APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE

FORM-I for MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANT at , ,

Submitted to: Ministry of Environment and Forests New

Submitted by:

M/s. Ltd Renukoot –231217 Dist.Sonbhadra U.P.

September, 2018 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

FORM-I (I) BASIC INFORMATION

S. No. Item Details 1. Name of the project/s Proposed Modernization and Expansion by Hindalco Industries Ltd., Alumina Refinery from 660 KTPA to 900 KTPA and Smelter Plant from 356 KTPA to 472 KTPA at Renukoot, Dist. Sonbhadra, Uttar Pradesh as per the EC vide letter No. F. No. J- 11011/929/2008-IA-II(I) dated December 02,2011. Through Modernization, we have enhanced Alumina production from 660 KTPA to 720 KTPA and Aluminium Metal from 356 KTPA to 420 KTPA by debottlenecking, improving process, operation & maintenance efficiency, increasing plant availability factor and addition of balancing equipment including 101 pots in the existing 11 pot lines of smelter plant.

We are now seeking extension of Environment Clearance for Alumina Plant from 720 KTPA to 900 KTPA and Smelter Plant from 420KTPA to 472 KTPA.

2. Sr.No. in the schedule 3 (a) 3. Proposed capacity /area/ length/ tonnage Alumina Refinery- 660 KTPA to 900 KTPA to be handled/ command area/ lease Alumina Smelter- 356 KTPA to 472 KTPA, area/number of wells to be drilled.3(a area about 9.25 hectare. 4. New/Expansion/Modernization Expansion 5. Existing Capacity/Area etc. Alumina Refinery- 720 KTPA Alumina Smelter- 420 KTPA 6. Category of Project i.e. ‘A’ or ‘B’ ‘A’ Primary metallurgical industry –All projects 7. Does it attract the general condition? If No yes, please specify. 8. Does it attract the specific condition? If No yes, please specify. 9. Location At Renukoot, Dist. Sonbhadra U.P. Plot/Survey/Khasra No. Longitude :83 003’ East Village Latitude: 24 0 12’ North Tehsil No alternative sites considered, because it District is an expansion project within our existing State plant. 10. Nearest railway station/airport along with Renukoot Railway Station :2 km,SE distance in kms Airport :135km, N 11. Nearest Town, city, District Headquarters Dudhinagar 20km,E

Page 2 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

S. No. Item Details along with distance in kms District HeadquartersRobertsgunj49km,N 12. Village Panchayats, ZillaParishad, Project site is located in Renukoot, Sonbhadra Municipal Corporation, Local body District, Uttar Pradesh. (complete postal addresses with telephone nos. to be given) 13. Name of the applicant M/s. Hindalco Industries Ltd ,Renukoot

14. Registered Address Shri S.N.Jajoo Chief Operating Officer(COO) Hindalco Industries Limited, P.O. Renukoot, Dist: Sonbhadra, Uttar Pradesh – 231217, 15. Address for correspondence: Name Shri S.N. Jajoo Designation (Owner/ Partner / CEO) Chief Operating Officer (COO) Hindalco Industries Limited, Pin code P.O. Renukoot, E-mail Dist: Sonbhadra, Telephone No. Uttar Pradesh – 231217, Fax No. Phone: (05446)-252077/79, 254791/96 Fax : (05446)-252107, 252427 Email: [email protected] 16. Details of Alternative Sites examined, if No alternative sites considered, because it is any. Location of these sites should be an expansion project within our existing shown on a topo-sheet. plant The location map of the project site is enclosed as Annexure-1. 17. Interlinked Projects None 18. Whether separate application of interlinked Not applicable project has been submitted? 19. If yes, date of submission Not applicable 20. If no, reason Not applicable 21. Whether the proposal involves No approval/clearance under: if yes, details of the same and their status to be given. i. The Forest (Conservation) Act, 1980? ii. The Wildlife (Protection) Act, 1972? iii. The C.R.Z. Notification, 1991? 22. Whether there is any Government No Order/Policy relevant /relating to the site? 23. Forest land involved (hectares) Nil

24. Whether there is any litigation pending No against the project and/or land in which the project is propose to be set up? a) Name of the Court b) Case No.

Page 3 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

S. No. Item Details c) Orders/directions of the Court, if any and its relevance with the proposed project.

(II) ACTIVITY

1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)

Details thereof (with approximate quantities/ Sr. Information/Checklist Yes rates, wherever possible) with source of No. Confirmation / No information data 1.1 Permanent or temporary change in No There will not be any major change in land use, land cover or topography landuse, land cover or topography. including increase in intensity of The land required for the total project is land use (with respect to local land about 9.25 hectare. use plan) The present land use at the project site is industrial land.

The general elevation of site is about 330- m above MSL.

The location map and Study area Map of the site are enclosed as Annexure-I& Annexure-II 1.2 Clearance of existing land, Yes At present, there is no vegetation and vegetation and building? building at proposed site. 1.3 Creation of new land uses? Yes The proposed Modernization and Expansion of Alumina Refinery & Smelter Plant will be established within the premises of the existing plant. 1.4 Pre-construction investigations, No Not required. e.g., bore houses, soil testing? 1.5 Construction works ? Yes Construction of Pot Cells, Baking Furnace, Boiler, Calciner, liquor tanks, Rectifier, compressor house, turbine, Coal Circuit etc., will be done. 1.6 Demolition Works ? No Nil. There will not be any demolition works. 1.7 Temporary sites used for No The construction workers will be provided construction works or housing of housing with the existing colony construction workers? premises.ill be done by our own employees who reside in colony and through the contractors who will hired labor from local area. Thus, there will not be any housing requirement for the construction workers at

Page 4 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

Details thereof (with approximate quantities/ Sr. Information/Checklist Yes rates, wherever possible) with source of No. Confirmation / No information data the project site . 1.8 Above ground buildings, structures Yes Limited excavation work will be carried out or earthworks including linear for construction of the structures. Minimum structures, cut and fill or cut and fill is required to make the land excavations. suitable for constructions.

Construction of Pot Cells, Baking Furnace, Boiler, Calciner, liquor tanks, Rectifier, compressor house, Coal Circuit etc., will be done. 1.9 Underground works including No Not envisaged mining or tunneling? 1.10 Reclamation works? No Not Applicable 1.11 Dredging? No Not Applicable 1.12 Offshore structures? No Not Applicable 1.13 Production and manufacturing Yes Proposed Modernization and Expansion by Process? Hindalco Industries Ltd., Alumina Refinery from 660 KTPA to 900 KTPA and Smelter Plant from 356 KTPA to 472 KTPA at Renukoot, Dist. Sonbhadra, Uttar Pradesh as per the EC vide letter No. F. No. J- 11011/929/2008-IA-II(I) dated December 02,2011. Through Modernization, we have enhanced Alumina production from 660 KTPA to 720 KTPA and Aluminium Metal from 356 KTPA to 420 KTPA by debottlenecking, improving process, operation & maintenance efficiency, increasing plant availability factor and addition of balancing equipment including 101 pots in the existing 11 pot lines of smelter plant.

The process description of Alumina Refinery & Smelter plant is enclosed as Annexure- III , along with the process flow sheet.

1.14 Facilities for storage of goods or Yes Storage of goods or materials will be stored materials? in existing storage area. 1.15 Facilities for treatment or disposal Yes Red Mud is the solid waste generated from of solid waste or liquid effluents? Bauxite refining. Rotary vacuum drum filters will be used to convert wet mud slurry into cake form having a solid content of about 70%. The well transportable mud cake (70% solids) with negligible caustic concentration will be disposed off in area

Page 5 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

Details thereof (with approximate quantities/ Sr. Information/Checklist Yes rates, wherever possible) with source of No. Confirmation / No information data specially earmarked surrounded by a strong earthen dam.

The fly ash generated in the boiler by the burning of coal will be dry fly ash and will be supplied to various cement and cement based industries.

We have patented process for utilization of spent pot lining (SPL) by recovering its fluorine values to produce valuable cryolite, a raw material used in smelting process. Its residue is efficiently used in our boilers as fuel with coal. Thus we will treat & recycle recycled total additional SPL generated.

We have an efficient Effluent Treatment Plant and Sewage Treatment Plant which has sufficient capacity to treat extra effluent generated through this expansion. 1.16 Facilities for long term housing of No The existing township shall cater the operational workers? requirement of Refinery & Smelter. 1.17 New road, rail or sea traffic during No Existing transport facilities will be used construction of operation? during construction or operation. 1.18 New road, rail, air waterborne or No The plant is located adjacent to at a other transport infrastructure distance of about 0.5 km of N.H. 76 E and including new or altered routes and State highway connecting Varanasi and stations, ports, airports etc.? Shakti Nagar is about 17 km. 1.19 Closure or diversion of existing No Not envisaged. transport routes or infrastructure leading to changes in traffic movements? 1.20 New or diverted transmission lines No Not envisaged. or pipelines? 1.21 Impoundment, damming, No Not required. culverting, realignment or other changes to the hydrology of watercourses or aquifers? 1.22 Stream crossings? No Not applicable 1.23 Abstraction or transfers of water No No additional water will be drawn for from ground or surface waters? proposed project .The water requirement for both Refinery and Smelter together will be about 239.58 m3/hr and will be met through recycled water from ETP and STP. 1.24 Changes in water bodies or the No No changes in water bodies or land surface

Page 6 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

Details thereof (with approximate quantities/ Sr. Information/Checklist Yes rates, wherever possible) with source of No. Confirmation / No information data land surface affecting drainage or is envisaged and hence Existing drainage run-off? network will not be affected.work. 1.25 Transport of personnel or materials Yes Project site is within the existing plant. for construction, operation or Existing facilities will be used for all decommissioning? activities. 1.26 Long-term dismantling or No Not envisaged. decommissioning or restoration works? 1.27 Ongoing activity during No Not envisaged. decommissioning which could have an impact on the environment? 1.28 Influx of people to an area in either Yes The construction labor will be hired from temporarily or permanently? the local area which may lead to temporary influx of the people. will be done by our own employees who reside in colony and through the contractors who will took labor from local area.

The additional manpower requirement during operation phase will be around 1200. 1.29 Introduction of alien species? No Not envisaged 1.30 Loss of native species or genetic No Not envisaged diversity? 1.31 Any other actions? No -

2. Use of Natural resources for construction or operation of Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply).

Sr. Information/ Yes/ Details thereof (with approximate quantities/ No. Checklist Confirmation No rates, wherever possible) with source of information data 2.1 Land specially undeveloped or No Proposed site is within the existing plant. agricultural land (ha) So no need to develop the new land.

2.2 Water (expected source & No No additional water will be drawn from competing users) unit KLD the source. The water requirement for both Refinery and Smelter together will be about 239.58m3/hr that will be met through recycled water from ETP and STP.

Page 7 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

2.3 Minerals (MT) Yes Minerals: Bauxite –5,15,960MTPA Lime –9,862 MTPA

Others – C.P.Coke – 50,000MTPA Aluminum Fluoride-1,740 MTPA LDO - 26420 MTPA Coal –2,00,000MTPA Caustic Soda –12,869 MTPA

2.4 Construction material – stone, Yes Construction material such as sand, aggregates, and/ soil (expected aggregates, soil etc., will be used. source - MT) However, the quantification of the materials will be made during detailed engineering stage. These materials will be sourced from surrounding 50-km radius area. 2.5 Forests and timber (source-MT) No Not envisaged 2.6 Energy including electricity and Yes The power requirement for the proposed fuels (source, competing users) expansion will be 169.7 MW that shall be Unit: fuel (MT), energy (MW) sourced from the Co – generation unit, Renukoot and captive power plant at . LDO – 26, 420 MTPA Coal – 2,00,000 MTPA 2.7 Any other natural resources No Not envisaged (use appropriate standard units)

3.0 Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health

Details thereof (with approximate quantities/ Information/Checklist Yes/ S. No. rates, wherever possible) with source of Confirmation No information data 3.1 Use of substances or No No such material will be used which are materials, which are hazardous as per MSIHC rules. hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies) 3.2 Changes in occurrence of No Not envisaged disease or affect disease vectors (e.g. insect or water borne diseases)

Page 8 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

3.3 Affect the welfare of people, No Not envisaged e.g., by changing living conditions? 3.4 Vulnerable groups of people No Not envisaged who could be affected by the project e.g. hospital patients, children, the elderly etc. 3.5 Any other causes No Not envisaged

4.0 Production of solid wastes during construction or operation or decommissioning (MT/month)

Sr. No. Information/ Checklist Yes/ Details thereof (with approximate quantities/ Confirmation No rates, wherever possible) with source of information data 4.1 Spoil, overburden or mine Yes The spoil and earthwork generated during wastes construction will be reused for construction as well as for filling in low lying ine area. 4.2 Municipal waste (domestic and Yes 10 MT/month domestic solid waste is or commercial wastes) being generated which will be vermi- composted and used within the plant and colony site for plantation as manure. 4.3 Hazardous wastes (as per Yes Used Oil –37.06 KL/month, ETP Sludge - hazardous waste management 72 MT/month and SPL-59 MT/month rules) will be generated.

4.4 Other industrial process wastes Yes Red Mud is the solid waste generated from Bauxite refining. Rotary vacuum drum filters will be used to convert wet mud slurry into cake form having a solid content of about 70%. The well transportable mud cake (70% solids) with negligible caustic concentration will be disposed of in an area specially earmarked surrounded by a strong earthen dam.

The fly ash generated in the boiler by the burning of coal will be dry fly ash and will be supplied to various cement and cement based industries.

We have patented process for utilization of spent pot lining (SPL) by recovering its fluorine values to produce valuable cryolite, a raw material used in smelting process. Its residue is efficiently used in our boilers as fuel with coal. Thus we

Page 9 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

Sr. No. Information/ Checklist Yes/ Details thereof (with approximate quantities/ Confirmation No rates, wherever possible) with source of information data recycled total SPL generated.

We have an efficient Effluent Treatment Plant and Sewage Treatment Plant, which have sufficient capacity to treat extra effluent generated through this expansion. 4.5 Surplus product No - 4.6 Sewage sludge or other sludge Yes Sludge from ETP and STP will be used for from effluent treatment plantation in red mud area. 4.7 Construction or demolition Yes This will be used internally for filling and wastes leveling of the sites within the plant site area. 4.8 Redundant machinery or No Not envisaged equipment 4.9 Contaminated soils or other No Not envisaged materials 4.10 Agricultural wastes No Not envisaged 4.11 Other solid wastes No Not envisaged

5.0 Release of pollutants or any hazardous, toxic or noxious substances to air (kg/hr)

Sr. No. Information/Checklist Yes/ Details thereof (with approximate quantities/ Confirmation No rates, wherever possible) with source of information data

5.1 Emissions from combustion of Yes SPM, SO 2 and NOx are the major fossil fuels from stationary or emissions from the proposed Expansion of mobile sources Refinery and Smelter and will be controlled through efficient pollution control equipment.

5.2 Emission from production Yes SO 2, PM, Fluoride and NOx emissions will be processes from Alumina Refinery and Smelter. These emissions will be controlled by installation of efficient Electrostatic Precipitators, FTP and Advance Dry Scrubbing System.

Fluoride emissions from pots < 0.8kg/ton of Aluminium.

5.3 Emissions from material Yes Fugitive emissions. handling including storage or transport 5.4 Emissions from construction Yes The construction activities would result in activities including plant and an incremental increase in the SPM levels.

Page 10 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

Sr. No. Information/Checklist Yes/ Details thereof (with approximate quantities/ Confirmation No rates, wherever possible) with source of information data equipment However, this is restricted to the project site only and would be marginal and temporary in nature. 5.5 Dust or odors from handling of Yes The construction activities may cause materials including construction changes in the SPM levels. The impact materials, sewage and waste would however be marginal, reversible and temporary in nature.

There will not be any odor generating substances. 5.6 Emissions from incineration of No Not Envisaged waste 5.7 Emissions from burning of No Not Envisaged waste in open air (e.g. slash materials, construction debris) 5.8 Emissions from any other No Not Envisaged sources

6.0 Generation of Noise and Vibration, and emissions of Light and Heat

Sr. No. Information/ Yes Details thereof (with approximate quantities/ Checklist Confirmation /No rates, wherever possible) with source of information data 6.1 From operation of equipment Yes Alumina Refinery - 90-105 dB(A) e.g. engines, ventilation plant, Smelter plant- 91-95 dB(A) crushers Carbon plant- 80-95 dB(A)

Regular maintenance of the equipment will help in reducing these noise levels.

Necessary PPEs shall be provided to workers. 6.2 From industrial or similar Yes The expected noise levels will be in the processes range of 75-85 dB (A).

Regular maintenance of the equipment will help in reducing these noise levels.

Necessary PPEs shall be provided to workers

Page 11 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

6.3 From construction or Yes During construction, temporary. demolition No demolition process.

The range will be 65-80 dB(A). Regular maintenance of the equipment will help in reducing these noise levels. 6.4 From blasting or piling No Not envisaged 6.5 From construction or Yes During construction: temporary. operational traffic During operation: less to moderate. The noise levels are expected to be in the range of about 70-75 dB(A). 6.6 From lighting or cooling No Not envisaged systems 6.7 From any other sources No Not envisaged

7.0 Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea

Sr. No Information/Checklist Yes/No Details thereof (with approximate quantities/ Confirmation rates, wherever possible) with source of information data 7.1 From handling, storage, use No Not envisaged or spillage of hazardous materials 7.2 From discharge of sewage or No The sewage wastewater will be treated other effluents to water or the and used for greenbelt development land (expected mode and place of discharge) The trade effluents will be treated and recycled for process use. 7.3 By deposition of pollutants No The incremental ground level emitted to air into the land or concentrations of air pollutants are likely into water to be well within the permissible limits. Hence, no impact on air is envisaged.

Hence, no risk of contamination of air, land or water is envisaged. 7.4 From any other sources No Not envisaged 7.5 Is there a risk of long term No Not envisaged build up of pollutants in the environment from these sources?

8.0 Risk of accidents during construction or operation of the project, which could affect human health or the environment

Sr. No Information/Checklist Yes/No Details thereof (with approximate quantities/ Confirmation rates, wherever possible) with source of information data

Page 12 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

Sr. No Information/Checklist Yes/No Details thereof (with approximate quantities/ Confirmation rates, wherever possible) with source of information data 8.1 From explosions, spillages, No No hazardous substance will be used fires etc. from storage, during construction or operation of the handling, use or production of project, however existing facilities for fire hazardous substances fighting and to handle any emergency will be used. 8.2 From any other causes No Not envisaged 8.3 Could the project be affected No There is no record of occurrence of floods, by natural disasters causing landslides, cloudbursts etc. The proposed environmental damage (e.g. project site comes under Seismic Zone-III floods, earthquakes, as per IS 1893 (Part-I):2002 landslides, cloud burst etc)? classification. Hence, seismically it is a stable zone.

9.0 Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality

Sr. No Information/Checklist Yes/No Details thereof (with approximate quantities/ Confirmation rates, wherever possible) with source of information data 9.1 Lead to development of supporting, utilities, ancillary development or development stimulated by the project which could have impact on the environment e.g.:

Supporting infrastructure No Existing infrastructure is sufficient. (roads, power supply, waste

or wastewater treatment, etc)

Housing development No Existing township will accommodate all the employees. Extractive industries No Not envisaged. Supply industries Yes Caustic Soda manufacturer, Coal Mines etc.

Other No Not envisaged. 9.2 Lead to after use of the site, No No Major impacts are envisaged. which could have an impact on the environment 9.3 Set a precedent for later No Not envisaged. developments

Page 13 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

Sr. No Information/Checklist Yes/No Details thereof (with approximate quantities/ Confirmation rates, wherever possible) with source of information data 9.4 Have cumulative effects due No Not falling under critical polluting area to proximity to other existing hence no pollution is envisaged. or planned projects with similar effects

(III) ENVIRONMENTAL SENSITIVITY

Sr. No Areas Name/ Aerial distance Identity (with 15-km) Proposed project location boundary 1 Areas protected under Nil in 15-km radius area. N.A. international conventions, national or local legislation for their ecological, landscape, cultural or other related value 2 Areas which are important or Reserve Forest near sensitive of ecological reasons – wetlands, water courses or other RF. (4.5-km, E) water bodies, coastal zone, biospheres, mountains, forests Muirpur RF (5.0-kms, SE)

Water bodies: - RihandReservoir (2.5-km, W)

3 Areas used by protected, Detailed Flora and Fauna - important or sensitive species of Studies will be conducted flora or fauna for breeding, and incorporated in EIA nesting, foraging, resting, over report. wintering, migration 4 Inland, coastal, marine or Nil in 15-km radius area underground waters 5 State, national boundaries Nil in 15-km radius area. -

6 Routes or facilities used by the Nil in 15-km radius area. - public for access to recreation or other tourist, pilgrim areas 7 Defense installations Nil in 15-km radius area. - 8 Densely populated or built-up area Renukoot 0.5-km 9 Areas occupied by sensitive man Yes Hospitals, made land uses (hospitals, Mandir, Masjid, schools, places of worship, Gurudwara, community facilities) Community health centres and schools exist in 5 to 10-km

Page 14 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

Sr. No Areas Name/ Aerial distance Identity (with 15-km) Proposed project location boundary radius area 10 Areas containing important, high Nil in 15-km radius area. - quality or scarce resources (ground water resource, surface resources, forestry, agriculture, fisheries, tourism, minerals) 11 Areas already subjected to Nil in 15-km radius area. - pollution or environmental damage. (those where existing legal environmental standards are exceeded) 12 Areas susceptible to natural There is no record of - hazard which could cause the occurrence of floods, project to present environmental landslides, cloud bursts etc. problems The proposed project site (earthquakes, subsidence, comes under Seismic Zone- landslides, erosion, flooding or III as per IS 1893 (Part-I): extreme or adverse climatic 2002 classification. Hence, conditions) seismically it is a stable zone.

Page 15 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

ANNEXURE-I LOCATION MAP OF THE PROJECT SITE

Page 16 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

ANNEXURE-II 10-KM RADIUS MAP OF THE PROJECT SITE

Page 17 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

ANNEXURE - III

PROCESS DESCRIPTION OF EXTRACTION OF ALUMINA FROM BAUXITE

Conventional Bayer’s process is used for the extraction of alumina from bauxite. Bauxite from various mines is received and unloaded with the help of Wagon Tippler. It is crushed to minus 100 mm lumps and stock piled. Bauxite from different sources get mixed and blended in the stockpile itself. Occasionally, a dozer is also used for this purpose. The minus 100 mm lump bauxite in the stock pile is further crushed to minus 12 mm in hammer mills and then again wet grinded in ball mills together with the Test tank liquor from the process to form a 50% slurry. The slurry is fed into digestors and the alumina content of bauxite is dissolved in caustic soda at a high temperature of 248 0C and 36 Kg/cm 2 pressure. The digested slurry is then sent for separation of red mud from sodium aluminate liquor. After settling, the red mud is washed free from caustic soda, filtered in drum filters and then dumped into the earmarked low lying areas within the complex. The areas that have already been reclaimed in this manner have been partly used for erection of new alumina plant and partly for green belt. The sodium aluminate liquor is filtered using filter aid as tricalcium aluminate (TCA). The alumina hydrate from this liquor is precipitated by agitating with seed alumina hydrate in the precipitator tanks. The precipitated alumina hydrate is classified through Seed & Product Hydro-cyclones.

The production hydrate from the Product Cyclone underflow is filtered and washed free of caustic and calcined in gas suspension calciner at a temperature of 1150(C to produce calcined alumina.

Page 18 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

ALUMINA PLANT PROCESS FLOW DIAGRAM

Page 19 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

ALUMINIUM SMELTING PROCESS

Hall – Heroult process of Al. extraction is an extremely energy intensive process where primary requisite is a source of economical electrical power. Furthermore, the process uses great quantities of high purity Alumina, Cryolite and also very low ash carbon electrodes. These source materials have to be prepared by fairly complicated methods.

Primary Aluminium is produced by electrolytic reduction of Alumina, the process is commonly known as Hall-Heroult Process. Alumina is dissolved in molten cryolite bath and electrolysis is carried out in specially designed Aluminium electrolysis cells commonly known as 'pots'. “Faraday Law of Electrolysis” governs the electrolytic process. Electrolytic cells consist of Anode, Cathode and electrolyte.

Anode (the +ve terminal) – Prebaked, made of CP coke and coal tar pitch Cathode (the – ve terminal) – made of cathode carbon blocks in which steel collector bars are embedded to make electrical connection Electrolyte – Medium for carrying out electrolysis, consisting of mainly, cryolite, aluminium fluoride and calcium fluoride in which alumina is dissolved for electrolysis In an electrolytic cell when DC current is passed from anode to cathode through molten electrolyte, alumina dissolved in electrolyte is dissociated into aluminium& oxygen. Aluminium being positively charged goes to the cathode while oxygen being negatively charged goes to anode. Aluminium continues to deposit at cathode, which is tapped out periodically. The consumed anodes are replaced in certain sequence periodically with new anode to continue the process. Hindalco Smelter has its own Carbon Plant to produce prebaked anodes, which comprises of three sections: Green anode making plant, Bake furnaces & Rodding shop.

Hot metal goes to different casting stations Billet Casting, Slab Casting, Wire Rod, Pig

casting etc. FUM ES FUME TREATMENT FRESH PLANT ALUMINA PACKING COKE FUME TREATMENT SYSTEM ENRICHED ALUMINA

RODDED ANODE ALUMINIUM FLUORIDE FUEL OIL BAKING BAKED RODDING ANODE BATH (CRUSHED) POT ROOM SPL FURNACE ROOM

USED RODS GREEN ANODE LIQUID METAL BUTTS (CRUSHED) BUTT & BATH SPENT ANODES HANDLING

FUEL OIL ALLOYING ELEMENTS GREEN ANODE DROSS FUEL OIL CAST HOUSE W ATER PLANT MAKE UP WATER

PITCH C.P. COKE BILLETS/SLABS WIRERODS 20 KG20 INGOT Page 20 of 21 APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT, U.P.

Page 21 of 21