

Agricultural development; and

Animal care.

PRE-FEASIBILITY REPORT...Pre-Feasibility Report for the Expansion of Aluminium Smelter Production...

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