report on environmental impacts & environment management...

REPORT ON ENVIRONMENTAL IMPACTS & ENVIRONMENT MANAGEMENT PLAN

FOR CHANGE IN SOURCE OF FUEL / FUEL MIX

Intimation on Fuel Source and Fuel Mix change for concurrence for 900 MW (750 MW in Operation and 150

MW Standby) Captive Power Plant

at

900 MW CPP of Mahan Aluminium Unit, Orgari Village, Bargawan, Singrauli District, Madhya Pradesh

Project Proponent:

M/s Hindalco Industries Ltd

PO - Bargawan - 486886, District Singrauli, Madhya Pradesh, India

Environmental Consultants:

Bhagavathi Ana Labs Pvt. Limited

(A Bureau Veritas Group Company) 7-2-C14, Industrial Estate, Sanath Nagar, Hyderabad- 500018

NABET Certificate No NABET/EIA/1316/RA008

December, 2016

Report on Environmental Impacts & Environmental Management Plan

for change in fuel source / fuel mix at 900 MW CPP of Mahan Aluminium Unit,

Orgari Village, Bargawan, Singrauli District, Madhya Pradesh

M/s Hindalco Industries Ltd

Document Reference : IND.BH.41.16.0108/HSR

Revision: Final, Rev01, dated 23/12/2016

Copyright Bureau Veritas India Pvt. Ltd. All rights reserved.

Report on Environmental Impacts and Environmental Management Plan for change in fuel source / fuel mix at 900 MW CPP of Mahan Aluminium Unit, Orgari Village, Bargawan, Singrauli District, Madhya Pradesh of M/s Hindalco Industries Ltd.

Report on Impacts & Environment Management Plan

Bhagavathi Ana Labs Pvt Ltd (a Bureau Veritas Group Company) Project Reference: IND.BH.41.16.0108/HSR Rev. 01, Final 3/53

REVIEW AND REVISION HISTORY

History of revisions of the present report:

Rev Date Modifications

00, Draft 29/07/2016 First issue for Customer review and inputs

01, Final 23/12/2016 Revised report, incorporating Customer review and inputs Table I: History of the Revisions

Document No. IND.BH.41.16.0108/HSR, Rev. 01, Final

01, Final 23/12/2016 Final Report PB ESS ESS

00, Draft 29/07/2016 Draft Report PB ESS ESS

REV DATE DESCRIPTION REVIEW-1 REVIEW-2 APPROVAL




TABLE OF CONTENTS

REVIEW AND REVISION HISTORY 3

TABLE OF CONTENTS 4

ABBREVIATIONS 6

1.0 INTRODUCTION 7

1.1 PREAMBLE 7 1.2 ABOUT PROJECT PROPONENT 7 1.3 PROJECT PROPOSAL 7 1.4 PROJECT LOCATION 9 2.0 PROJECT DETAILS 8

2.1 PREAMBLE 8 2.2 PROJECT BACKGROUND 8 2.2.1 Summary of Project Proposal 10 2.2.3 Impact Assessment 11 2.3 STATUS OF THE PROJECT-STATUTORY CLEARANCES 11 2.4 DETAILS OF EXISTING FUEL 13 2.4.1 Coal sources 13 2.4.2 Coal transportation & Handling Details 13 2.5 DETAILS OF EXISTING ASH GENERATION AND UTILIZATION 13 3.0 ENVIRONMENTAL BASELINE STATUS 16

3.1 PREAMBLE 16 3.2 STACK EMISSION DETAILS 16 3.3 ASH GENERATION DETAILS 16 4.0 IMPACTS DURING OPERATION PHASE 19

4.1 PROPOSED FUEL BLENDING QUALITY 19 4.3 FUEL TRANSPORTATION DETAILS 19 4.3 DISCUSSION ON INCREMENTAL EMISSION LOAD 21 4.4 IMPACT OF SOLID WASTE 22

4.5 SUMMARY OF ANTICIPATED ENVIRONMENTAL IMPACTS AN D MITIGATION 22

5.0 ENVIRONMENT MANAGEMENT PLAN 24

5.1 Preamble 24 5.2 Ambient Air Quality 24 5.3 Ash Management Plan 25 5.4 Greenbelt Details 25 6.0 CONCLUSIONS 28

ANNEXURE-1: COPY OF MAHAN COAL BLOCK ALLOCATION LET TER 29

ANNEXURE-2: COPY OF MAHAN CONSENT ORDER FOR 6 TH UNIT 35

ANNEXURE-3: COPY OF HAZRADOUS WASTE AUTHORIZATION F ROM MPPCB 43




List of Figures

Figure 1: Location Map - Mahan Plant .................................................................................................... 7 Figure 2: Google Map (10 km radius) - Mahan Plant .............................................................................. 8 Figure 3: Plant Layout Map - Mahan Plant ............................................................................................. 9 Figure 4: Project Site Photographs - Mahan Plant ................................................................................. 7 Figure 5: Project Site Photographs depicting........................................................................................ 27 List of Tables

Table 1: Details of the Mahan Project of Hindalco Industries Limited .................................................... 7 Table 2: Parameter of Coal - Mahan Unit as per EIA ............................................................................. 9 Table 3: Summary of Project Proposal ................................................................................................. 10 Table 4: Summary of the Statutory Clearances of the Project .............................................................. 12 Table 5: Details of the Fuel Mix as per EC ........................................................................................... 15 Table 6: Ash Generation & Utilization Details, Mahan Baragawan....................................................... 15 Table 7: Stack Emission (mg/Nm3) – Captive Power Plant – Mahan Plant .......................................... 17 Table 8: Stack Emission (mg /Nm3) - Smelter Plant – Mahan Plant ..................................................... 18 Table 9: Typical Fuel Quality Details from Various Sources ................................................................. 20 Table 10: Projected Blending Quality .................................................................................................... 20 Table 11: Coal Requirement for 5x150 MW Power Plant ..................................................................... 21 Table 12: Predicted 24-Hourly Short Term Incremental Concentrations .............................................. 21 Table 13: Ash Generation Quantity ....................................................................................................... 22 Table 14: Anticipated Environmental Impacts & Mitigation ................................................................... 23




ABBREVIATIONS

1 BALPL Bhagavathi Ana Labs Private Limited

2 BV Bureau Veritas

3 EMP Construction Environmental Management Plan

4 CPCB Central Pollution Control Board

5 CPP Captive Power Plant

6 DSIR Department for Scientific & Industrial Research

7 EC Environmental Clearance

8 EIA Environment Impact Assessment

9 EMP Environmental Management Plan

10 ES Environmental Statement

11 ESP Electro Static Precipitator

12 GoI Government of India

13 HFO Heavy Fuel Oil

14 HIL Hindalco Industries Ltd

15 ISO International Standard Organisation

16 KLD Kilo Litres per Day

17 KTPA Kilo Tonnes Per Annum

18 MoC Ministry of Coal

19 MoEF&CC Ministry of Environment, Forests and Climate Change

20 MTPA Million Tonnes Per Annum

21 MW Mega Watt

22 R&D Research & Development

23 TPA Tonnes Per Annum




INTRODUCTION

1.1 PREAMBLE The present Report provides the study on environmental impact and Environmental Management Plan w.r.t. intimation on Fuel Source and Fuel Mix change for concurrence for captive power plant of 900 MW capacity (5x150 MW in operation and 1x150 MW as standby) at Mahan Aluminium Unit, Village Orgari, Tehsil, Deosar, P.O.- Bargawan, District Singrauli, Madhya Pradesh by M/s Hindalco Industries Ltd (HIL) hereinafter called Mahan Project.

1.2 ABOUT PROJECT PROPONENT

Hindalco Industries Limited (HIL) is a flagship company of the Aditya Birla Group which is one of the largest industrial groups in India. The company is the leading manufacturer of aluminium in India. Mahan Project has an installed smelting capacity of 359 KTPA. HIL has an excellent track record with respect to productivity, energy conservation, quality control and management of environmental pollution control. Details of the Mahan smelter plant capacity, with reference to Captive Power Plant (CPP) are provided in Table-1.

Table 1: Details of the Mahan Project of Hindalco I ndustries Limited

S. No

Unit Location Smelter

Capacity (KTPA) CPP Capacity

(MW)

1

Mahan Aluminium Unit: Integrated Aluminium Smelter Complex at Village Orgari, Bargawan, District Singrauli (Previously known as District Sidhi) in the State of Madhya Pradesh MoEF&CC File No J-11011/217/2007-I.A. II (I) dated March 18,2009

325 750 MW

(5x150 MW)

2 EC amendment on February 15, 2012 359

900 MW (6x150 MW

including standby unit of

1x150 MW)

1.3 PROJECT PROPOSAL

Mahan Smelter Plant was set up on 3.5 MTPA indigenous coal sourced from Captive Mahan Coal Mines based on which, EC was granted by MoEF on March 18, 2009 for producing 325 KTPA Primary Aluminium along with Captive Power Plant of 750MW capacity (5x150 MW) and amended on February 15, 2012 for Aluminium production to




359 KTPA and 1x150 MW as standby within installed captive coal based power plant of 900 MW at Mahan Aluminium. Mahan Project was commissioned and Forest clearance was still being considered for Mahan Coal Mines by MoEF&CC. Therefore, Project Proponent submitted a request letter 09-07-2012 to MoEF&CC to permit it to source coal from alternate sources, i.e, linkage coal, e-auction, imported coal etc during the pendency of the grant of Forest Clearance to operate the CPP. Meanwhile, Hon’ble Supreme Court vide its judgment dated 25-08-2014 read with judgment dated 24-09-2014 cancelled the allocation of all coal blocks including Mahan Coal block allocated to HIL for Mahan Project. The Hon’ble Supreme Court issued directions to Central Government for fresh allocation of all the cancelled coal mines. Accordingly, The Central Government promulgated Coal Mines (Special Provisions) Ordinance, 2014 / 2015 and framed thereunder Coal Mines (Special Provisions) Rules, 2014. The said Ordinance was replaced by Coal Mines (Special Provisions) Act, 2015. By virtue of the said Ordinance and Rules, Kathautia Coal Mines (0.80 MTPA) and Dumri Coal Mines (0.40 MTPA) in the State of Jharkhand were put on auction by the Central Government. In the auction process, Project Proponent became successful bidder and the said coal mines were allotted to it by Vesting Order No. 104/3/2015/NA dated 23 March, 2015 issued for Kathautia Coal Mines and by Vesting Order No. 104/24/2015/NA dated 22 April, 2015 for Dumri Coal Mines respectively. The necessary implementation steps are being taken to operationalize the allotted mines in auction. The coal availability scenario in India has drastically changed and quality coal is available in India. The method of procurement has also undergone through stringent changes by CIL through auction route and as per the policy of the Government long term coal linkage. Auction has started and in recent auction which has taken place. HIL has also secured coal linkage for 12,314.1 KTPA Mahan for a period of 5 years and HIL will be participating in future for firm linkage auction to secure requirement on long-term basis. Project Proponent proposes intimation on change in fuel source in place of Mahan coal mine by using mix fuel as domestic coal (allotted mine coal, coal from open market e-auction, washery tailing/rejects), imported coal apart from adding small quantity of Agri Residues (rice husk with agro waste) (1-2%) and pet coke (1-2%) to top-up and enhance the fired coal CV to achieve the minimum required fired coal CV suitable for boiler in case when plant sets Indian coal with lower CV due to bad coal quality at the existing 750 MW CPP (150 MW Standby) at Mahan Aluminium Unit, referred in Sr. No. 1 of Table-1.




1.4 PROJECT LOCATION

The Mahan Aluminium Unit project site is located at Orgari Village, Bargawan, Singrauli District, Madhya Pradesh. The project location map is given in Figure-1 . The Google map is given in Figure-2 . The plant layout map is given in Figure-3 . The photographs of the existing plant complex are given in Figure-4 .




Figure 1: Location Map - Mahan Plant




Figure 2: Google Map (10 km radius) - Mahan Plant




Figure 3: Plant Layout Map - Mahan Plant




Figure 4: Project Site Photographs - Mahan Plant




PROJECT DETAILS

2.1 PREAMBLE The present chapter provides the project and fuel options w.r.t. the request for change in source of fuel at 900 MW CPP (750 MW in opeartion + 150 MW standby unit) of Mahan Aluminium Project, Village Orgari, Tehsil Deosar P.O.- Bargawan, District Singrauli, Madhya Pradesh by M/s Hindalco Industries Ltd (HIL).

2.2 PROJECT BACKGROUND HIL has established an Integrated Greenfield Aluminium Smelter Complex for 359 KTPA and CPP of 900 MW (including 150 MW Standby) at Village Orgari, Tehsil Bargawan, District Singrauli in the State of Madhya Pradesh hereinafter called Mahan Aluminium Project. Environment Clearance bearing No J-11011/217/2007-I.A. II (I) dated 18 March, 2009 as amended on 15 February, 2012 in respect of Mahan Aluminium Project was granted by MoEF. The commercial production of Aluminium metal has commenced at the said project from 11 May, 2013. Mahan Aluminium Project has been set up based on the availability of indigenous coal from Mahan Coal Block. The, Ministry of Coal (MoC), Government of India (GoI), vide its letter dated 12-04-2006 allotted “Mahan Coal Block” to Hindalco Industries Ltd for captive use at Mahan Aluminium Project. As per EIA Report quality and requirement of coal for Mahan Aluminium Project was as under: “At an expected heat rate of the Turbine cycle at 2060 kcal/kWh & considering boiler efficiency as 89% i.e. at the plant heat rate of 2315 kcal.kWh and considering average GCV of coal 4025 kCal/kg, the coal consumption is estimated to be around 388 tonnes per hour, i.e., around 9316 tonnes per day or approximately 3.5 million tonnes per year considering 2.0-2.5 % losses. The ash shall be reduced by face quality control so that a GCV of 4025+100 kCal/kg is obtained from the mine.” The parameters of the coal to be used as fuel for the power plant as per EIA report are given below in Table-2 .




Table 2: Parameter of Coal - Mahan Unit as per EIA Parameters Range Design Coal

Grade based on UHV Grade E to F Grade E to F Fixed Carbon 26 - 45% 35% Moisture 4 - 9% 6% Ash content 24 - 42% 34% Volatile matter 24 - 28% 25% Gross Calorific Value (kCal/kg) 3780 - 4700 4025 - 4300 Grindability (HGI) 51 52 Sulphur 0.3 - 0.5% (max) 0.3 - 0.5% (max)

Source: EC for existing unit Mahan Project was commissioned and Forest Clearance was still being considered for Mahan Coal Mines by MoEF&CC. Hon’ble Supreme Court vide its judgment dated 25-08-2014 read with judgment dated 24-09-2014 cancelled the allocation of all coal blocks including Mahan Coal block allocated to HIL for Mahan Project. Kathautia Coal Block allotted to M/s Usha Martin Ltd and Dumri Coal Mine allotted to M/s Nilachal Iron & Power Ltd for captive use was also cancelled by the Hon’ble Supreme Court by the said judgment. Kathautia coal Mines land acquisition process is in progress in three different ways - for land acquisition, HIL mining team has been in dialogue with the raiyats to resolve writ petition in Hon’ble High court for early disposal and for other non-land Acquisition private land consent from land owners are being obtained and land acquisition process is in progress through District Administration. Some lands are expected to be available soon, where the mining may commence. Under the above circumstances, dispatch of coal may commence in financial year 2018 from Kathautia to Mahan plant.

Dumri Coal block is Schedule III category, which is a greenfield project. While the project work is in progress in terms of clearances like transfer of EC, acquisition of CA land etc, Dumri coal block is likely to start operation sometimes in FY18 as per the timeline given by MoC. Under the above circumstances, it has become necessary for HIL to continue to procure coal from alternate sources, i.e., domestic coal (linkage coal, coal from open market, e-auction) and imported coal. To ensure that the environmental parameters do not get disturbed, it will be HIL’s endeavour to ensure that the average quality of coal to be used to meet energy requirements for the Mahan Aluminium Project remain as close as to that of Mahan Coal Block. The present report studies the change in impacts due to change in fuel source and proposes EMP for the same.




2.2.1 Summary of Project Proposal HIL is seeking change in fuel source and fuel mix for concurrence for 900 MW (5x150 MW in Operation and 1 x 150 MW Standby) Captive Power Plant in EC as follows:

• Due to cancellation of Mahan Coal block, change in fuel source consequent to allotment of Kathautia Coal Mines and Dumri Coal Mines in place of Mahan Coal Mines.

• So long Kathautia Coal Mines and Dumri Coal Mines do not become operative & after in become operative to meet the balance coal requirement to procure Domestic coal (alternate sources, i.e., linkage coal, coal from open market, e-auction, washery tailing/rejects ) and imported coal.

• Proposal to use small quantity as an additive of Agri Residues (1 – 4 %) and Pet coke (1-2%)

Table 3: Summary of Project Proposal

S. No

Item Existing Source

as per EC Proposal for Change in Fuel

Source & Fuel Mix

1

A proposal for using mix fuel as Coal

Captive Mahan Coal Block allocated to HIL Existing practice: As the allocation of Mahan Coal Block to HIL has been cancelled by Hon’ble Supreme Court, HIL is continuing to source coal from alternate sources i.e. Domestic Coal, E-auction, imported coal, Pet Coke, etc.

1. Captive Kathotia and Dumri Coal Block allocated to HIL

2. Coal from other sources, i.e., Domestic Coal (Linkage Coal, coal from Open Market, E-auction, Washery reject/tailing), imported coal, etc.

3. Small quantity of Agri Residues (1 – 4 %) and Pet coke (1-2%)

Coal requirement of CPP is 3.5 MTPA of domestic coal from Mahan Coal Block as per EC.

Mahan Coal Block 3.5 MTPA S - 0.5% Ash - 34% GCV - 4300 Kcal/kg

The following is the proposed combination of fuel sources and fuel mix:




1 Linkage coal from own mines (Kathautia & Dumri mines) and coal from open market from CCL/ NCL, washery tailings/ rejects

90 – 97% S - 0.49% Ash - 31.78% GCV - 3000 Kcal/kg

2 Pet Coke 1 – 2 % S - 4.7% Ash - 1.23% GCV - 8104 Kcal/kg

3 Imported Coal 1 – 10% S - 0.62% Ash - 16.61% GCV - 5850 Kcal/kg

4 Agri Residues 1 – 4% S % - 0.22% Ash - 15.2% GCV - 3400 Kcal/kg

Average fuel quality S % - 0.49% Max Ash - 33% Max GCV - 3974 Kcal/kg

HIL has retained M/s Bhagavathi Ana Labs Pvt. Ltd. (BALPL) for carrying out the study on changes in impacts due to change in fuel for the plant. BALPL is a NABET accredited company for carrying EIA Study for Thermal Power Plants. The changes in impacts due to change in fuel have been studied and presented in this report.

2.2.3 Impact Assessment The report presents the change in environmental impacts due to change in coal source, quantity and quality w.r.t. the proposed coal as per the EC granted by MoEF&CC to the Project. A comparative analysis of impacts due to usage of existing and proposed fuel has been done to estimate pollution load. Since the project is already under operation and there has not been any change in the project facilities, the changes in impacts during construction phase will not be there and have not been discussed. The changes in impacts due to change in type of coal on ambient air quality and solid waste generation are only anticipated during operational phase due to change in fuel characteristics. The impacts and mitigation w.r.t. the same have been discussed in the report.

2.3 STATUS OF THE PROJECT-STATUTORY CLEARANCES

The permissions and consents for the plant as on date are summarized in Table-4.




Table 4: Summary of the Statutory Clearances of the Project S. No Permission/ Consent Reference Letter

Date A Mahan Aluminium Unit: Integrated Aluminium

Smelter Complex at Village Orgari, Tehsil Bargawan, District Sidhi in the State of Madhya Pradesh

MoEF&CC File No J-11011/217/2007-I.A. II (I)

1 Public Hearing for the Project 14 March, 2008

2 Original EC letter for Integrated Greenfield Aluminium Smelter Complex for 325 KTPA and CPP of 750 MW at Village Orgari, Tehsil Bargawan, District Singrauli in the State of Madhya Pradesh

18 March, 2009

3 EC amendment letter 15 February, 2012

4 Ministry of Coal, Government of India, allotted “Mahan Coal Block” to Hindalco Industries Ltd for captive use at Mahan Aluminium Project.

12 April, 2006

5 THE COAL MINES (SPECIAL PROVISIONS) ACT, 2015 for, coal mines and coal blocks the allocation of which was cancelled by the judgment dated 25th August, 2014 and its order dated 24th September, 2014.

March 30,2015

6 Kathautia Coal Mine Block in favour of HIL with effect from 1 April, 2015

(No mining work is being carried out at Kathautia mine as of now by HIL due to land issues which is under litigation at the Hon’ble Jharkhand High Court at Ranchi and are subject matter of four writ petitions)

Vesting Order No. 104/3/2015/NA dated 23 March, 2015 from the Nominated Authority, MoC, GOI

7 Dumri Coal Mine Block in favour of HIL with effect from 22 April, 2015

No mining work is being carried out at Dumri mine as of now by HIL as this is a Schedule – III category project, which will likely to commence coal production in FY2018)

Vesting Order No. 104/24/2015/NA dated 22 April, 2015 from the Nominated Authority, MoC, GOI

8 Latest Consent to Operate under Air (Prevention & Control of Pollution) Act, 1981 and Water (Prevention & Control of Pollution) Act, 1974

01 June 2016

9 MoU letters to take-off fly ash 20 July 2015,

10 August 2015

10 Hazardous Wastes Authorization 27 April 2015

11 Long Term linkage Coal LOI issued by CIL for Mahan 24.08.2016




2.4 DETAILS OF EXISTING FUEL

The details of the existing fuel mix being fed to the CPP are provided in Table-5 .

2.4.1 Coal sources

At present Mahan Aluminium is procuring coal from open market i.e. from subsidiaries of Coal India, Import & through e-auction. Maximum coal comes from Rail mode including imported coal and rest coal comes from road mode at different area of UP, MP, Chhattisgarh and Jharkhand.

2.4.2 Coal transportation & Handling Details

• Authorized/appointed transporters are allowed to provide and arrange the truck/tippers at colliery/railway siding for transportation.

• Checking of documents related to RC Book with registration number, driver license no. and the vehicle chassis number with RC book details.

• Ensure that all necessary statutory compliance is followed by the transporters.

• Trucks/tippers are loaded with the laden capacity as permitted by the RTO office.

• Trucks/tippers are properly covered with tarpaulins so as to ensure no dust nuisance enroute. Vehicles without tarpaulin are strictly prohibited.

• At the Railway siding/Morwa, deployed a 24 hours water sprinkling facility to ensure no dust nuisance at the siding.

• A company patrolling vehicle keeps a watch over the vehicular movements from the designated routes with specified speed.

• Water tanker has been deployed for regular water sprinkling inside and outside the plant premises.

• Trucks reporting at plant security gate are checked with the details of the Documents and tarpaulin state of the vehicles.

• Yard Supervisor verifies the documents before unloading of vehicle.

• Trucks unloaded through machines and labours are provided with necessary Personal Protection Equipments (PPE) and regular water sprinkling facilities in the coal yards.

• Adequate illumination facility has been provided at the coal yard.

2.5 DETAILS OF EXISTING ASH GENERATION AND UTILIZAT ION

Details of ash generation and utilization during the past three years are provided in Table-6.




Ash is being supplied to the following industries in vicinity:

• ACC Cement (Kymore)

• Birla Corporation Ltd (Satna)

• KJS Cement Maihar Satna

• Prism Cement Limited (Satna)

• Reliance Cement Company Ltd

• Maihar Cement

• Dilip Buildcon Limited




Table 5: Details of the Fuel Mix as per EC

Coal Description Received Quantity (MT)

QUALITY AS RECEIVED BASIS Moisture% ASH% VM% FC% CV (Kcal/Kg ) S%

As per EIA Report 3500000 6% 34 25% 35% 4025- 4300 0.5

Table 6: Ash Generation & Utilization Details, Maha n Baragawan

S. No. Year

Generation (LMT) Utilization (LMT) Total Ash

Utilized

% Utilization of Total Ash Bottom Ash Fly ash Total Ash Cement

Companies Brick Plant

Ash Dyke/ Low lying area/ Others

1 2013-14 0.51 2.03 2.54 2.04 0.00 0.00 2.04 80

2 2014-15 1.62 6.48 8.10 6.46 0.00 0.00 6.46 80

3 2015-16 2.52 10.10 12.62 9.03 0.00 0.52 9.55 76

4 2016 -17 [up to Nov]

1.71 6.85 8.57 5.02 0.00 0.20 5.22 61.27




ENVIRONMENTAL BASELINE STATUS

3.1 PREAMBLE

Regular Ambient Air Quality (AAQ) as well as stack monitoring is conducted by HIL within the project premises.

3.2 STACK EMISSION DETAILS Regular monthly monitoring of the existing stacks is undertaken by HIL. The monitoring SPM, SOx and NOx values range between 24.3 to 42.1 mg/Nm3, 102.8 to 506.2 mg/Nm3 and 22.7 to 148.7 mg/Nm3 respectively, which is well within the prescribed norms. The stack emission details of the CPP and Smelter Plant of the past eight months is provided in Table-7 and Table-8 respectively.

3.3 ASH GENERATION DETAILS Details of ash generation and utilization during the past three years are provided in Table-6.




Table 7: Stack Emission (mg/Nm 3) – Captive Power Plant – Mahan Plant

S. No LOCATION \ PARAMETER SPM SOx NOx SPM SOx NOx SPM SOx NOx

NORMS (mg/Nm 3) �� 50 600 300 50 600 300 50 600 300 DATE�� Nov 15 Dec 15 Jan 16

1 CPP Unit # 1 26.85 115.26 26.79 31.15 492.55 138.79 30.85 488.62 132.84 2 CPP Unit # 2 34.25 113.85 25.42 30.55 503.45 141.63 27.63 499.52 143.85 3 CPP Unit # 3 41.87 120.6 29.97 40.42 498.6 144.94 42.12 492.8 146.4 4 CPP Unit # 4 28.71 107.99 28.58 36.2 501.5 148.65 38.8 506.2 148.25 5 CPP Unit # 5 37.62 102.8 22.71 39.42 496.54 145.66 36.98 494.85 141.66

S. No DATE�� Feb 16 Mar 16 Apr 16 1 CPP Unit # 1 29.55 350.22 108.8 24.25 310.15 98.5 25.68 336.22 122.46 2 CPP Unit # 2 29.10 374.5 134.45 24.70 342.6 118.8 25.98 341.56 126.56 3 CPP Unit # 3 38.55 392.4 139.1 34.85 368.5 131.7 32.64 361.82 136.34 4 CPP Unit # 4 34.6 424.6 140.15 32.4 410.2 132.45 30.46 390.12 137.68 5 CPP Unit # 5 30.4 375.6 128.45 29.2 319.5 120.25 28.84 324.32 125.42

S. No DATE�� May 16 Jun 16 July 16 1 CPP Unit # 1 29.7 318.22 102.54 27.35 314.15 96.75 25.15 305.20 95.35 2 CPP Unit # 2 28.91 324.06 111.58 27.85 345.2 119.75 25.10 341.25 117.35 3 CPP Unit # 3 33.57 315.86 109.54 38.75 365.2 135.5 36.25 360.15 133.40 4 CPP Unit # 4 34.88 385.76 110.7 35.2 415.35 136.25 38.35 410.55 133.15 5 CPP Unit # 5 - - - 31.3 325.5 121.24 34.15 320.25 123.55

DATE�� Aug 16 Sept 16 Oct 16 1 CPP Unit # 1 23.85 301.40 92.40 28.31 315.12 105.23 33.25 307.24 112.34 2 CPP Unit # 2 23.40 348.85 112.65 30.21 331.55 115.24 30.45 330.32 130.44 3 CPP Unit # 3 38.80 355.60 127.80 32.44 345.19 124.37 27.61 319.45 109.56 4 CPP Unit # 4 35.15 398.40 129.80 30.51 372.49 111.58 34.78 370.88 125.66 5 CPP Unit # 5 30.72 307.65 120.45 34.62 320.66 125.33 30.55 365.89 137.75

S. No DATE�� Nov 16 1 CPP Unit # 1 29.5 304.50 115.20 2 CPP Unit # 2 38.48 421.51 120.32 3 CPP Unit # 3 25.90 384.50 111.51 4 CPP Unit # 4 33.78 364.15 130.42 5 CPP Unit # 5 37.54 377.85 135.62 Source: Monitoring Reports (Nov, 2015 to Nov, 2016) by M/s Ecomen Laboratories Pvt Ltd




Table 8: Stack Emission (mg /Nm 3) - Smelter Plant – Mahan Plant

Sl. No LOCATION \ PARAMETER SPM HF PAH SPM HF PAH SPM HF PAH

NORMS (mg/Nm 3) 50 - 2 50 - 2 50 - 2 DATE Nov 15 Dec 15 Jan 16

1 GTC 1 26.9 0.08 - 27.7 0.07 - 29.8 0.08 - 2 GTC 2 29.95 0.06 - 26.99 0.06 - 25.57 0.06 - 3 FTC 20.8 0.06 BDL 22.4 0.07 BDL 24.10 0.08 BDL

Sl. No DATE Feb 16 Mar 16 Apr 16 1 GTC 1 27.6 0.09 - 26.15 0.07 - 26.76 0.08 - 2 GTC 2 26.95 0.07 - 27.62 0.0 - 19.26 0.07 - 3 FTC 21.15 0.07 BDL 19.85 0.08 BDL 17.95 0.09 BDL

Sl. No DATE May 16 Jun 16 July 16 1 GTC 1 23.39 0.09 - 28.55 0.06 - 26.20 0.08 - 2 GTC 2 22.13 0.04 - 28.15 0.05 - 29.20 0.06 - 3 FTC 19.14 0.06 BDL 20.8 0.08 BDL 21.35 0.07 BDL

Sl. No DATE August, 2016 September, 2016 October, 2016 1 GTC 1 28.90 0.07 - 25.34 0.09 - 11.85 0.06 - 2 GTC 2 27.80 0.08 - 26.42 0.06 - 10.40 0.08 - 3 FTC 24.85 0.08 BDL 37.31 0.07 BDL 22.15 0.07 BDL

Sl. No DATE November, 2016 1 GTC 1 19.34 0.07 - 2 GTC 2 22.64 0.06 - 3 FTC 14.20 0.08 BDL

Source: Monitoring Reports (Nov,2015 to Nov, 2016) by M/s Ecomen Laboratories Pvt Ltd




4.0 IMPACTS DURING OPERATION PHASE

Impacts during operation phase are potentially permanent in nature and may continue till the time the plant operates unless mitigation measures are put in place. There will be changes in impact for air environment and ash disposal due to change in fuel quality and quantity.

4.1 PROPOSED FUEL BLENDING QUALITY Various fuel sources and fuel mix combinations have been considered for the proposed project. The summary of typical fuel analysis of various fuel sources is provided in Table-9 . The following option has been considered for prediction of impacts and analysis of proposal w.r.t. incremental environmental impacts.

• Coal from (domestic & own mine), pet coke, agri residues and imported coal.

The details of proposed options considered for change in coal requirement source and quantity is given in Table-10 .

4.3 FUEL TRANSPORTATION DETAILS

At present Mahan Aluminium is procuring coal from open market, i.e, from subsidiaries of Coal India, Import and through e-auction. Maximum coal comes from rail mode including imported coal and rest coal comes from road mode at different area of UP, MP and Chhattisgarh.

There will not be any change in the impact due to vehicular traffic as proposed in present proposal.




Table 9: Typical Fuel Quality Details from Various Sources

Fuel Source IM % TM % ASH % VM % FC % CV Kcal/Kg

Sulphur

%

Avg Min Max Avg Min Max Avg Min Max Avg Min Max Avg Min Max Avg Min Max Avg

Imported 2.24 0.94 2.75 7.8 5.5 10.95 16.61 12.33 22.50 24.30 22.33 25.73 51.29 42.24 53.95 5850 5500 6000 0.62 Pet Coke 0.42 0.10 0.89 3.81 2.74 5.32 1.18 0.78 1.85 8.81 8.57 9.19 86.19 84.82 87.35 8104 7942 8206 4.70 CCL-Amrapali 4.41 1.31 7.28 14.08 10.04 17.73 37.21 31.23 46.76 20.01 19.05 21.08 28.71 23.19 32.44 3513 2937 3868 0.45 NCL –Jhingurdah exclusive /spot auction

5.54 1.08 9.67 16.55 10.52 21.29 39.65 33.19 51.21 19.15 16.65 22.28 24.66 15.52 29.07 2982 2127 3387 0.40

NCL -Bina 2.96 0.63 7.12 12.09 8.89 17.74 41.19 33.33 48.80 20.71 19.73 23.06 26.01 22.20 31.46 3269 2870 3938 0.35 NCL -Jayant (Dhudhichuwa- Wharfall)

3.02 1.51 5.48 13.57 11.73 17.18 34.21 29.09 44.29 21.53 20.27 22.63 30.67 22.50 33.79 3778 3000 4173 0.40

NCL - Krishnashila 7.77 5.20 9.80 15.34 11.75 16.75 29.41 28.80 30.00 23.90 23.25 24.50 31.35 30.80 31.80 4011 3975 4025 0.40

SECL –Chirimiry/Vijay West

3.94 2.00 7.37 11.84 8.03 14.40 25.38 19.15 32.52 22.40 20.50 25.00 40.38 35.41 42.58 4813 4363 5218 0.48

Kathutia 5.5 3 8 11.4 7.9 14.9 15.2 6.4 24 32.65 25.3 40 46.3 38.5 54.1 5850 4900 6800 0.47 Dumri 3.7 1.6 5.8 10.75 7.5 14 32.6 14.2 51 22.32 17.8 26.85 40.625 30.55 50.7 4100 3210 5010 0.61 Agri Residues 6.5 5 8 10 9 11 16 15 17 62 58 65 16.1 15.75 16.5 3400 3300 3500 0.22

Table 10: Projected Blending Quality: (Domestic + O wn Mine+ Imported + Pet coke + Agri Residues)

Fuel Type/ Source Average Required Quantity (MT) Percentage

QUALITY AS RECEIVED BASIS IM% TM% ASH% VM% FC% CV (Kcal/Kg) S%

Total Blended Coal Quality 3445100 100.00 3.79 12.63 33 21.33 33.48 3974 0.49




4.3 DISCUSSION ON INCREMENTAL EMISSION LOAD

The main pollutants from the proposed project will be Particulate Matter, Sulphur dioxide (SO2) and Oxides of Nitrogen (NOx) from the burning of coal. The pollutants are dispersed adequately by providing suitable stack height. The particulate matter emissions from the CPP will be restricted to 50 mg/Nm3 and SO2 emissions depend on Sulphur content in fuel mix used.

There will be no change in incremental NOx and PM load due to change in fuel mix.

However, emission load of the major pollutant, i.e., Sulphur dioxide (SO2) emitted from the stacks from the project in the following options:

1. Option-1: Existing EC Option

2. Option-2: (Domestic + Own mine + Imported + Pet coke + Agri Residues+ Washery tailings/rejects)

Table 11: Coal Requirement for 5x150 MW Power Plant

S.No Parameters Unit Option-1 Option-2

1 Fuel Mix Quantity TPA 35,00,000 34,45,100 2 GCV Kcals/kg 4025 - 4300 3974

3 Sulphur Content % 0.50 0.49

4 Ash Content % 34 33

5 Imported Coal % 0 1-10 6 Pet Coke % 0 1-2 7 Indigenous Coal % 100 90-97 8 Agri Residues % 0 1-4

Considering 1% for ageing loss

The incremental ground level concentrations for SO2 for different considered scenarios are given in Table-12 .

Table 12: Predicted 24-Hourly Short Term Incrementa l Concentrations

Pollutant Total SO 2 Emission Rates (g/s)

Option-1 Option-2

SO2 1110 1071

It is evident from the above table that the SO2 load will be less than the existing EC conditions as Sulphur in Fuel mix shall be maintained <0.5%. Thus, there will be no incremental SO2 load due to the proposed change in fuel mix.




4.4 IMPACT OF SOLID WASTE

The ash generation quantity as per previously proposed and now proposed fuel mix quality and quantities are given in Table-13.

Table 13: Ash Generation Quantity

Item Option-1 Option-2

Type of Fuel Existing EC Option

(Domestic + Own mine + Imported + Pet coke + Agri

Residues) Coal Consumption (TPA) 35,00,000 34,45,100 Max Ash Percentage (%) 34 33 Fly Ash Generation (TPA) 9,52,000 9,09,506 Bottom Ash Generation (TPA) 2,38,000 2,27,377 Total Ash Generation (TPA) 11,90,000 11,36,883

Computed for 100%PLF

HIL will comply with the Fly Ash Utilization Notification and as amended thereof. HIL will explore maximum possibilities for ash utilization considering new technologies and avenues and try to achieve the target fixed by MoEF&CC in this regard. Proper disposal of solid waste and its management will not pose any contamination problem to surrounding land environment. Both the coarse ash from the furnace bottom and the fly ash from the dust collecting hoppers are proposed to be taken to the ash disposal areas. Presently HIL is operating an ash dyke with area about 9.0 hectors which is in operational having life of more than 10 years. Total ash dyke area is 220 ha including green belt area. The ash pond has been designed considering environment friendly storage of ash lined with LDPE lining at the bottom and sides. Decanting well has also been provided for recirculation of ash water. Therefore, changes in impacts due to change in fuel are not expected due to disposal of solid waste. The fly ash is being utilized in various cement companies to the maximum extent.

4.5 SUMMARY OF ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION

The summary of the anticipated adverse environmental impacts and possible mitigation measures are given in the Table-14. The table further describes the mitigation measures to be taken and also identifies the probable sources of the pollution.




Table 14: Anticipated Environmental Impacts & Mitig ation

Discipline Environmental Impacts Mitigation Measures

Air Quality Reduction in SO2

concentration due to proposed change in fuel mix with Sulphur content lesser than the EC condition

Existing mitigation measures will be continued for the proposed change in fuel mix;

Existing green belt in 189 ha area that will take care of pollution and Proposed greenbelt development in 415 ha.

The resultant air quality will conform to the stipulated standards.

Ash Generation

Reduction in generation of ash due to proposed change in fuel mix

100% ash utilization targeted Insignificant/ manageable impact due to additional ash generation




5.0 ENVIRONMENT MANAGEMENT PLAN

5.1 Preamble The EMP reflects the commitment of project to create an environmental friendly project. The potential impacts on the environment from the project are identified based on the nature of the various activities associated with the location, construction and operation of the proposed project and also on the current status of the environmental quality at the proposed area. Major EMP aspects already implemented by HIL, which also mitigate the identified environmental impacts due present proposal are mentioned as under:

5.2 Ambient Air Quality

Various efforts have been taken to reduce particulate matter levels in ambient air as summarized below:

• Proper upkeep and maintenance of vehicle, water sprinkling, sweeping on

roads and construction site doing regularly for dust Suppression. • Internal roads completed. • Effective ESPs (with 2 passes and 7 fields in each pass for single unit)

installed for controlling source emission from Boilers in CPP (Captive Power Plant).5Nos ESPs are running efficiently.

• Stacks have been constructed with adequate height for wider dispersion of gaseous emissions.

• Online Continuous monitoring system has been provided for Stacks. • Closed conveying system for alumina handling, completed. • Bag filters provided at all transfer points to control fugitive emission. • Dust suppression system has been provided at coal crushing house, conveyor

belt, transfer points, raw material handling area etc. • Regular water sprinkling done at site to minimize fugitive emission due to

vehicle movement. • Developing of green belt in and around the plant and colony is in progress.

We have planted about 4,43,000 plants till date covering land of area 189 ha and Target to cover 33% of total land.

• All the units of CPP are equipped with individual ESP designed for emission level 50 mg/Nm3.

• Online monitoring system at ESP stacks installed and maintaining properly. • All the circuits are closed and covered to avoid/minimize the spillage from

material handling circuits. • Water sprinklers installed in raw material (coal) handling area.




• Dust suppression /extraction (bag filter) systems provided in crushing house, conveyor belt, transfer points etc.

• The layout of the smelter and CPP is designed to minimize transport distance of raw materials and intermediate products. The project is employing best material handling techniques.

• At present, coal for the captive power plant transported by rail/road both. • Housekeeping already in place at plant premises. • Suitable dust suppression system provided to control fugitive emission during

material handling. • HIL has already invested more than 850 Crores for pollution control and

appropriate recurring cost has been earmarked for smooth running of the facilities.

• Control equipment is installed to restrict particulate emission below 50 mg/Nm3.

5.3 Ash Management Plan

Details of ash generation and utilization during the past three years are provided in Table-6. Ash is being supplied to the following industries in vicinity:

• ACC Cement (Kymore) • Birla Corporation Ltd (Satna) • KJS Cement Maihar Satna • Prism Cement Limited (Satna) • Reliance Cement Company Ltd • Maihar Cement • Dilip Buildcon Limited

5.4 Greenbelt Details The greenbelt development map is given in Figure-4 . Photographs depicting greenbelt development at site are given in Figure-5 . We have taken initiative to develop green belt right from the beginning of project stage in form of in-situ plantation under sustainable development policy. Till date we have planted more than 4.43 Lacs number of tree sapling in different location of CPP smelter and township covering about 189 ha area, which are now in well growth with good canopy. Beside the Hindalco has taken a drive to increase the greenery in the premises by in situ method by direct sowing of seed at site of local species mainly Ziziphus




mauritiana, Butia monosperma, Mangifera indica, Acasia nilotica and Acasia catechu etc since early project stage, which have now become big tree with good canopy and compensating the environment loss. The numbers of plants through in situ plantation are more than one lacks in 40 ha.




Figure 5: Project Site Photographs depicting




6.0 CONCLUSIONS

The plant has already obtained EC and is already fully equipped with effective pollution control measure and environmental management action plan. By using mix fuel from alternate sources as linkage Coal, Coal from open market, E-auction (90 – 97 %), apart from adding small quantity of Agri Residues (1-4%), Imported coal (1 – 10 %) and Pet coke (1-2%) to top up and enhance the fired coal CV to achieve the minimum required fired coal CV suitable to Boiler in case when Indian coal CV comes lower due to bad quality in domestic coal, there will not be significant impact in air quality owing to higher GCV and lesser quantity of coal consumption. Further, the ash generation will be reduced, owing to lesser ash percentage in the proposed fuel mix. In view of considerable benefits from the project to the sustainable development of the region, the proposed change of fuel mix and process optimization is most advantageous and beneficial.




ANNEXURE-1: COPY OF MAHAN COAL BLOCK ALLOCATION LET TER




ANNEXURE-2: COPY OF MAHAN CONSENT ORDER FOR 6 th UNIT




ANNEXURE-3: COPY OF HAZRADOUS WASTE AUTHORIZATION F ROM MPPCB