Expansion of Alumina Refinery from 1 MMTPA to 6 MMTPA capacity

Rapid EIA & EMP Report by GLOBAL EXPERTS, Bhubaneswar

For M/S Vedanta Aluminium Limited (VAL), Lanjigarh, Kalahandi, Orissa
Sitara D. 2011 215 008 M.E. Environmental Engg.

General Introduction
VAL Alumina Refinery: 1 MMTPA Expansion to 6 MMTPA Expand the capacity of aluminium smelter by 13.5 LTPA with

Captive Power Plant of 5 x 135 MW (675 MW) capacity at Jharsuguda, Orissa.

After expansion, the total capacity of smelter will be 16 LTPA and

1350 MW CPP.
Estimated cost, including environmental management of Rs. 593

crores = Rs.6,500 crores

Justification of the project

More than 50 % of Indias

Purpose of the study

Category A project Sub-rule(3) of rule 5 of the

bauxite deposits Orissa (2 BT) VAL to use Lanjigarh deposit of 75 MT (3.7 Km from plant) Agreement with Orissa Mining Corp. (OMC) for + 150 MT Environmental Clearance is in advanced stage with MoEF
VAL to be made world class

Environmental(Protection) Rules 1986: Environmental Clearance (EC) from MoEF

refinery with best practices

LOCATION
Within & adjacent to existing plant at Lanjigarh - Kalahandi district of Orissa. Nearest towns: Lanjigarh is 3.7km Bhawanipatna 65 Km Road access: 6.5 Km Rail access from site 21 Km Ambadola Airstrip: Utkala (80km NW) Tel river: 67 km away.

420 430 m above MSL Reserve Forests: 10 in no., 2 to 5 km distance each all directions Eco ~/ History/ Defence/ industries: None in 10 km Coal: IB valley coalfield (MCL)

Topo sheet no. 65M/6/NE

Bauxite: 3.7 Km conveyor

Lime: Katni / Jabalpur

PURPOSE

EXISTING (Ha)

ADDITIONAL (Ha)

LAND REQUIREMENT
The total area of the expanded Alumina Refinery will be

Main Plant

279.87

140.84

Red Mud

182.94

890.34

2007.72 Ha
Ash Pond
No forest land will be utilized for the project. The additional land will be acquired through IDCO. The project site is mostly barren land.

95.42

218.94

Township

52.45

28.33

Railway line

53.81

64.75

One third the area

would be covered under Green Belt.

TOTAL

664.49

1343.20

Energy requirement: Facility upgrade

Final: 250 MW Steam turbine: 3 X 25 MW + (3 X 50 MW & 2 X 30 MW) 3 X 287 TPH boilers + (5 x 320 TPH)

Steam
Calcination, boilers 16000 tons storage Bauxite digestion 140oC Coal based cogeneration 400 TPH 2200 TPH

Fuel oil

Electricity

Water requirement
Tel river 67 Km

away Intake tower, Collection field, 2stage pumping facility, 67-km pipeline of 700 mm dia., Intermediate pumping station @ Lanjigarh Road - 32 km from the plant. Expansion would be met from the allocation already available The approval for drawing 56,500 MTPD of water is already available.

Particulars CGPP Boiler and Cooling tower Refinery And Mines Cooling tower make-up and Process make-up Dust Suppression system CGPP Refinery Domestic Onsite

Existing (m3/d) 6665 5450

After expansion (m3/d) 29398 22541

480 180 120

831 300 180

Township
Total

2000
14895

3000
56250

Process description: Bayer process

Bauxite
Grinding: 80 mm to D50 350 m (< 1.2mm)

Filtrate
(Spent liquor)
Filtration: Seed filters Evaporation: MEE

water

coal

cake
Hydrate slurry tank/ Pan filtration: to produce a washed coarse hydrate cake suitable for feeding to calciners.

NaOH
Predesilication: silica impurity as Sodalite (95oC, 12 h)

overflow
Hydrate Classification: Cyclone classifier

CGPP
steam

under flow

Slaked lime
Digestion: 145oC using steam, 40 min

Alumina crystals
Heat Interchange & Precipitation: Cooling to alumina trihydrate crystals Calcination: fuel oil burner: 11000C to remove water

ash

Tri-Ca Aluminate
Clarification & Filtration:

pregnant liquor red mud (undissolved gangue, sodalite)

smelter or other requirement grade alumina

Raw material Inventory

EXPANSION REQUIREMENT
Calciners
1.0 MMTPA plant - 2 calciners -2500 TPD each. To be raised to 3000 TPD each. For 6.0 MMTPA plant, 3 more calciners of 3300 TPD capacity will be added.

PARAMETERS (Units / Tonne alumina) Bauxite (Dry Basis) T/T Caustic Soda (as Na2O) Kg/T

EXISTING 2.61 70

AFTER EXPANSION 2.58 65

Lime (CaO 70%) Kg/T

Flocculant Kg/T Furnace Oil / LDO L/T Steam T/T Coal (3500 Kcal/Kg) T/T Energy (Aluminium) KWh/T

44
0.50 72 2.1 0.67 250

50
0.40 70 1.9 0.67 220

Baseline Data collection

Study area: 10 km radius of proposed expansion project

Preliminary survey: Mar 2007

Primary data: 1 Mar 2007 - 29 Feb 2008
All 4 seasons: Pre Monsoon (Mar - May), Monsoon (Jun - Sep),

Post Monsoon (Oct Nov) & Winter (Dec - Feb) Monitoring: meteorology; quality of ambient air, surface water, groundwater; soil; noise levels; flora & fauna
Secondary data:
socio-economic profile, land use pattern etc. collected from govt.

agencies
Primary socio-economic survey - Asian Institute for Sustainable

Development, Ranchi.
Process waste generation details

Present environmental setting

Topography: Valley at foothills, Barren land, Clay soil

Geology: Denuded hills 50% study area

Hydrogeomorphology: Pediplain 32% area, flood plain Drainage: River Vamsadhara, moderately undulating pattern Land use pattern:
Particulars Forest land Study Area (ha) % of Study Area 3172.95 427.08 9524.13 3042.28 6536.29 22702.73 14.0 1.9 42.0 13.4 28.8 100.0

Land under cultivation

Irrigated Unirrigated Cultivable waste land Area not available for cultivation Total

Micro meteorology: 2007 - 2008

Location: plant site

Season

Mon- Temperatur Rel. Humid. th e oC % Max Min 15.0 19.0 20.0 21.5 8.30 hrs 71.0 68.5 76.0 79.1

Rain mm

At. Pressure mb 8.30 hrs 17.30 hrs

Cloud cover Max 1/8 1/8 3/8 0

17.30 Tohrs tal 13.5 15.5 18.0 63.6 6.5 9.5 19.0 421

Pre m. Mar Apr May Monsoon (m.) Jun

39.0 41.5 41.0 41.5

979.9 978.8 979.7 975.3 978.4 973.8 969 967

Jul
Aug Sep Oct Nov Dec Jan Feb

34.5
34.5 33.5 39.0 33.0 30.6 30.7 32.7

22.5
21.0 21.5 19.0 15.0 10.6 8.4 10.0

92.2
91.4 86.5 88.0 79.0 78.7 81.8 80.3

70.7
77.0 80.1 38.0 32.0 43.9 38.3 40.2

146
802 325 52.0 182 0 12.5 2.5

971
968 971

970
967 969

1
1 1 1/8 3/8

Post m. Winter

997.0 996.0 997.0 996.0 979.6 978.7 978.4 978.4 979.0 977.8

Season

Predominant wind direction [%] First Second ESE [12.8] SE [10]

Predominant wind speed kmph 0.92 to 3.54 0.63 to 14.29 7.56 to 20.5 7.56 to 8.28

Calm

% 6.34 8.30

Wind pattern
Location: plant site

Pre m. Monsoon

SE [15.5] SW [27.5]

Post m.
Winter

SW [14.5]
NNE [50.4]

SE [11.2]
NE [ 27.5]

0.82 to 3.12 0.72 to 11.29

0.5 to 2.1

15.10
14.10

Summarized (Annual) Ambient air quality status: 2007 - 2008 Compliance to CPCB, IS: 5182 2 AAQM stations at plant site 8 AAQM stations in 10 km radius - rural setting working & residential places 7 crosswind & 1 downwind direction Parameters: SPM, RPM, SO2, NOX

Site Code A1 A2 A3 A4 A5

Station distance from site km Project office Power block 4W 3.5 NW 2.5 SW

Average annual concentration g/m3 SPM 217.85 268.7 137.95 82.55 140.55 RPM 79.6 104.85 65.55 44.5 72.05 SO2 15.2 19.45 9.55 6 7.25 NOX 22.5 31.1 12.4 10.25 12.75

A6
A7 A8 A9 A10

1.5 SW (downwind)
6.2 SW 3.8 N 5.5 E 3.5 SW

147.5
153.8 148.15 177.7 100.75

79.7
77.8 65.3 83.8 48.15

15.05
7.8 7.35 6.75 7.1

24.95
12.55 10.95 11.1 12.25

No material used in the alumina refinery generates PAH, unlike in smelters. However, as advised in the TOR condition, the same has been measured in May 2008 and is found to be BDL.

Ambient air quality - summary

SPM and RPM concentrations are within the Industrial permissibile

Limit at plant site and red mud pond areas mostly during postmonsoon and winter periods.
In alignment with SPM & RPM, the SO2 and NOx values are

comparatively higher in the same areas during the same period but are well within the standards prescribed for residential / rural areas.
The high SO2 and NOx values are attributable to the heavy traffic

and vehicular movements in construction zones and material handling areas within the plant site.

LOCATION OF AAQMS

Most noise monitoring sites are the same as the Ambient Air Quality Monitoring stations.

Summarized (Annual) Ambient Noise Level: 2007 - 2008 Noise levels are well within the limits. Better technology & working env. will further reduce the work zone noise levels.

Site Code

AAQM Station site distance from site

km A1 A3 A5 A7 A8 Plant site 4 2.5 6.2 3.8

Lday
dB(A) Max Min 64.9 58 52.7 47.8 53 54 48 46

Lnight
dB(A) Max 59.8 46.5 45 45 39.7 Min 46 41.7 42.4 42.6 36

Ldaynight
dB(A) Max 67.4 54.5 54.4 47.8 50.4 48.9 55.5 49 55.1 72.2 Min 57.3 49.7 50 43.26 47.9 45.6 49.9 47.9 52.6 60

N1 N2 N3 N4 N5

53.86 51

46.2 40

N6
N7 N8 N9 N10 N11 N12

A9
A4

5.4
3.5 1.6 1.5 3.5

54

46

42
42.3 41.1 47.8 40.4 46.1 66.6

38.2
41 38.5 42 39 45 50

52.59 46.5

48.9 46 46.8 42 53.3 48 47.1 45 53.5 50 78.2 60

So no noise pollution is anticipated.

A6 A2

1.5 Power block

Water environment
Surface water
Nearest source - River Tel 67 km

Ground water
Avg. groundwater depth: 2-4m

away.
Private pipeline to a reservoir

within the core zone - a moderately available zone.

During the rainy season, the

located within the premises.

Also Rain Water Harvesting for the

off season.
All the storm water drains to be

groundwater table rises to 1-2m above usual.

Other than the fractured zones,

networked to the Water Treatment Plant then to reservoir.

The reservoir has a capacity to

the seepage factor is very low for any ground water recharge.
The existing project has not

hold 3960000 KL of water to be used for two months.

explored the groundwater resources for any purposes.

Code Surface water SW1 SW2 SW3 SW4 SW5 SW6 SW7

Location

Distance (km) & direction w.r.t site 4 1.5 5.8 1.6 2 2 4 W W SW N S W E

V - Lanjigarh V - Bundel Stream - Tetulipadar V Chatrapur u/s Stream Rengopali d/s Stream - Kenduguda Stream - Bundel

WATER ANALYSIS
Grab samples from 16 locations 7 SW, 9 GW Physico-chemical, heavy metals & bacteriological parameters IS:10500 APHA methods

Ground water

GW1 GW2
GW3 GW4 GW5 GW6 GW7

Plant Site B - Lanjigarh

B Rengopali d/s B Chhatrapur u/s B - Chanalima B - SW of Redmud pond B S of Ash pond B- Process Water Lake B - Bundel
4
2 1 1.4 1.5 4 1.6 4

W
S N WNW SW NW NW W

V denotes Vansadhara river

B denotes Borewell

GW8 GW9

Summary
Reference location w.r.t Vamsadhara river (both SW & GW) Upstream: Chatrapur (North of the core zone) Downstream: Rengopali (South of the core zone) The d/s of Vamsadhara River has increased conc. of Alkalinity and

hardness, and all other parameters have decreased values which indicate some form of dilution d/s
As there is no industrial discharge to this river, the increased values

could be due to some surfacial contamination d/s

The net effect from the proposed project will have a minimum

impact on the water quality of the area.

Surface Water Quality Comparison

Ground Water Quality Comparison

Code

Location

Distance (km) & direction w.r.t site

SOIL QUALITY
Clayey Sandy Yellowish, reddish pH: neutral (good culitivation) sufficient quantity of organic carbon E.C. Average for crop growth Nitrogen : 2 3 mg/kg, fertile soil

SSL1 SSL2 SSL3 SSL4 SSL5 SSL6 SSL7 SSL8 SSL9

Plant Site Lanjigarh Rengopali d/s Chhatrapur u/s Chanalima Near Redmud pond Near Ash pond Process Water Lake Bundel
4 2 1.6 1.7 1.5 4 1.6 4 W S N WNW SW NW NW W

SSL10

Rehab colony

SW

Fair amount of phosphorus

Overall soil quality does not vary much. The pH and nutrient content of the soil indicates no or minimal effect due to the existing red mud pond and ash pond i.e. no leakage or overflow to any land nearby. Impermeable lining of the waste disposal ponds So proposed expansion will have no or minimal effect on soil pollution or any groundwater contamination.

Geotechnical summary
Topsoil: Very stiff to hard silty sandy clay layer Subsoil: Good quality -residual in origin - very high shear strength

and medium to low compressibility.

Below this, the weathered rock layer starts. With increase in depth,

the rock turns hard.

Bore Holes:
Standing water level - 0.20m depth (BH-16A location) In many bore holes, the SWL was not found. Foundation, placed at a depth of 1.50 to 4.50m may be problematic

in some cases. However, due to medium to high percentage of fine content and sticky nature of the subsoil, the percolation of water will be less and ordinary pumps, operated from surface, will be able to tackle the situation.

Name of the Forest Block

ECOLOGICAL ASSESSMENT
Study of general area of 20-km radius Nearest forest block: Patragurha Reserved Forest (NE) - mainly composed of Shorea robusta (Sal tree)

Distance (km) & direction w.r.t site 5.2 3.5 5.2 3.5 2.0 NW NW WNW SW SW

Bori reserve forest Hatsal reserve forest Raula jhimiri reserve forest Niyamgiri reserve forest Khambesi reserve forest

Kudilima reserve forest Patra gurha reserve forest (Rayagada district)

Batarilima reserve forest Dahikhala reserve forest Patragurha reserve forest (Kalahandi district) Nimagiri reserve forest

9.7 6.4
2.3 2.5 2.2 9.0

SE ESE
E E NE S

TERRESTRIAL ECOLOGY
Flora
Braun-Blanquet system for plants: 5/10 classes; Max. 451 species - none endangered

Station code & Location TE 1 TE 2 TE 3 Lanjigarh village Kasibarhi village Niyamgiri Vedanta nagar

(km) & direction w.r.t site 4.0 3.5 2.5 W NW SSW

TE 4 TE 5
TE 6 TE 7 TE 8 TE 9 Class

Balabadrapur village Harikrishnapur village

Bijamendeli village Bhaliapadar village Trilochanapur village Hill Top(Mine area)

6.2 3.8
5.4 11.0 10.5 5.0

SW NE
E SE SW S % of species (100) 49.00 29.71 3.55 11.09 2.22 4.43

Crops: rice, jowar, maize, Brassica nigra, Gossypium sp rain dependent

No. of species (451) 221 134 16 50 10 20

Phanerophytes Therophytes Hydrophytes Hemicryptophytes Geophytes Epiphytes

TERRESTRIAL ECOLOGY

Wildlife Protection Act, 1972

Schedule I

No. of Common name Species

7 Python, Golden Gecko, Monkey, Elephant, Leopard, Pangolin, Bison Varanus, Rat snake, Cobra, Viper, Jackal, Langur, Common mongoose, Wild fox, Wild Dog Indian coral snake, Krait, Hyaena, Wild pig, Wild bear, Sambhar, Deer, Barking Deer

Fauna
Two 12-h observation periods : 1 day & 1 night time. (10 km radius) According to threat of extinction, Schedule-I contains those species which need topmost priority, while II, III, IV and V have lesser degree of threat.

Schedule II

Schedule III

Schedule IV

88 112 (Total species)

Avi-fauna: Most are listed in Sch IV & local migrant species.

AQUATIC ECOLOGY
Sampling: premonsoon season of 2007
Plankton is an indicator of environment. It is apparent from the mesotrophic distribution of planktons, that the aquatic life is not yet polluted for any extinct criteria.

Code AE 1 AE 2

Location (freshwater) River Vamsadhara near Lanjigarh Village Nala near plant boundary (lentic ecosystem)

Plankton Phytoplankton Zooplankton

No. of species 25 14

Plankton diversity Index 2.59 to 3.02 2.59 to 3.02

Density of phytoplankton high in (AE-2) than in (AE-1). No study on fish or similar species in this area

BASELINE SOCIOECONOMIC STATUS

(Langigarh CD block, Kalahandi district) 1985 drought badly affected agriculture in the district. Population mainly - Landless agri. labour.

Particulars No. of Households Average Household Size Sex ratio Density of population No. Total Population 38465 Male Female SC 18945 19520 7465

General Study Area 9057 (50 villages) 4.25 (moderate family size) 1030 169.43/km2 (22703 ha study area) % 100
Literates Literacy %

9706

Average : 25.23 Male L. : 37.49 Female L. : 13.34

49.25 7102 50.75 2604 19.41

ST
SC + ST Other castes

16450
23915 14550

42.77
62.17 37.83 (2001 census)

OCCUPATIONAL STRUCTURE
Over 70% of Kalahandi district depends on agriculture
Paddy 69%, Pulses 12%, Oil seeds 5%, Fibre 4% Vegetable 2%,

Occupation 1 Total Main Workers Male

No. of workers 11383 8302

% to Work classes Population 29.59 21.58 cultivators, agri. labour, household industry workers & other services

Female 2 Marginal Workers

Male Female 3 NonWorkers Male Female

3081 8348
2470 5878 18734 8173 10561

8.01 21.70
6.42 15.28 48.71 21.25 27.46

work for < 6 months during the reference year prior to census
unpaid household duties, students, retired persons, dependents, beggars, vagrants institutional inmates, etc

etc. Massive cultivable wasteland is available

Total Population 38465 100.00

AVAILABILITY OF INFRASTRUCTURE
The study area as a whole, has poor to moderate level of infrastructure facilities.

Educational Institution
Primary Schools Middle Schools High Schools Other Education Center

Total no. in Study area

55 5 2 1 (6)

No educational facility in some small villages

Malaria is a predominant disease among locals Malnutrition is common

Health Institution Primary Health Centre

Total no. in Study area 1

Sub-Centre
Dispensaries Registered Practitioners Family Planning Centres Others

1
1 1 1 1

 Access to Drinking Water

AVAILABILITY OF INFRASTRUCTURE

Most villages: Wells & tube wells

Many villages: Village tanks & river

Most villages are electrified Banking: SBI (with ATM) in Lanjigarh

Communication
Only 7 villages have post offices Tele-communication expanded by various

service providers
Transport
Overall - poor
Transport facility Railway station Bus pucca approach roads kachcha approach roads No. of villages served 1 11 28 10

IMPACT PREDICTION & EVALUATION

IMPACT PREDICTION MATRIX

ACTIVITY

CONSTRUCTION
Earth work X X X Mech. fabrica tion Work Force

OPERATION
Raw mat. Man. handling & Prostorage cess X X X X Env. Mgt.

POST OPERATION
Indust rializa tion X X Trans port X Urbani zation X X

Attribute (X - Negative impact - Positive impact) Air S.W. Quality

G.W. Quality
Water resources

X
X

X
X

X
X

X
X

Noise
Soil Land use Ecology Economic benefits Employment Infrastructure dev. Peripheral social dev. Health & safety

X
X X X

X
X X

X
X X X X

X
X X

X
X

X
X

Aesthetic
Displacement & rehabilitation

X
X

X
X

X
X

Environmental impacts during construction

Transient & reversible negative impacts R & R policy of Govt. of Orissa

Env. aspect Water Quality Air Quality Noise

Potential impact Increase in suspended solids due to soil run-off during heavy precipitation Increase in dust and NOx concentration Increase in noise level

Probable source Soil Erosion

Heavy vehicular Movement Construction equipment (70 85 dB(A)) During construction

Terrestrial Ecology

CSR economic upliftment of locals

Clearing of Vegetation (The proposed layout sites do not cover any area with thick vegetation) Impact on surface and ground water resources

Aquatic Ecology

No specific Impact is predicted (ZLD)

Construction activity constitutes excavation civil construction mechanical erection transport of various construction materials stockpiling materials

Environmental impacts during operation

Env. aspect
Air Quality

Potential impact
Increase in SO2, NOX and SPM level in ambient air Increase in SPM in ambient air

Probable source
Alumina Plant Cogeneration plant Vehicular traffic; Coal, Bauxite & Lime handling area Discharge from plant rejects, filter backwash and effluents

Water Quality

Deterioration of surface water quality

Noise
Terrestrial Ecology Aquatic Ecology SocioEconomics Land Environment

Increase in noise levels in the plant area

Impact on plant species Impact on aquatic species

Equipment in main plant and auxiliaries

Emissions from stacks W/w, if any, from Alumina plant, heat exchanger, cooling tower, power plant..

Strain on existing Influx of people (employees amenities: housing, water, as well as contractors sanitation, health care .. employees/ labourers) Depletion of cultivable area, if any Land acquisition (red mud pond, ash pond & township)

Environmental impacts during operation

Unit Calciner [from each of 5 stacks] Co-generation plant

Emissions (kg/h) SO2 575 ( 3.5% S) 1245 (0.5%S)

-

NOX 37.5 -

SPM 7.8 (after ESP - 95% ) 120 (after ESP - 95% ) 3.2 (Bauxite dust) 4.7 (Coal dust) 0.68 (Lime dust) - based on T lime used/T Alumina)

AIR QUALITY

Bauxite transport and crushing Coal handling area Lime handling area

ISCST-3 10Km x 10Km area GLC at every 500m grids points

Rank 1 2 3 4 5

Max 24 h Avg INCREMENT CONC. of pollutants (g/m3) SPM Rengopali- 2.65 Rehab colony- 1.99 Kasibari- 1.99 Mines area- 1.99 Lanjigarh-1.99 NOX Rengopali- 6.9 Lanjigarh-6.45 Kasibari- 4.31 Mines area- 4.31 SO2 Rengopali-22.34 Lanjigarh-4.47 Kasibari-8.93 Mines area-4.47

Rehab colony-6.45 Rehab colony-8.93

Environmental impacts during operation

Maximum Predicted GLCs Value at Rengopali (g/ m3)

Parameter SPM Baseline (Winter) 187.2 16.2 25.1 Max. increment 2.65 22.34 6.9 Max. predicted values Residential area - CPCB 200 80 80

AIR QUALITY

SO2 NOX

189.85 38.54 32

Unit

Sound Level dB(A) Blower Room Oil heating Unit Digestion Unit Ball Mill 95-105 80-85 90-95 95-105 90-95 90-95 80-85

Environmental impacts during operation

Gas Suspension Calciner Aluminium Plant Compressor House Crusher Vacuum Pump

NOISE

Cooling Water Pumps Power Plant Steam Turbine

Boiler Generator Coal Handling Plant Work Shops Transfer Points Coal Crushing

85 85-90
85-90 80-85 79 73-79 65-75

Machine operations in isolated areas - Individual source control Analysis: Noise drops below 45 dB (A) at 1 km distance from the
plant Residential areas more than 1 km away

Liquid effluent

Treatment & management The entire treated w/w will be reused in the process In monsoon, esp., strictly as per CPCB standards.

Environmental impacts during operation

WATER QUALITY & WASTEWATER TREATMENT Only Tel River as source for all needs No groundwater use No impact there

Process wastewater

Heat exchangers
Evaporators (acidic w/w) Cooling tower blowdown

DM plant regeneration
Filter backwash Laboratory effluent Alkaline w/w - many units Fully recycled within the plant Sanitary wastewater Red mud pond run off Red mud pond leachate? Ash pond overflow STP use in green belt Holding pond Use in sprinkling during dry season Red mud is less water-soluble Min. leaching Recycled to ash slurry system

Water Balance

Environmental impacts during operation

SOLID WASTE MANAGEMENT
Red Mud Pond & Ash Pond designed for 15 years

Solid Waste

Source

Quantity generated Existing plant Proposed plant

Red Mud Ash Sewage Sludge Solid Waste Red Mud Ash

Settler & washer 1.28 MMTPA 7.5 MMTPA Coal fired boiler Domestic 0.23 MMTPA 0.86 MMTPA

Municipal SW Domestic

1.2 TPD
14 Kg/day

6.7 TPD
60 Kg/day

Mode of Disposal Red Mud Pond via HCSD System 1. Downstream industry use: cement, brick making and agriculture. 2. Remaining: Ash pond using High Concentration Slurry Disposal system (HCSD) Composting Facility Organic solids from STP as manure in greenbelt development after composting

Municipal SW Sewage Sludge

Environmental impacts during operation

Hazardous Waste Used oil Oily cotton Waste

Quantity generated / year (app.) Existing 150 KL 2000 Kg Proposed 280 KL 8000 Kg

Disposal Method

Selling to Registered Recyclers Fire in Boiler

NON PROCESS HAZARDOUS WASTE

Used oil filters

Used batteries

150 nos
400 nos

280 nos
900 nos

Sold to recycle agents

Buy Back System with manufacturers Into engineered landfills

Spent Resins 4500 L (for 5 10200 L (for of DM Plant years) 5 years)

Socio Economic Impacts

No other industry within 10 km from project site.

Study area: 3 zones 3, 5 & 10 km radius

Mostly urban communities commerce

Only 5% - agriculture
Crop
Paddy Others

Area (% of GCA)
36 64

Productivity (Qtl./Ha)
15 T 4T

Vedanta employment impact

Rise in local education: CSR actions

Health care improvements

Direct - 2500 locals technically trained Indirect - Outsourced agencies to the daily workers ~ 10000 workers various skill levels

Scholarships, awareness programs, sponsored events

Partnering with local govt. Programs: Mobile Health unit, First to Reach, Project Sushtha Parivar, Health Awareness Camps, Family Planning Operation Camp, Pulse Polio Program

Environmental component

Rank 4
4 2 2 1 2 3 3 2 3 4 4

W 0.10
0.10 0.05 0.05 0.02 0.05 0.07 0.07 0.05 0.07 0.10 0.10

PIV 95
95 48 48 24 48 71 71 48 71 95 95

EVALUATION OF IMPACTS
Leopold matrix

Ambient air Quality

Technology Surface water Quality Surface water resources Ground water Quality Noise Quality Soil Quality Land use pattern Flora & Fauna Aesthetics Employment Trade & Business

The importance
of impact on an env. component is ranked on a scale of 1 < x < 5

Rank
probability or weightage i.e. W

Human Health & Safety

Infrastructure Development Social & Education Development Human displacement & resettlement Total

2
3 2 1 42

0.05
0.07 0.05 0.02

48
71 48 24 ~1000

PIV (Parameter
Importance Value) = W x 1000

Assessment Value Index Scale

EVALUATION OF IMPACTS
Leopold matrix

TIS = PIV x Impact values Up to (-) 2000 (-) 2000 to (-) 4000

Implication No appreciable impact on environment. Adverse impact is minimal. Appreciable impact on environment but not injurious in general. Adequate mitigating measures are important. Significant impact upon the environment. Major environmental control measures to be taken.

Impact on Impact env. by an value (subjective) activity Minimal 12

(-) 4000 to (-) 6000

(-) 6000 to (-) 8000

(-) 8000 and above Up to 2000 Up to 4000 Up to 6000 Up to 8000 8000 and above

Moderate
Significant Extreme (+) sign (-) sign

34
78 9 10 Good Adverse

Major injuries impact on environment. Site selection to be considered

Alternative site to be considered. Minimally beneficial. Moderately beneficial. Appreciably beneficial. Significantly beneficial. Extremely beneficial.

Appreciable 5 6

IMPACT EVALUATION MATRIX

TIS for Project activities without EMP & project benefits

Environmental component Ambient air Quality

Technology S. W. Quality S. W. Resources G. W. Quality Noise Quality Soil Quality Land use pattern Flora & Fauna

PIV
95 95 48 48 24 48 71 71 48

Land acquiring

Mech. work -3
+4

Raw mat. & Product -3

+2

Plant Op. -4
+1 -1 -1 -3

Civic needs -1
+1 -2 -2 -1 -1 -1

Total
-11 +8 -3 -3 -4 -5 -3 -2 0

TIS
-1045 +760 -144 -144 -96 -240 -213 -142 0

-2 -1 +2 +1 -1

-2 -2

-1 -1 -1

Aesthetics Employment
Trade & Business Human Health & Safety Infrastructure Dev. Social & Edu. Dev. Human R & R Total

71 95
95 48 71 48 24

+1

-1

-1 +1
+1

-2 +2
+1 -2 2 -1 +3

-3 +1
+1 +1 +2 +1 +3 +2

-213 +380
+285 -48 +213 0 +144 -503

+4
+4 +3 -1 0 +6 -11

-1 -1 -6

-1

1000 +4

-3

-8

Environmental management plan (EMP)

For sustainable development in the study area (10-km) Environmental Management Systems (EMS) for carrying

capacity (supportive and assimilative capacity) based issues Bureau of Indian Standards Specification IS: 13967 (1993): Environmental Management Systems - Specification (equivalent to British Standard BS 7750) Annual Environmental Statement Reviews - continuous improvement

Overview of EMP

General Manager,

EMP Cell
Services on env. issues during construction and operation phases Implements EMP interaction with the env. regulatory agencies Reviewing draft policy & planning. Qualified Senior Executive, Env. management cell manager (env. engg) manager (env. monitoring)

Dept. Of EHS Manager,

Safety & Disaster management cell

Doctor, Occupational health

3 safety officers

2 chemists

3 samplers and 2 helpers

Environment Management Records

To track Compliance with environmental management systems Extent of achievement of the environmental objectives and targets Legislative, audit and review reports To address: Details of failure in compliance and corrective action; Details of indigents and corrective action; Details of complaints and follow-up action; Appropriate contractor and supplier information; Inspection and maintenance reports; Product identification and composition data; Monitoring data; Environmental training records

Environmental Laboratory
Manager (environmental lab), 2 chemists, 3 samplers and 2

helpers The main analytical instruments/ equipments

High volume sampler Stack monitoring kits Digital pH meter Conductivity/ TDS meter Nephelometer UV/VIS spectrophotometer Soxhelt apparatus to measure oil & grease Ammonia distillation apparatus BOD incubators

Environmental Monitoring
Sampling location for soil, water, air Stack sampling point at CFB Identification of dug well sampling point Observation well point Bore well at red mud pond, process water lake, ash pond and dirty water pond Stream flow measurement (To monitor the flow of water) AAQ station (Air quality) On Line pH monitoring and Neutralisation System before
dirty water pond
clear water pond

EMP DURING CONSTRUCTION PHASE

Env. aspect Water Quality

Potential impact suspended solids: soil run-off (rains)

Probable source Soil Erosion

Mitigation measures Temporary sedimentation tank

Air Quality

Increase in Heavy dust and NOx vehicles conc.

Regular sprinkling of water in the construction area. Tarred main approach road for low impact
Good equipment noise within 85 dB (A). Ear plug, ear-muffs for workers Plantation at start of the project Wastewater will be treated in STP. No significant impacts on aquatic life and water resources

Noise

Increase in noise level

Construction equipment

Terrestrial Clearing of Ecology Vegetation Aquatic Ecology Impact on water resources

During construction Non-specific

Env. aspect

EMP DURING OPERATIONAL PHASE

Potential impact

Probable source

Mitigation measures

Air Quality

in SO2, NOX and SPM in ambient air

in SPM in ambient air

Alumina Plant, Cogeneration plant

Vehicular traffic Coal, Bauxite & Lime handling area Discharge of effluents

GLC in limits + stacks: 145 m CGPP, 120 m calciner + boiler design for NOx
Paved motorable roads Dry fog system, bag filters , water sprinkling in dust generating areas W/w - complete recycle for various uses in plant. ZLD. During monsoon, excess treated water may be discharged

Water Quality Aquatic Ecology

of surface water quality Impact on aquatic species

Noise
Terrestrial Ecology SocioEconomy Land Env.

in noise in the plant area

Impact on plant species Strain on existing amenities of cultivable area, if any

Process equipments
Stack emissions Influx of people

Equipment redesign, Green belt

Emission control by design, within limits Existing township will be utilized HCSD for Red mud and ash.

Land acquisition

Pollution control: Alumina plant

Major Process Bauxite crushing & Grinding Impact Air Pollution Pollution Control Equipment Dry Fog System Water Sprinkling System Sump pits Red Mud Pond (red mud from refinery solid waste) Process water lake, Dirty Water Pond Caustic Effluent drain, Storm water drain For solid waste disposal and caustic recovery Caustic recovery and reuse in the Process Collection of specific w/w Purpose Dust Suppression Dust Suppression

Predesillication, Evaporation, Digestion & Heat Recuperation System, Settling Counter current Mud Washing & Disposal Air Pollution in dry season Water pollution Contamination with soil & land Security Filtration, Heat Interchange -

Pollution control: Alumina plant

Major Process Impact Pollution Control Equipment Precipitation, Hydrate Classification, Hydrate Seed thickening, Fine seed wash Product Filtration, Hydrate washing & Storage Gas Suspension Calcination Alumina handling Caustic Storage Cooling Tower Lime handling System Sumps Purpose Caustic recovery and reuse in the process

Air Pollution

ESP, Stack height, On Line gas monitoring System Bag filter Dyke wall and spill collection system Reuse of Cooling water system Wet scrubber

Alumina dust

Air Pollution Soil and water pollution

Alumina dust For spill protection

Dust collection system

Pollution control: Power plant (CGPP)

Major Process Coal Unloading Coal Storage Coal Crusher/ Grinder, Coal Conveyer Impact Airborne dust in windy seasons Property loss & heat stress Dust around conveyors - unsafe work area Pollution Control Equipment Water Sprinkling System Fire Hydrant System Dry Fog System Purpose Suppress dust due to material handling Suppress any fire Suppress suspended particles & dust due to coal processing

Coal fired Boiler

Airborne dust in windy seasons

Slurry overflow to nearby farms. Air pollution

ESP with Chimney

Ash Pond (also for flyash from boiler solid waste)

Collect SPM from Flue Gas

Reclaim water from pond

Dust - unsafe work area

HCSD system

Ash Slurry disposal

Pollution control: Power plant (CGPP)

Major Process Turbine Impact Heat stress in the work area Oil sludge overflow to nearby water source Pollution Control Equipment Noise and Heat control System Dyke wall and spill collection System Purpose Turbine, Steam Pipelines Insulation & Exhaust Ventilators Oil Sewage Pump House to collect leaked/waste oil

Furnace Oil Storage

Pollution control: Utilities

Major Process D M plant Impact Acid/ alkali sludge overflow to nearby water source Loss of water & pollution Cooling Tower Domestic effluent at plant Loss of water Water Pollution Pollution Control Equipment pH neutralization pits Purpose 1 for Acid & 1 for Alkali neutralization For reuse

Use neutralized water in ash slurry / divert to clean water pond Cooling water reuse STP

Recycling of water Treatment of liquid waste from Latrine, bathroom and canteen

Domestic effluent at colony D G Set Air pollution

STP Stack Height and Acoustics measures

Water & wastewater management

Water Supply and Distribution
Water meter with totalizer at Tel River, domestic use, process use &

boiler (D M Plant) Garland drain for refinery Water cess payment Raw water - processed in primary treatment chamber
Wastewater management
Process wastewater is 100% recycled (ZLD) During monsoon treated waste water will be discharged Domestic w/w: treated in FAB (360 KLD) - 85-87 % efficiency Rain water harvesting in township area

Solid waste management

Red mud pond
Red mud generation: 20500 TPD High Concentration Slurry

Design features

Disposal (HCSD) or dry stacking technology Run-off is fed to the Process Water Lake constructed to store alkaline water It is reclaimed for process use. Designed in line with CPCB and local soil conditions
Worley - Australia; IISc

Red mud pond 890.34-ha area @ 1.3 km away Containment dykes Base sealed by native soilbentonite mixture
Catchment pond To protect d/s natural water reservoir Process Water Lake 1.5mm HDPE; 500mm compact earth

Bangalore; Tailings Management System- Canada.

Solid waste management

Ash pond
Proposed flyash: 2388 TPD HCSD The water so used will be

Ash disposal alternatives

Value added products Land filling Construction of sub-base of

recycled back to plant for slurry preparation or reused after treatment Pond A: 1800000 m3 Pond B: 3600000 m3

roads, canal, railway line, dykes, etc Cement industries To consider: cost of transporting

Solid waste management

Facility proposed Ash pond A Ash pond B Red mud Pond west cell Red mud Pond east cell Area (m2) 3.57 x 105 20.4 x 105 2.8 x 105 89 x 105 Volume (m3) 18 x 105 36 x 105 32 x 105 104 x 105 Lifetime (years) 12 13 12 13 34 9 10

The above capacities are designed with 75% capacitation of estimated solid waste generation by the plant. Compaction of the Red mud and Ash in their dump site can extend use up to 15 years.

Measures for improvement of ecology

Greenbelt Development 1/3 of the total project complex area Road sides: Partial thermal capping & control of fugitive

dust emissions Slopes of Red mud pond & ash pond: Nursery to prove that no soil contamination occurs
Trees: Sinks for air pollution, absorb noise, improve the ecology and

aesthetics of the area; long-term impacts on soil quality and the ground water table.

Environmental Statement
Annual

Internal or external audit consumption of total resources (raw material and water per tonne of product), quantity and concentration of pollutants discharged in air and water, quantity of hazardous and solid waste generation, pollution abatement measures, conservation of natural resources and cost of production vis--vis the investment on pollution abatement.

SAFETY RISKS & DISASTER MANAGEMENT

Hazardous Material Inventory

Determination of Risk Potential

Environmental Risk Potential Evaluation

primarily based on
human errors or faulty operation or failure of the control systems

Risk management measures

HAZOP study for the fuel gas distribution network and

propane handing facilities prior to commissioning Adequately rated and quick response circuit breakers, aided by reliable and selectively digital or microprocessor based electro-magnetic protective relays in the electrical system ON SITE EMERGENCY PLAN central disaster control cell under GM EHS Alarm systems Mock drills Safety training Medical services

Socio- economic services: Present

Child Care Centres Pre schooling for 3 5 year old children 7 villages 302 children Education Guarantee Scheme School Primary education for 6 14 year old children 122 pupils from 3 villages Mid-day meal on every working day Health and Sanitation Dispensary in the Rehabilitation Colony First Aid Centre in the plant Rural Health Camps - Mobile Health Unit 14800 patients inflicted with Malaria, Diarrhea, Viral fever and Scabies treated from Dec 2003 to Nov 2005

Socio- economic services: Present

Sustainable Livelihood
Mobilized SHGs (Self Help Group) for rural women of Below-

Poverty-Line households and arranged income-generating activities for them

8 SHGs with 92 members in Niyam Giri Vedanta Nagar 11 SHGs with 216 members in other villages These SHG members have mobilized nearly Rs. 92 thousand savings One SHG - Phenyl production and another - spice making

80 farmers from Chhatrapur and Lanjigarh villages have undergone

training on better practices for paddy and vegetable cultivation Soil-testing camps in the villages
In the last Camp, 31 soil samples were tested and accordingly soil

treatment measures were suggested to the farmers

Socio- economic services: Present

Sports and Youth Development
10 youth clubs 2 football matches conducted Promotion of volleyball, football

and other cultural activities Support cultural programmes & festivals of the villages
Infrastructure Development
VAL executed development of metal roads, pucca drains, installation

of hand pumps for clean and safe drinking water, installation of street lights, construction of temples, the Dharani ghars, construction of school buildings, etc

Socio- economic development: Plans

Education Operating the existing 16 Nursery Schools with 16 local teachers with intake of 640 children (3 6 yrs age) Formal and vocational education Promoting Girls education Health and Nutrition Participation of tribal/traditional healers to develop herbarium health camps with NGOs partnership in select villages - every alternative month Infrastructure Invest in village roads, irrigation facilities, solar lights, educational and health and market, through cooperative efforts with local govt. Bodies in Dongria Kondh villages

Socio- economic development: Plans

Drinking Water and Irrigation
Assess to safe drinking water - cisterns, tube wells &stream based

gravitational flow tap water projects in problem villages Construction of check dams , diversion weirs , canals and water channels from dam sites to farms
Income Generation
Plantation of fruit trees & spices in the hill farms of the Dongarias. Rice cultivation in the small chunks of wetlands Agro-forestry-vocation training for youth

Extension of market facilities

Women SHGs

PROJECT BENEFITS AND CONCLUSION

TIS for Project activities with comprehensive EMP and project benefits

Environmental component Ambient air Quality

Technology S. W. Quality S. W. Resources G. W. Quality Noise Quality Soil Quality Land use pattern Flora & Fauna

PIV
95 95 48 48 24 48 71 71 48

Civil constrxn

Mech. work

Raw mat. & Product

Plant Op.

Civic needs

Total

TIS

1 1 2 4 1

2 2 1

2 2 -1 -1 -3

1 3 -1 -2 -1 -1 -1 4

6 12 2 -3 -4 -6 -3 -4 4

570 1140 96 -144 -96 -288 -213 -284 192

-1 -1 1

-2 -1 -1

-2 -1

-1 -1 -1

Aesthetics Employment
Trade & Business Human Health & Safety Infrastructure Dev. Social & Edu. Dev. Human R & R Total

71 95
95 48 71 48 24 1000

-1 2
1 1 1 -1

-1

-1 1
1

-2 3
1 -2 2 -1

2 1
1 2 2 3 -1

-3 7
3 -1 4 4 -3

-213 665
285 -48 284 192 -72 2066

-1

-1 -1

Conclusion
The total score of the impact on all significant subjects

changes from negative to positive after EMP implementation

The socio-economic importance of the project outweighs its

perceived impact on air quality