PRE-FEASIBILITY REPORT

(In terms of provision of EIA Notification 2006)

For
The Proposed Alumina Refinery of 3.0 MTPA along with
Co-Generation Power Plant of 150 MW at Kansarigurha Village,
Kashipur Tehsil, Rayagada District, Odisha

M/s Aditya Aluminium: Alumina Refinery

(Hindalco Industries Limited)
Odisha

To:

Ministry of Environment Forest& Climate Change

(MoEF&CC), New Delhi

August, 2020
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

TABLE OF CONTENTS
_______________________________________________________________
Chapters Page No.
______________________________________________________________________

1.0 Executive Summary 3

2.0 Introduction of the Project 5
3.0 Project description 9
4.0 Site Analysis 37
5.0 Planning brief 39
6.0 Processed Infrastructure 40
7.0 Rehabilitation and Resettlement (R & R Plan) 43
8.0 Project Schedule and Cost Estimates 43
9.0 Analysis of Proposal (Final Recommendation) 44
10.0 Conclusion 45

Tables

Table-1 Salient Features of the Project 3

Table-2 Proposed Employment 8
Table-3 Environmental Setting of the site 11
Table-4 Major Equipment list for Total Plant Capacity of 3.0 MTPA 25
Table-5 Major Equipment list for Co-Generation Power Plant 29
Table-6 Products and Byproducts 29
Table-7 Raw Material 30
Table-8 Solid Waste Generation by Alumina Refinery & CPP 35
Table-9 Land Use of the Proposed Project Area 37
Table-10 Proposed Land Use 40
Table-11 Major Activities for First Phase 43
Table-12 Cost break up for the proposed project 44

Figures

Figure-1 Process Flow Diagram 23

Figure-2 Material Balance Diagram 24
Figure-3 Water Balance 33
Figure-4 Flow Diagram of Wastewater Management in
Refinery and CPP 34
Figure-5 Environmental Clearance Process 36
Figure-6 Plant Layout 41

Annexures

Annexure-I Index Map

Annexure-II Study Area Map – SOI Toposheet
Annexure-III Study Area Map of 10 km Radius (google Image)
Annexure-IV Lease Land Details (First Page)
Annexure-V Water Allocation Letter
Annexure-VI Earlier EC for 1.0 MTPA dated 18.03.2006
Annexure-VII Earlier EC for Expansion from 1.0 to 1.5 MTPA dated 04.10.2013
Annexure-VIII Application for Forest Land (FP/RO/IND/454652020)
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 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

1.0 Executive Summary

Introduction

Hindalco is proposing the Alumina refinery project located in Kansarigurha village,

Kashipur Tehsil, Rayagada district, Odisha State. The proposed capacity of the
project is 3.0 MTPA along with cogeneration power plant of 150 MW capacity.

The proposed refinery project of 866.28 ha, which includes forest land of 44.342 ha
(Patra Jungle 30.217 ha, Gramya Jungle- 11.68 ha and Proposed Reserved forest-
2.445 ha). 866.28 Ha includes govt. land 263.249 Ha, private land 558.689 Ha and
forest land: 44.342 Ha.

Salient Features of the Project

The salient features of the proposed Alumina Refinery and co-generation power plant
project are given in Table-1.

TABLE-1
SALIENT FEATURES OF THE PROJECT
Sr.
Parameters Description
No.
Proposed Aditya Aluminium : Alumina refinery
project of M/s Hindalco Industries Limited at
1 Name of the project
Kansarigurha village, Kashipur Tehsil, Rayagada
district, Odisha State
Index map, Study area map and Google map
2 Location of the project are given in Annexure-I, Annexure-II and
Annexure-III respectively
3 Nature of the project Alumina refinery
4 Project Proponent M/s Hindalco Industries Limited, Mumbai
5 Total area 866.28 ha
6 Life of project 30 years
Detailed lease deed and land schedule is given in
7 Details of the Lease Area Annexure-IV.

Corner Latitude Longitude

Plant Site
A 19° 06’ 29” N 83° 04’ 36” E
B 19° 07’ 29” N 83° 05’ 29” E
8 Coordinates C 19° 06’ 58” N 83° 06’ 1.0” E
D 19° 06’ 16” N 83° 05’ 39” E

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 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

Sr.
Parameters Description
No.

Corner Latitude Longitude

Red Mud Pond Site
1 19° 04’ 19” N 83° 05’ 30” E
2 19° 03’ 25” N 83° 05’ 10” E
3 19° 03’ 04” N 83° 06’ 06” E
4 19° 03’ 40” N 83° 06’ 14” E
Corner Latitude Longitude
Ash Pond Site
X 19° 05’ 22” N 83° 05’ 38” E
Y 19° 05’ 53” N 83° 06’ 05” E
Z 19° 05’ 35” N 83° 06’ 30” E
Corner Latitude Longitude
Skill development centre
19° 07’ 20.48” N 83° 04’ 32.37” E
R& R Colony-1
19° 07’ 52.17 N 83° 04’ 15.32” E
R & R Colony-2
19° 05’ 14.42 N 83° 06’ 14.68” E

Capacity of the project

9 3.0 MTPA Alumina Refinery
(peak)
10 Category of the project “A”
11 Land Type Agricultural land / Barren land / Forest land
12 Methodology adopted Bayer’s Process
13 Operational days/year 330 days
14 Total water requirement 20,000 m3/day
The water requirement will be met from nearby
Patagarha river near Kutinguda through 16 km
long pipeline. Patagarha river near Kutinguda is
the source of water. Water withdrawal permission
15 Source of water for 25,000 KLD from Department of Water
Resources, Odisha.

Water allocation was obtained from State Water

Resource department vide letter no:
4272/2006/dated: 07.02.2006. (Annexure-V)
Construction phase: 150 permanent and 8000
contract workforce.
16 Man power requirement
Operation phase: 750 Permanent and 4000
contract workforce.
Nearest Railway Station
Nearest Railway Station/
Singarama Railway station : 0.9 km, SE
17 Airport along with distance in
Jeypore airstrip: 60.0 km, SW
km.
Visakhapatnam : 152 km, S
SH-44, 6.0 km, NE
18 Nearest Highway
SH-4, 8.5 km, SE

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 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

Sr.
Parameters Description
No.
Nearest Town, city, District
19 Headquarters along with Tikiri, 6.0 km, N
distance in km
Ecological Sensitive Areas Reserved/Protected Forests
(Wild life Sanctuaries, 1. Karhinga PF, 1.0 km, S
National Parks, Biosphere 2. Kendripadar RF, 1.6 km, E
Reserves, Reserve/Protected 3. Titigurha RF, 2.8 km, NE
Forest etc.) 4. Baghmari PF, 3.5 km, SE
5. Bariguma PF, 3.5 km, E
6. Masimandi PF, 4.8 km, NW
7. Shankararha RF, 5.4 km, NE
20 8. Sargighati PF, 5.9 km, SE
9. Kutil PF, 7.5 km, E
10. Minaharu PF, 8.2 km, ENE
11. Dhamanaganda PF, 9.4 km, SE
12. Kutinga PF, 9.6 km, SE
13. Karajhol PF, 9.6 km, NE
14. Champi RF, 11.4 km, SSW
15. Rapukana PF, 11.6 km, E
16. Kumbhikota PF, 14.2 km, SE
17. Patagarhanala adjacent to project site,
N
21 Water Bodies 18. PoragarNadi 8.2 km N
19. BaghriNala 9.8 km, W.
20. ChikambNala 12.9 km, W
22 Historical Places Nil
23 Seismicity Seismic zone-II as per IS 1893 (Part-I):2002
*Distances are measured as aerial distances

2.0 Introduction of the Project

1. About HINDALCO

Aditya Aluminium, a group company of Hindalco Industries Limited, intends to set

up an integrated green field Alumina Refinery complex at Kansarigurha, in the state
of Odisha, based on Kodingamali bauxite deposit in Rayagada district of Odisha and
other source of Govt. of Odisha (GOO).

Hindalco Industries Limited, a flagship company of the Aditya Birla Group, is an

industry leader in aluminium and copper in Asia. Hindalco ranks among the global
top five aluminium majors, as an integrated producer with low- cost alumina and
aluminium facilities combined with high- end rolling capabilities and one of the
biggest producers of primary aluminium in Asia. Its copper smelter is the world’s
largest custom smelter at a single location. Its combined turnover of US$ 18 billion,
places it in the fortune 500 league. Hindalco was incorporated in 1958 and are
listed on the Indian Stock Exchanges since 1958 and on the Society de la Bourse
de Luxembourg since 1993.

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 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

In the copper business, Hindalco is a custom smelter and are partially integrated
with upstream copper mines. Hindalco’s Birla Copper Unit is the world’s largest
single location custom copper smelter with 500,000TPA capacity.

2.1 Identification of Project & Project Proponent

Hindalco has alumina refining capacity of 31,00,000 TPA located at Renukoot, UP;
Muri, Jharkhand; Belagavi, Karnataka and Doraguda, Odisha. It is also the largest
producer of primary Aluminium with a capacity of 13,00,000 TPA located at
Renukoot, Uttar Pradesh; Mahan, Madhya Pradesh; Hirakud and Lapanga, Odisha.
The requirement of power for all the locations is met by Hindalco’s captive power
plants except Belagavi. Significant portions of Hindalco’s sales come from value-
added products. This is in line with our ‘market-grower’ philosophy. Hindalco has
introduced numerous new products in the Indian market. Novelis is wholly owned
subsidiary of Hindalco with best in class capabilities in Aluminium value- added
products. Aleris has been recently acquired by Hindalco with footprints in high-end
aerospace segments.

Hindalco is currently embarking on a growth plan designed to make it a global-

sized, globally competitive metals producer. In their Aluminium business, their
competitive strengths include globally competitive cost structure, fully integrated
operations, cost effective access to abundant supply of quality raw materials and
domestic market leadership.

Towards realizing their vision of attaining global size and further improve their cost
competitiveness in the global Aluminium industry, Hindalco is embarking on several
expansions at their existing facilities and Greenfield projects. These include:

i. Ongoing Brownfield Expansion of existing facilities at Utkal (500,000

TPA capacity expansion – Project Suryaprabha)

ii. Greenfield alumina project in Odisha including Bauxite Mining; 9.3

million TPA, Alumina Refinery 3 million TPA as a part of Aditya
Aluminium. (Proposal in this document)

Odisha having the highest reserve with the best quality bauxite in the country,
Hindalco plans to add further capacity of Alumina refinery. Presently, a state of the
art alumina refinery, Utkal Alumina International Limited is operational in
Doraguda, Odisha. It has a capacity of 17,00,000 TPA capacity of Alumina
production with captive mines at Baphlimali, which is located ~20 km from the
plant. A co-generation power plant of 90 MW is set up as a part of the Alumina
refinery to provide steam and power to the unit. Hindalco’s proposed Greenfield
project in Odisha is aimed at setting up a 3.0 million TPA (MTPA) alumina refinery
under the name of Aditya Aluminium Project. This, besides providing job
opportunities, will contribute towards the socio-economic and industrial
development of the state of Odisha.

Aditya Aluminium refinery is located at a distance of 6.0 km north of Tikiri. The

nearest railway station is Singaram 1.5 km, (SE). The plant is well connected by a

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 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

metaled road from Rayagada. The plant falls in Survey of India Topo sheet No.
E4416 & E44F4.

2.1.1 Brief Description of Nature of the Project

The proposed project involves the alumina refinery and falls in schedule 3(a)
Metallurgical industries (ferrous & non-ferrous) minerals of category ‘A’.

The proposed plant is for 3.0 million TPA of alumina refinery and cogeneration
power plant of 150 MW. The proposed project involves stacker, reclaimer, crusher
house, grinding mill, tanks, stacks, boilers, storage unit, crushing unit, CHP, cooling
tower, compressor house etc.

2.2 Need for Project and It’s Importance to the country and region

Aluminium is the second most used metal in the world after steel with an annual
consumption of approximately 88 million tonnes (including scrap). It is also the fastest
growing metal, which has grown by nearly 20 times in the last sixty years (compared
to 6 to 7 times for other metals).

India is developing at a record growth rate of 10% Gross Domestic Production (GDP).
The proposed project is in line with the increased demand of Hindalco in terms of
smelter requirement and aggressive aluminium growth in the region.

2.3 Demand-Supply Gap

India has nearly 10% of the world’s bauxite reserves and a growing aluminium sector
that leverages this. Demand in the domestic market is expected to raise by 8-10%.
It holds a fair advantage in cost of production and conversion costs in steel and
alumina.

2.4 Import Vs Indigenous Production

The present production capacities of aluminium in India are sufficient to meet the
domestic requirements. However, the demand for aluminium in India is expected to
grow at a 7.1%, which makes it viable for installing new alumina refinery. Further the
deficit in international market during the upcoming years provides opportunity for
export.

2.5 Export Possibility

Indian exports majorly catered to South East Asian and African nations. In India, since
Hindalco is one of the largest producer of Alumina & aluminium, export of aluminium
is highly feasible and shall bring value addition.

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 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

2.6 Domestic/Export Market

The alumina from the refinery is of metallurgical grade and the Bauxite is of
Gibbsite nature (+40% Al2O3 on an average), therefore is suitable for Alumina
plants, like NALCO, Hindalco and Vedanta.

2.7 Employment Generation

Due to the operations of proposed plant various direct and indirect employment is
generated. The alumina production along with co-generation power plant shall extend
the employment opportunities. Potential direct employment is made for the proposed
project based on current technology and standard operating practices are given in
tabular format in Table-2.

TABLE-2
PROPOSED EMPLOYMENT

Sr. No Description Proposed (Construction Phase)

1 Permanent Employees 150
2 Contract Employees 8000
Total 8150

[Link] Description Proposed (Operational Phase)

Permanent Employees
1. Management 170
2. Supervisory 250
3. Workmen 330
4. Total (a) 750
Contract Employees
5. Total (b) 4000
6. Grand Total (a+b) 4750

2.8 Legal Aspects

The relevant NOCs and licenses will be obtained from the statutory agencies under
the following Acts, Rules and amendments and Hindalco will adhere to the
guidelines specified in:

1. The Factories Act, 1948

2. Environment (Protection) Act – 1986 and its amendments to date
3. Manufacture, Storage and Import of Hazardous Chemical Rules 1989 amended
in 2010.
4. Hazardous and Other Wastes (Management and Trans boundary Movement)
Rules, 2016.

Hindalco will comply with the prescribed limits laid down for air, effluent and noise
emissions for protection of the environment under the following Acts, Rules and
amendments:
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Village, Kashipur Tehsil, Rayagada District, Odisha

5. The Water (Prevention and Control of Pollution) Act, 1974

6. The Air (Prevention and Control of Pollution) Act, 1981
7. The Environment (Protection) Act, 1986
8. The Forest Conservation Act, 1980
9. The Environment Impact Assessment, Notification, 2006 issued under
10. Environment (Protection) Act 1986 and Environment (Protection) Rules 1986
and amendments thereafter to date.
11. Construction and Demolition (C&D) Waste Management Rules, 2016
12. Solid waste management rules 2016

Compliance to State Rules and Notifications will also be ensured.

3.0 Project Description

I. Type of Project including interlinked and independent projects, if any

Aditya Aluminium is a division of M/s. Hindalco Industries Limited (HINDALCO) of

Aditya Birla Group. Hindalco 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. HINDALCO has an excellent track record with
respect to productivity, energy conservation, quality control and environmental
pollution control.

The following were the principal objectives, kept in mind while working on the
feasibility of this proposal:

1. Adopting environment friendly technology & equipment and working on

reduction of pollution load of high volume solid wastes i.e. Red mud storage and
ash;
2. Conserving natural resources like water, thermal & electrical energy;
3. Waste reduction and recycling options;
4. Aiming at waste heat recovery to best possible extent by state of art proven
technology; and
5. Value added By- Products.

The proposed alumina refinery and co-generation project is classified as

“CATEGORY-3(a)” by Ministry of Environment Forest& Climate Change, New Delhi
as per the EIA Notification dated: 14th September 2006.

3.1 Details of Alternative Site Analysis

The proposed project site is located at Kansarigurha village, Rayagada district, Odisha
state. The proposed plant site has been selected based on the following environmental
siting considerations as follows:

1. Availability of raw material (bauxite ore) from the nearby Kodingamali mines;
2. Availability of water at Kendupai tributary of Patagarha river located at a distance
of about 13 km from the proposed site;
3. Availability of land; and
4. Environmental conditions.

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Village, Kashipur Tehsil, Rayagada District, Odisha

The proposed site was already awarded environmental clearance vide Letter No J-
11011/141/2004/ [Link] dated 18.03.2006 & Land allocation ,IPICOL approval ,
SJ/HLCA-221/17-18/216 Dated 18/20.01.2020.

3.2 Location (map showing general location, specific location, and project
boundary and project site layout) with coordinates:

The proposed alumina refinery plant will be located at Kansarigurha village at a

distance of about 0.5 km in Rayagada & Koraput districts of Odisha state. The
nearest railway station is Singaram, about 1.6 km, SE. The plant site is well
connected by road from Rayagada. The plant falls in Survey of India Topo sheet
No. E44E6 & E44F4.

Geographical location of the project site, study area map and google image of the
study are attached.

3.3 Size and Magnitude of the Operations:

The total area of the proposed plant is 866.28 Ha out of which 220 Ha land will be
for main plant and is occupied by various facilities viz, refinery, power plant and
associated facilities, storage area, crushing unit etc.

The present proposal is for 3.0 MTPA of alumina refinery along with co-generation
power plant of 150 MW to meet the needs of Hindalco, in the allocated premises
and others. The Environmental settings of the study area with respect to proposed
site is given in Table-3.

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along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

TABLE-3
ENVIRONMENTAL SETTING OF THE SITE

Sr. No. Particulars Details

1 Project Location Kansarigurha Village, Kashipur tehsil,
Rayagada district, Odisha State.
2 Project Coordinates
Corner Latitude Longitude
Red Mud Pond Site
1 19° 04’ 19” N 83° 05’ 30” E
2 19° 03’ 25” N 83° 05’ 10” E
3 19° 03’ 04” N 83° 06’ 06” E
4 19° 03’ 40” N 83° 06’ 14” E
Corner Latitude Longitude
Ash Pond Site
X 19° 05’ 22” N 83° 05’ 38” E
Y 19° 05’ 53” N 83° 06’ 05” E
Z 19° 05’ 35” N 83° 06’ 30” E
Corner Latitude Longitude
Skill Development Centre
19° 07’ 20.48” N 83° 04’ 32.37” E
R & R Colony-1
19° 07’ 52.17 N 83° 04’ 15.32” E
R & R Colony-2
19° 05’ 14.42 N 83° 06’ 14.68” E

3 Elevation above MSL 840 m

4 Topo sheet No E44E6 & E44F4
5 Climatic conditions Annual Maximum Temp: 34.2oC
(IMD Koraput, 55 km from Annual Minimum Temp: 11.4oC
project site) Annual Total Rainfall: 1647.8 mm
Annual Predominant Wind Direction: NW, SW
6 Present land use at the The proposed project site includes Barren land,
proposed plant site forest land and agricultural land
7 Nearest Highway SH-44, 6.0 km, NE ,

SH-4, 8.5 km, SE

8 Nearest Railway Line Visakhapatnam : 152 km, S

9 Nearest Railway Station Singaram Railway station : 1.6 km, SE

10 Nearest Airstrip/Airport Jeypore airstrip: 60.0 km, SW

Visakhapatnam : 152 km, S

11 Nearest Seaport Visakhapatnam (170 km, S)
12 Nearest Village Proposed plant site will be located in
Kansarigurha village;
Puhundi village (0.5 km, W)
13 Nearest Town Tikiri (6 km, N)
14 Nearest City Rayagada (40 km, NE)
15 Surface Water Bodies 1. Patagarhanala adjacent to project
site, N
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Village, Kashipur Tehsil, Rayagada District, Odisha

Sr. No. Particulars Details

2. PoragarNadi 8.2 km N
3. BaghriNala 9.8 km, W.
4. ChikambNala 12.9 km, W
16 Hills/Valleys No hills/valleys within the plant area
17 Industries 5. Kodingamali bauxite mine, 1 km, S
6. Utkal Alumina International Limited,
Alumina Refinery (Existing 1.7 MTPA)- 8.1
km, NW
18 Ecologically sensitive zones, Data from the forest department reveals that
including National Park, there are no protected areas as per Wildlife
Wildlife Sanctuary, Elephant / Protection Act 1972, within 15 km radius from
Tiger Reserve (existing as the project site
well as proposed), Migratory
routes etc
19 Protected/Reserve Forests Reserve Forest/ Protected Forest
7. Karhinga PF, 1.0 km, S
8. Kendripadar RF, 1.6 km, E
9. Titigurha RF, 2.8 km, NE
10. Baghmari PF, 3.5 km, SE
11. Bariguma PF, 3.5 km, E
12. Masimandi PF, 4.8 km, NW
13. Shankararha RF, 5.4 km, NE
14. Sargighati PF, 5.9 km, SE
15. Kutil PF, 7.5 km, E
16. Minaharu PF, 8.2 km, ENE
17. Dhamanaganda PF, 9.4 km, SE
18. Kutinga PF, 9.6 km, SE
19. Karajhol PF, 9.6 km, NE
20. Champi RF, 11.4 km, SSW
21. Rapukana PF, 11.6 km, E
22. Kumbhikota PF, 14.2 km, SE
20 Historical Places None within 10 km radius
21 Socio-economic factors Detailed R&R plan and its implementation will
be addressed as per LA & RR 2013.
22 Defence Installations None within 10 km radius
23 Seismic Zone Zone-II as per IS:1893 (Part-1) 2002

3.4 Project Description with Process Details:

Bauxite Handling System:

Bauxite handling system consists of Bauxite receipt, Storage/Stacking and

Reclamation.

The primary crushed bauxite (-150 mm), from Kodingamali Bauxite Mines is
conveyed by 1.0 km LDC (Long Distance Conveyer) and discharged into transfer
hopper. Belt Conveyor below the transfer hopper feeds the bauxite to storage
(Stacker) conveyor leading to the stockpiles.

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The stacker system of 1500 TPH capacity consists of a long storage conveyer with
a mobile boom conveyor mounted on a travelling platform and a tripper mounted
on the same platform, which ensures the transfer of bauxite from storage conveyor
to the stacker boom conveyor. The stacker system delivers the bauxite to one of
the two stockpiles, each of 180,000 T capacity, which is approximately equivalent
to 30 days of bauxite requirement. At any given time, one stockpile will be under
reclamation. When the stack formation is complete, the stacker will move to the
other stockpile and interchange its position with the reclaimer.

The bucket wheel reclaimer reclaims the stacked bauxite from one of the stockpiles
in which the stacker is not operating. The reclaimer consists of a boom conveyor,
cross conveyor and a mobile hopper, which feeds the reclaiming conveyor, which
in turn feeds the Secondary Crusher via transfer conveyors. The reclaimer moves
on rails from one end of the stockpile to the other end. Reclaiming is thus made
perpendicular to longitudinal axis of the heap so as to remix the bauxite layers
together. This ensures uniform blending and proper homogenization of the
reclaimed bauxite. The reclaiming conveyors feed the vibrating screens of
secondary crushing plant via transfer conveyors. A magnetic separator and a metal
detector are installed on each transfer conveyor for detecting and picking up
metallic pieces on this conveyor.

3.4.1 Secondary Crushing:

Primary crushed bauxite received from reclaimer is screened and crushed to ‘-38
mm’ size in Secondary Crushing Plant having two sets of crushing lines each
consisting of Hammer Crushers. In each set, one crushing line will be operating
and other will be standby during dry seasons, but during monsoon, both crushing
lines would be operating simultaneously because of reduction in overall throughput
due to sticky nature of the wet bauxite.

The bauxite from transfer conveyor is either diverted to one of the two crushing
lines in the crushing plant via belt conveyor feeding respective vibrating screens.
It is also possible to feed both the crushing lines during monsoon season.

3.4.2 Bauxite Grinding:

Crushed bauxite is transferred to Rod Mill feed bins by means of belt conveyors.

Bauxite grinding is carried out in open circuit overflow type Rod-mills owing to high
solids concentration required for pre-desilication. Rod mills, each being
independent from the others and complete in all respects, feed ground bauxite
slurry to pre-desilication area. Crushed bauxite is fed to the Rod-mills from the feed
bins with the help of apron feeder, which in turn feeds a weight belt conveyor. In
case of bridging of bauxite particles inside the silo, the vibrating cone will operate
to ensure smooth flow of bauxite. Weigh belt conveyors feed bauxite to Rod-mills,
SF liquor is added at feed end and at the discharge terminal as per requirement.
Bauxite slurry from mill slurry tanks called Relay tanks is pumped to Pre-
Desilication area.

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3.4.3 Pre-desilication:

Ground bauxite slurry, containing 55-60% solids is heated to about 95 deg C in two
stages of indirectly heated slurry heaters, first exchanging heat with regenerated
condensate and then with flash steam from second flash tank of the Digestion Area.
If heaters need to be bypassed, the bypass slurry is heated in dedicated online live
steam injection heaters before entering the tanks. The heated slurry is fed to a
series of six agitated pre-desilication tanks to separate out the reactive silica
present in the bauxite. Pre-desilicated bauxite slurry from the last tank is pumped
to digestion area. One pre-desilication stream of above description is provided.

3.4.4 Digestion, Flashing & Dilution:

Pre-desilicated bauxite slurry is further heated to about 95 deg C in two stages of

indirect slurry heaters. The first stage utilizes flash steam from the last Flash Tank
of the same digestion stream and the balance heating is carried out by feeding low
pressure live steam to the second stage of bauxite slurry heaters.

Spent liquor from Evaporation Area is heated by flashed steam from the four flash
tanks in a series of four shell and tube heat exchangers and in two live steam shell
and tube heaters, prior to mixing with the bauxite slurry. The first live steam heater
is fed low pressure live steam while the second is fed with high pressure live steam.

The live steam heaters heat the spent liquor so that the required digestion
temperature can be maintained through the digester trains with minimum direct
live steam injection. Normally, steam is injected to first-in-line digester only.

The preheated spent liquor at about 172 deg C along with preheated bauxite slurry
at about 95 deg C are pumped to a train of Medium Pressure Digesters (6 kg/cm 2)
consisting of four agitated vertical cylindrical vessels connected in series. Four
separate streams of spent liquor are fed from the test tanks through heat
exchangers to four parallel trains of digesters.

Normally, the extent of preheating of the feed streams is sufficient to maintain the
required temperature of about 145 deg C in the Digesters but suitable provisions
are made for direct injection of live steam to the first and second digester vessels.

A relatively small quantity of lime slurry may also be fed to the digester train along
with spent liquor and bauxite slurry. Controlled quantity of lime slurry addition to
the digesters not only helps in increasing digestion efficiency but also improves the
settling characteristics of the red mud.

The temperature (145 deg C) and pressure (6 kg/cm 2) of the digester contents is
brought down in four stages of Flash Tanks in series. The flash cooled digested
slurry is finally brought to atmospheric pressure in the Blow-Off Tank where the
overflow of the first Washers also be added at controlled rate for dilution. The
contents of the blow-off tank at about 105 deg C are pumped to clarification area.

Live steam and flash vapour condensates are collected separately. Live steam
condensate are flashed in two stages before being pumped to either cogeneration

PFR-14
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

plant or condensate storage tanks depending upon its quality and overall process
requirement. Flash steam condensate is collected in a separate receiver from where
it is pumped to condensate storage area for reuse in the process.

3.4.5 Clarification – High Rate Decanters:

The slurry from Blow-Off Tank is sent to Hi Rate Decanters, which separates the
mud from the sodium aluminate liquor. Synthetic flocculants are added to the
decanters for aiding the separation process and fast settling of mud particles.
Underflow from the decanters is sent to Washers for recovery of caustic. The
overflow from the decanters is sent to the disaster filters for removal of remaining
suspended & colloidal solid particles which may otherwise contaminate the final
product alumina.

3.4.6 Red Mud Washing –Deep Cone Washers:

The underflow from the Clarifiers is transferred to washing section comprising of a

series of six deep cone washers. The clarifier underflow slurry moves counter
current to a stream of wash water. The overflow of the last washer is sent to the
next washer and so on up to the first Washer. Wash water at a controlled rate is
added to the last Washer. Wash water used for the purpose is drawn from the Mud
disposal area as supernatant liquor and also includes all process area wastewater
collected centrally through a dedicated drainage network in the caustic pond and
process condensate stored in the storage tanks.

The system operates as a mixer-settler circuit to wash the solid waste, i.e. the Red
mud to make it substantially free of caustic liquor. Flocculants are used to aid the
settling of the solids.

Presently the last washer underflow slurry at about 55-60% solids is pumped to
the Red Mud Filtration area using High Pressure Positive Displacement Pumps called
Geho pumps.

3.4.7 Red Mud Disposal:

Red mud, a residue of the bauxite refining process is the major solid waste. About
4.08 MTPA (Dry Mud Generation = 1.36 t/t X 3 MTPA = 4.08 MTPA, dry basis) of
red mud will be generated annually. Considering 20% moisture in the mud bed;
the red mud generation (wet basis) will be about 5.1 MTPA (1.7 t/t X 3 MTPA = 5.1
MTPA). Red mud disposal system shall be combined through thickened tailing
disposal technique of Alcan. This shall be disposed of by GEHO pumps (high
pressure positive displacement pumps) to the Red Mud Filtration Area. The state of
the art Red Mud Filtration technology using high-pressure plate and frame with
membrane filters shall be installed for disposal of dry Red mud cake at 75% solids
through a set of conveyors directly to the pond. Mechanical dozers and excavators
shall be used to spread and stack the dry Red Mud in the pond with continuous
compaction so as to reduce land usage by 20-30%. The filtrate of the unit is again
pumped back to the Alumina plant for reusing in the mud washing process. An area
covering 210 Ha has been dedicated for this purpose. All filtrate & surface run-off
water from the Red mud pond is collected and pumped back into the Alumina Plant.

PFR-15
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

3.4.8 Flocculant Preparation:

Flocculant solution is required to assist the settling process in Decanters and

Washers. Flocculant is supplied in bulk and could be either in powder or liquid
emulsion form. Facilities are provided for storage of one type of powder Flocculant
in hoppers and one type of liquid emulsion Flocculant in storage tanks. Storage
capacity is provided for one-month consumption. Flocculant solution is prepared by
mixing it with dilute caustic solution and stored in large Flocculant solution storage
tanks. Independent pumps are provided for Flocculant dosing to all Decanters and
Washer with necessary spares.

3.4.9 Liquor Causticisation:

The purpose of liquor causticisation is to maintain the causticity i.e. ratio of total
caustic to total soda content, of process liquor stable in order to maintain
processing efficiency. A portion of second red mud washer overflow is heated to
95°C in indirect heat exchanger using low pressure flash vapour from Digestion
area. Heated liquor is mixed with lime slurry and held in a series of agitated
causticisation tanks for about one hour. The causticised slurry is pumped back to
first red mud washer.

3.4.10 Security Filtration:

The clarified liquor streams overflowing the decanters is routed separately to the
filtration area where the last traces of insoluble material are removed from the
pregnant liquor before it is sent to Precipitation Unit. This is achieved by passing
the pregnant liquor through high productivity Disaster Filters; which are nothing
but vertical, self-sluicing, pressure leaf filters. Filtered hot pregnant liquor is
pumped off to heat inter-change area for further processing.

Reacted lime slurry is added to feed liquor as filter aid for better filtration and
enhancing removal of deposited mud cake. Initially, when a filter is taken into
operation, the quality of filtrate is poor requiring return of filtrate to clarification
area for recycle. At the end of each cycle, deposited mud cake is washed off using
high-pressure wash liquor and the resultant slurry is pumped back to mud washing
area.

3.4.11 Heat Interchange:

The Sodium Aluminate Liquor after security filtration attains a purity level, which is
adequate for meeting the chemical specification of metallurgical grade alumina.

Before being fed to the precipitators, the pregnant liquor needs to be cooled
sufficiently to attain the desired super-saturation level with respect to dissolved
alumina concentration in the liquor.

Heat interchange area is designed to cool the filtered pregnant liquor coming from
the security filtration area to the required temperature in the precipitation area.
Here the filtered pregnant liquor coming from security filtration area, is cooled

PFR-16
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

through Plate Heat Exchangers (PHE) by means of cold spent liquor coming from
the hydrate filtration area on its way to evaporation, thereby transferring the heat
from pregnant liquor to spent liquor.

Hydrate & Silica scales deposited on the heat exchanging plates are cleaned
frequently with caustic cleaning liquor and periodically with dilute Sulphuric acid.

3.4.12 Precipitation

The alumina content of bauxite dissolved in the caustic soda liquor is in the form
of sodium aluminate. In precipitation area the sodium aluminate gets hydrolyzed
to produce Aluminium tri-hydrate as precipitate while the free sodium hydroxide is
released according to the following reversible reaction:

2NaAlO2 + 4 H2O 2 Al (OH)3 + 2 NaOH

The above reaction is slightly exothermic in nature. Operating conditions in the

precipitators are maintained in such a manner, which is conducive to propagate the
reaction in the forward direction.

The cooled pregnant liquor from the Heat Interchange Area is pumped to the
Precipitation Area. This area consists of Agglomerators and Growth Precipitators in
series.

The Agglomerators are used to agglomerate the finest fraction of seed hydrate into
larger particles. In the growth precipitators, the agglomerates as well as the coarser
seed are further grown in size to produce desired particle size of product and also
to maximize productivity.

Part of Pregnant liquor stream is first seeded with fine seed in the agglomerator
tanks. The resulting slurry from the agglomerator along with coarse seed re-slurry
(coarse seed mixed with remaining pregnant liquor stream) enters the series of
growth tanks.

The slurry from a precipitator flows by gravity to next-in-line precipitator and

successively through all the tanks.

To achieve the required soda content in the product alumina and to maximise the
alumina yield it is necessary to maintain certain temperature profile during the
growth phase of precipitation. This is achieved by installing inter stage coolers on
growth precipitators.

During operations, hydrate scales get deposited in the tanks, which retard natural
cooling. In order to maintain good conditions in tanks, circulating hot caustic
cleaning liquor cleans the tanks. A caustic cleaning heater with necessary
circulation system is provided for this purpose.

PFR-17
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

3.4.13 Hydrate Classification:

The slurry from the last-in-line growth precipitator is separated into three streams
namely; Product, Fine Seed and Coarse Seed in the classification area. This is done
in two stages of hydro cyclones. Hydro-cyclones are selected for this service on the
basis that they are well proven and offer many advantages over the alternative
classification system of gravity sedimentation using large classifier tanks.

The slurry from the last growth precipitator is pumped to dedicated Primary
Classification Cyclones where the fine material is removed via the overflow stream
and collected in an overflow tank from where it is pumped to the seed de-liquoring
filters in seed preparation area. The under flow stream from each cluster of primary
cyclones is collected in agitated tank from which the slurry is pumped to the
associated Scalping Cyclones.

The underflow stream from the scalping cyclone forms the product hydrate slurry
of the product hydrate having a narrow particle size distribution. This slurry is
transferred to the Product De-liquoring Filters in seed preparation area. The
overflow stream from the secondary cyclones containing the secondary seed
hydrate, is collected in a tank and pumped to the Secondary Seed De-liquoring
Filters in seed preparation area.

The area is designed to be flexible and is capable of responding to changes of plant

flow without major impact on classification efficiency. This is achieved by providing
adequate number of bypass nozzles and spare cyclones in each cyclone clusters
are provided. Of these, two cyclone clusters each for primary and secondary
cyclone clusters are provided. Of these, two cyclone clusters each for primary and
secondary services, are provided as common space to take care of maintenance
requirements.

Manual operations are minimised by providing adequate number of auto open/close

valves in each cyclone cluster.

3.4.14 Seed Preparation:

The purpose of this area is to:

1. De-liquor the product and seed slurry.
2. Minimise spent liquor recycle with the seeds.
3. Produce spent liquor containing not more than one gpl solids.
4. De-liquor and then wash the tertiary seed free of solid phase oxalate.

High capacity large diameter Rotary Disc Filters having a filtration area of 110 m 2
each are envisaged for these services.

The overflow slurry from the primary cyclones is filtered on rotary disc filters to
remove spent liquor and the cake is re-slurried with hot condensate to dissolve any
solid phase oxalate or organic which may be present. This washed slurry is re-
filtered on disc filters and the filter cake is re-slurried with hot pregnant liquor and
transferred to the precipitation area for use as fine seed in the agglomerating

PFR-18
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

precipitators. Ten nos. of rotary disc filters including common spares are provided
for this service.

The overflow slurry from the secondary cyclones is de-liquored on disc filters to
reduce the recycle of spent liquor to precipitation and, therefore, to improve the
process yield. The de-liquored secondary seed filter cake is re-slurried with a mix
of product wash filtrate and agglomeration slurry from the precipitation area, and
returned to the first-in-line growth precipitator in each chain. Twelve nos. of rotary
disc filters including common spares will be provided for this service.

Product hydrate slurry i.e. the secondary cyclones underflow is de-liquored on disc
filters. The filter cake from the de-liquoring filter is discharged and re-slurried with
recycle product wash filtrate and transferred to the product hydrate washing area
for further processing.

The filtrates from the de-liquoring of tertiary and secondary seeds as well as the
product combine as spent liquor and go to the spent liquor tanks.

All the filters are required to be washed with hot condensate and caustic cleaned
from time to time. Caustic cleaning liquor heater with necessary recirculation
system are provided to facilitate the caustic cleaning of filters.

3.4.15 Product Hydrate Filtration and Washing

Filtrate from the product hydrate wash filter is recycled to product de-liquoring
filter. The product slurry is filtered in Rotary Disc Filter for 1 stStage Product
Filtration. The hydrate cake from 1stStage product filtration is re-slurried and sent
for 2ndStage Product Filtration in Hydrate Filter area.

The final washing of hydrate is carried out on three horizontal Rotary Pan Filters
(three operating + two standbys). The slurry is de-liquored of wash filtrate on the
first zone of the filter and the de-liquored filter cake then is washed with hot high
quality condensate to remove the remaining caustic liquor. To minimize the soda
content and moisture of the cake, a drainage aid is added to condensate. The
product hydrate filter cake is discharged via a chute system to a conveyor which
transfers the moist hydrate to the calcination and/or hydrate storage area.

Filtrate from the product hydrate wash filter is recycled to product de-liquoring filter
for washing / re-slurrying purposes and the “excess” is purged to the secondary
seed re-slurry tank in the seed preparation area. Pan filters are required to be
washed with hot condensate and caustic cleaned from time to time. Caustic
cleaning is envisaged from caustic cleaning system of seed preparation area.
Necessary arrangements are provided to facilitate the same.

A common vacuum and blower air system is provided for all the filters in the area.
Adequate storage facilities for storage of hydrate shall be provided in the Hydrate
storage Area in order to take surges of hydrate production and downtime of
calcination area.

PFR-19
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

3.4.16 Hydrate Storage:

Hydrate storage unit shall have a covered storage area to stock about 67,000
tonnes of hydrate with 3-5% moisture. Hydrate storage facility has been envisaged
for carrying out the maintenance of the Calciners. Without affecting the up-stream
production processes. When Calciner is restarted, the hydrate from this storage
area shall be utilized for feeding the Calciner. This facility may also be utilized when
the product hydrate filters are not able to supply the required quantity of hydrate
due to any reason.

Conveying system along with loaders and day bin are provided to reclaim the stored
hydrate for calcination.

3.4.17 Calcination:

This is the final step in the alumina production process where the water of
crystallization of alumina tri-hydrate is removed by heating to temperature of about
1100 deg C in stationary Calciners.

The alumina calcination area consists of four stationary fluidised bed gas
suspension Calciners each of 2500 TPD capacity. The alumina Calciner heat hydrate
to a temperature of 1000-1100°C by contact with an oil flame in a fluidised bed,
and then uses other fluidised beds to recover heat from the effluent gases and
alumina product. After final cooling in a fluidised cooler (by recirculating cooling
water which in turn is cooled in common cooling tower), the product alumina is
conveyed to the alumina storage area, by conveyors, air lift / air slides.

3.4.18 Alumina Storage and Handling System:

Calcined alumina produced in the Calciner units needs storage at the plant till
onward transportation. A complete system consisting of storage silos and wagon
loading system is provided within the alumina plant.

The concrete storage silos, of typically 12,500 tonnes capacity, are provided as a
buffer between Calciner units and the Wagon Loading System. All the silos are
located directly over the railway tracks. Calcined alumina is conveyed to the storage
silos through a system of conveyors, air lifts and air slides. The alumina loading
system is designed to load 2 wagons at a time from two different tracks.

The storage silo is equipped with anti-segregation pipes. Discharge from the silo is
effected through fluidisation of the alumina bed in the silo.

The each silo is fitted with a set of air slides and telescopic chutes for feeding
alumina directly to the specially designed rail wagons. The entire loading operation
is controlled through a local control room. The rail wagons used for transport of
alumina are specially designed BTAP (Bogie Tank Alumina Powder) wagons and
have a capacity of 60-tonnes each. Bag filters are provided to collect all the dusts
during transportation to silos & wagon loading.

PFR-20
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

3.4.19 Evaporation:

The purpose of an evaporation unit in the Bayer’s process is to maintain the overall
water balance in the closed circuit system. Evaporation is required in alumina plant
to counter balance the ingress of water, into the process from various sources
owing to process requirement and to maintain desired caustic concentration levels
at digestion and precipitation in order to maximise process yield. In wet season,
ingress of rainwater further amplifies evaporation requirements. The ingress of
water in the system at various points, major part of which shall be in the mud-
washers circuit, needs to be effectively counterbalanced by removing nearly the
same quantity of water from the system circuit in the evaporation unit.

Four nos. of parallel and independent evaporation batteries with 250-300 TPH
maximum evaporation capacity each are provided. It is envisaged that all batteries
are operated in dry season as well as wet season. Battery capacity to be utilised to
the fullest during the monsoon. However, the batteries will be operated at reduced
capacity during dry season. Also, all maintenance works will be under taken during
dry season only.

Each evaporator battery consist of six bodies with suitable facilities to operate the
battery in either six effect or five effect configuration. When one body is out for
maintenance, it can operate as five effect evaporation with five bodies without
significant loss of evaporation efficiency. Evaporation batteries use low pressure
live steam mainly. However, minor quantities of high pressure steam are also used
in vacuum system.

The feed to the evaporation unit is the spent liquor from Heat Interchange Area
and collected in Feed Tanks. Concentrated liquor from evaporator is directly
pumped into Test Tanks for use in digestion and grinding unit.

Arrangements for acid cleaning of live steam heaters are provided. Acid circulation
is envisaged from centralised acid cleaning area.

3.4.20 Condensate Storage:

Condensate is generated in various areas by indirect condensation of live steam

and flashed steam. The purpose of condensate storage area is to receive these
condensate streams, grade and store them according to their quality and supply
the stored condensate to various process areas as per desired quality. Necessary
instrumentation and tankage system along with pumps are provided to achieve this
objective.

3.4.21 Lime Slaking:

Burnt lime, as hydrated lime, of approximately 100-mm size and containing 65 to

70% active CaO is supplied in wagons. The unloaded lime is transferred to storage
silos via double roll crusher, which reduces the lump size to less than 10mm. The
crushed lime is slaked and classified to give 20% solid lime slurry. The lime slurry
is stored in tanks and pumped off to digestion, liquor filtration and causticisation

PFR-21
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

area via a ring header. Slaking, classification and pumping system is designed for
continuous operation.

3.4.22 Caustic Cleaning:

Process liquor in a Bayer Plant causes hydrate scaling of vessels, pipelines and
equipment requiring cleaning with hot and strong caustic solution on routine basis.
Frequency of cleaning varies from area to area.

The purpose of caustic cleaning area is to prepare and supply fresh and hot caustic
cleaning liquor to precipitators and satellite caustic cleaning systems located in
various process units, and dispose of the spent caustic cleaning liquor without
upsetting process liquor inventory.

Caustic cleaning solution is prepared by mixing fresh caustic lye (50% NaOH
solution) and spent liquor in a large volume tank for caustic cleaning of precipitators
and in a small volume tank for other area.

Freshly prepared caustic cleaning liquor is heated in a caustic cleaning heater

before supplying to process units. A large spent caustic cleaning liquor tank is
provided for receiving spent caustic cleaning liquor, which is pumped continuously
to digestion area for caustic addition to process liquor.

3.4.23 Acid Cleaning:

During operation, silica scales are deposited on the heat transfer surfaces resulting
in loss of heat transfer efficiency. To overcome this problem, heat exchangers are
required to be acid –cleaned periodically. Silica scales are readily dissolved in dilute
solution of inhibited Sulphuric acid. Chain cleaning concept is used to optimize the
size of acid cleaning facility and time required for acid cleaning. The heat exchangers
required acid cleaning are:

o Digestion area spent liquor heaters (live and regenerative both)

o Heat interchange area spent liquor heaters
o Evaporation heat exchangers
o Digestion area bauxite slurry heaters
o Pre-desilication area bauxite slurry heaters

Concentrated Sulphuric acid is received at the plant in road tankers and is stored in
a storage tank with one month requirement capacity. Concentrated acid storage tank
is provided with a vent, desiccator and overflow line is directed to a seal pot filled
with water.

It is envisaged to prepare the dilute acid solution for acid cleaning in a dilute acid
tank, having a capacity which is sufficient for cleaning the largest chain of three
heaters, by adding concentrated acid in water. Corrosion inhibitor and de-foamer
agent is also added to the dilute acid tank.

The process flow diagram of the proposed alumina refinery is given in Figure-1 and
material balance is given in Figure-2.

PFR-22
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

FIGURE-1
PROCESS FLOW DIAGRAM
PFR-23
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

FIGURE-2
MATERIAL BALANCE DIAGRAM

PFR-24
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

List of Major Equipments:

The list of major equipment of the Alumina Refinery are listed in Table-4

TABLE-4
MAJOR EQUIPMENT LIST FOR TOTAL PLANT CAPACITY OF 3.0 MTPA

Sr. Name of Equipment/

No. Package Qty Unit Capacity Unit Remarks
1 BAUXITE HANDLING PACKAGE
1. LDC system 1 No 2000 TPH
- Stacker 3 No 2000 TPH
- Reclaimer 3 Nos 1600 TPH
- Vibratory screen 3 Nos 1600 TPH
- Secondary Crusher 3 Nos 1600 TPH
2 GRINDING MILL PACKAGE
3. 4.
N 30 5. TP 6. Comb
- Rod-Ball mill 2. os 6 0 H ination Mill
3 PRE-DESILICATION
m3/hr (Per
Bauxite Slurry Heaters 12 nos 115 Heater)
- Tanks with agitators 12 nos 2000 m3
4 DIGESTION PACKAGE
- Test tanks 3 nos 3000 m3 per tank
- Digester Tanks with
agitators 12 nos 230 m3 per vessel
Shell & Tube Heat
Exchangers 27 nos ~1600 m2each
- Flash tanks + BOP tank
+ Relief Tank 18 nos 100-200 m3 each
5 THICKENER & WASHER PACKAGE
- High Rate Decanter 6 nos 20 m dia.
- High Rate washers 18 nos 20 m dia.
6 FILTRATION PACKAGE
- Diaster filter 12 nos
7 PRECIPITATION PACKAGE
- Plate Heat Exchangers 12 nos
Agglomerator
tank volume
- Precipitator tanks with will be lower at
agitators 63 nos 4500 m3 per tank 3000m3
- Interstage coolers 24 nos
8 HYDRATE CLASSIFICATION PACKAGE
- Primary Cyclones 9 nos
- Scalping cyclones 9 nos
9 SEED FILTRATION PACKAGE
m2 area per Fine Seed and
‘- Disc Filter 6 Nos 90 filter Product
m2 area per
- Disc filter 12 nos 180 filter Coarse Seed
10 EVAPORATION PACKAGE
- Evaporators batteries 5 nos 250 TPH each

PFR-25
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

11 HYDRATE FILTRATION PACKAGE

- Pan filter 5 nos 80 m2 per filter
12 CALCINATION PACKAGE

- Gas Suspension Calciner 3 nos 3500 TPD each

13 RMF Filters
Filters 18 Nos 40 TP Heach
14 CO-GENERATION PACKAGE
TPH per
- Boilers 6 nos 300 boiler
- Turbines 6 nos 50 MW each
- De-mineralizing unit 4 nos 140 m3/hr
- Diesel Generators 3 nos 5 MW

Process description of Co-generation Power Plant

Coal Handling Plant

Coal is received in the plant in size of (-) 200 mm and unloaded by wagon tipplers.
It will then be stacked in uncrushed form in the storage yard, which will have a
capacity to store around three week’s plant requirement. Thereafter, coal is
reclaimed and conveyed to the crusher house where coal size reduced to (-) 25
mm. The crushed coal is conveyed and stored in the coal bunkers in the steam
generation plant. Suitable ventilation and dust suppression facilities is installed in
various areas of coal handling plant.

Steam Generating Units

The steam generating units would be of pulverized coal, natural circulation,

tangentially fired, water tube type of bi-drum arrangement. The standard
components for waste heat recovery system and steam generation are
Economizers, Air-preheaters, Super heaters, Induced Draft and Forced draft fans,
De-aerator, Vertical spindle mills or XP series mills, Light Diesel Oil for startup and
Heavy Furnace oil for low load operation. Provision for Flue gas entrapment by
means of Electrostatic Precipitator (ESP) is provided in the downstream of flue gas
path leaving economiser so as to limit the dust emission concentration at its outlet
to 30 mg/Nm3.

Turbine generator units

Two double extraction condensing type steam turbine generators of 30-MW

capacity each with two condensers of 60-TPH capacity each are proposed. The
double extraction condensing type steam turbine generators have two controlled
extractions matching with the pressure requirement of the high and low pressure
process steam.

PFR-26
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

Ash Handling System

Dry ash disposal system begins at the outlet of fly ash silo and bottom ash silo at
steam generation plant and terminates to ash disposal area located about 5.5-km
away from the alumina plant battery limit.

Dry ash disposal system consists of the following major components:

 High Concentration Slurry Disposal (HCSD) system shall be utilised for
disposal of thick ash at the ash pond area. (Wet disposal)
 Water spraying on ash dump area by water spray system if required.
 HDPE lining under ash dump area settling pond to prevent seepage to
ground water.

Demineralization Plant:

De-mineralized water will be produced in the de-mineralization plant using filtered

water as input. The configuration of DM plant has been envisaged to include pressure
filter, cation exchangers, degasser, anion exchangers, mixed bed exchangers, DM
storage tanks, etc. Arrangement will be provided for regeneration of the exchangers
by acid & alkali and their storage. The effluent evolved during regeneration will be
neutralised and used for dust suppression in coal storage yard.

Cooling Water System

The cooling water is required in turbine condensers and various auxiliaries in the
steam and power plant. A dedicated cooling tower with separate circulation pumps
for turbine condensers and auxiliaries is envisaged to cater to these needs.
Chlorination is done in the cooling tower pump sump to control algae growth.

Fuel Oil System

Heavy fuel oil will be used for flame stabilization of bodies at low load and light fuel
oil will be used for boiler start-up and emergency diesel generator. Heavy fuel would
be pumped from the central storage and stored in the day tank within the steam and
power plant. Light fuel oil is received by road tankers, unloaded and stored in a day
tank within the steam and power plant. Suitable systems are provided for supplying
heavy and light fuel oil to the boilers and DG set.

Chemical Feed System

To maintain required alkalinity and thereby reduce corrosion and also to remove scale
forming compound in water, tri-sodium phosphate is dosed intermittently in the
boiler drum. To bring down the concentration of dissolved oxygen and thereby reduce
corrosion, hydrazine and cyclo-hexylamine are dosed continuously in the boiler feed
pump suction. The dosing systems include mixing tanks, dosing pumps, piping,
valves etc.

PFR-27
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

Stack Arrangement

Two multi-flue stacks are provided for the steam generating units sized for boilers
operating at MCR. The chimney height has been considered as 150-m, which is higher
than the requirement based on the statutory guideline for SO2 dispersion, and for
keeping ground level concentration within acceptable limits.

Fire Protection System

Fire hydrant system has been envisaged for the complete steam and power plant
including coal and oil storage areas. Automatic spray system has been proposed for
transformer, fuel oil tanks and turbine oil storage areas. Automatic sprinkler system
has been envisaged for coal conveyor galleries. The above systems will be an
extension of the fire water system of the alumina plant complex.

In addition to above, adequate number of portable and mobile fire extinguishers

would be provided at strategic locations. Fire detection and alarm system would also
be provided in vulnerable areas for detecting, fire/smoke.

Compressed Air System

A centralised compressed air system is provided for meeting plant and instrument
air requirement of the alumina plant complex including steam and power plant.

Ventilation System

The ventilation system would be evaporative cooling type with air washer units for
the Power House Building, in general. Exhaust ventilation would be provided in
battery room and coal tripper operating floor.

Mechanical ventilation system would be provided in miscellaneous pump houses,

MCC/Control rooms with suitable wall mounted supply/exhaust fans &louvers or
unitary air filtration units, as necessary.

Plant Operation and Control System

The steam and power plant control system basically comprises Boiler control system,
Turbine control system and high and low pressure process steam header pressure
control system. The very high pressure steam header pressure is maintained by the
dedicated control system of the individual boilers. A master control system is
incorporated for ensuring equal load sharing amongst the operating boilers.

The steam consumption is based on the process model. Saturated steam at absolute
pressure of 12 bar (MP) and 4.2 bar absolute (LP) is considered for the process
equipment. However, at the power plant battery limit the absolute pressures of 14
bar (MP) and 6 bar (LP) are proposed to take care of the pressure drop.

The average hourly steam requirement for the process plant in normal operating
conditions is 380 TPH (MP –140 TPH & LP-240 TPH) and during the peak loads this
requirement can go up to 455 TPH (MP- 165 TPH & LP – 290TPH).

PFR-28
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

Keeping in view the rating of steam turbine and the metallurgical constraint of the
pressure parts of the boiler, a pressure of 68 bar and temperature of 495 O C are
considered for the proposed project.

In order to increase the plant efficiency, condensing section flow needs to be

minimised. The steam flow through the extractions would follow the process plant's
steam demand which will be achieved by the turbine governing system by
activating control valves depending on the respective header pressures. However,
in case the power demand drops substantially in relation to process steam demand,
additional process steam requirement under this situation will be met through
pressure reducing and de-superheating stations directly. The major equipment of
the co-generation power plant is given in Table-5.

TABLE-5
MAJOR EQUIPMENT LIST FOR CO-GENERATION POWER PLANT

Name of Equipment / Package Proposed (150 MW)

Capacity Qty
CO-GENERATION POWER PLANT PACKAGE
Boiler 300 TPH 5
Turbo Generator 30 MW 5
CHP & Wagon tippler 866 TPH 2
DM Plant (Steam) 150 m3 5
1000x4 m3/hr 16
ACW, CW Pump & CT Fan 4000x4 m3/hr
3000x6 m3/cell

TABLE-6

PRODUCTS AND BYPRODUCTS

Unit Quantity
Products
Alumina refinery
Alumina 3.0 MTPA
Co-generation Power Plant
Power 150 MW
By-Products, Solid Waste (TPA/TPD)
Red Mud 51,00,000 TPA
Ash (Fly Ash (80% Fly Ash + 20% Bottom
5,84,000 TPA
Ash)
Lime grit 43,800 TPA

PFR-29
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

Co-generation Power Plant

Co-generation power plant of 150 MW is envisaged to meet the energy requirements.

VI. Raw material required along with estimated quantity, Likely source,
marketing area of the final products, mode of transport of raw material and
finished products.

The major raw materials for the project are bauxite, caustic soda, lime, oil and coal. The
raw materials requirement is given in Table-7. Deficit, if any, shall be met through import.
These materials will be sourced from the market, based on techno-economic feasibility.
The requirement of other consumables (fuels & process chemicals) required in the plant has
been estimated and furnished in Table-7.

TABLE-7
RAW MATERIAL

Raw Material Total Requirement Source Mode of Transport

(TPA)
Kodingamali and other Closed Conveyor / Rail
Bauxite 9.3 Million
sources
Caustic soda( 100% Domestic / Imported Rail / Road
2,04,000
NaOH basis)
Coal 14,05,000 e-auction/ Linkage/ Import Rail / Road
Lime 90,000 Local Suppliers Rail / Road
Synthetic Flocculent 1350 Import& Domestic Road
Oil for Calcination 2,13,000 Oil Refineries Rail / Road
Source: Hindalco

3.6 Raw Material Storage

The bauxite is unloaded at unloading station and stored in storage yard. From the
stockyard, a pay loader feed the material into different hoppers. By means of
discharge and transport belt conveyors including an over-belt magnetic separator,
the material is transported to a transfer tower, from where bauxite is routed to the
crushing plant.

Transportation

The main raw materials that are proposed to be transported to the proposed refinery are
as follows:

• Bauxite from mines through LDC

• Caustic lye

• Fuel oil

• Coal

• Lime

PFR-30
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

• Miscellaneous items from Vizag

Outward traffic shall consist of:

• Alumina to Hindalco Smelters

• Alumina to Vizag (For exports)

Inplant Railway

In order to facilitate easy loading/unloading of materials from railway wagons within the
plant boundary, separate railway sidings will be provided for the loading/unloading of
following materials:

• Coal (unloading)

• Caustic soda (unloading)

• Fuel oil (unloading)

• Lime (unloading)

• Alumina loading (3 tracks)

In addition to the above tracks, there shall be separate tracks for main line and engine
escape line. Provision will also be kept for additional tracks for future requirement.

3.7 Resource optimization/recycling and reuse envisaged in the project, if

any

Water Treatment Plant

The objective of water treatment is to produce a boiler feed water so that there is no scale
formation causing resistance to passage of heat and burning of tube, no corrosion, no
priming or foaming problems. This will ensure that the steam generated will be clean and
the boiler plant will provide trouble free uninterrupted service. Water treatment plant is
designed in such a way that it provides water, which is very low in dissolved solids known
as “dematerialized water”. There are two stages in water treatment process viz. pre-
treatment section and demineralization section.

3.8 Availability of water its source, energy/ power requirement and sources

Water Sources and Requirement

The water requirement in the proposed aluminium refinery is predominantly for, process
needs, cooling purpose, dust suppression, firefighting, drinking and sanitary needs.
Water supply system for the refinery consists of the following:

PFR-31
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

1. Make-up water supply system consists of

o Water reservoir and raw water pump house.

o Water treatment plant, clarified water storage.

o DM water system

o Soft water system

o RO water system

o Piping and valves

2. Re-circulation water system

o Circulating water pumps

o Heat exchangers

o Cooling towers

o Adiabatic cooling towers

Water Requirement
Water requirement for industrial usage will be met from nearby Patagarha river
near Kutinguda through 16 km long pipeline and stored in a water reservoir of
2,50,000 m3 capacity.

Water agreement will be signed between Department of Water Resources (DoWR)

and Hindalco for supply of 20,000 m3/day water from Patagarha river. The water
permission letter is enclosed as Annexure-V. Water balance is given in Figure-3.

Power Source and Requirement

Based on the sizing calculation, the power plant of 150 MW each for phase-1, 2 &
3 is envisaged to meet the power requirement. The availability of power plant is
considered for 330 days while the entire process plant operation is 350 days. The
annual shutdown of power plant shall be carried out in phased manner.

During the above maintenance period, the additional power requirement shall be
made available from the grid. In order to meet auxiliary power and exigency power
requirement for process & CPP, set of four nos. of 2.5 MW DG set has been
envisaged. Each DG set will have a respective day storage tank of min. 990 kl.

PFR-32
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

FIGURE-3
WATER BALANCE

PFR-33
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

3.9 Quantities of wastes to be generated (liquid and solid) and scheme for
their management.

Wastewater from Refinery and Co-generation Power Plant:

The effluent generated from the process and utilities have been categorized into
three streams viz. storm water stream, utility stream and process water stream
which is alkaline in nature. The storm water generated from the refinery shall be
collected in Guard Pond and process water shall be collected in caustic pond. Holding
pond will be provided at power plant to collect blow down, neutralization water etc.
The wastewater management in Alumina Refinery and Co-generation Power Plant
are given in the following flow charts

Alumina Refinery

Wastewater from
Refinery Surface Run off water

Settling in Caustic Neutralisation

Pond

Red mud washing Guard Pond

unit

High Rate Decanter (HRD) Treated Water

for dilution

To precipitation as Classification and seed Spent Liquor to Multi

Pregnant Liquor (PGL) filtration Effect Evaporation

Co-generation Power Plant

Wastewater from CPP

Neutralisation

Settling/Holding Pond

Treated Water

Sprinkling, Dust Suppression & Ash Conditioning

FIGURE-4
FLOW DIAGRAM OF WASTEWATER MANAGEMENT IN REFINERY AND CPP
PFR-34
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

Hazardous waste generation:

The major hazardous waste generation anticipated from the Alumina Refinery &
Power plant are Used or spent oil, Wastes or residues containing oil, Empty barrels/
containers /liners contaminated with hazardous chemicals/ wastes, Sludge
containing oil during cleaning, emptying of oil storage tanks. Contaminated cotton
rags or other cleaning materials. Spent ion exchange resin containing toxic metal.
Adequate steps shall be taken for collection, storage, transportation in the plant
prior to final disposal to the recyclers of HW as per the Hazardous and Other Wastes
(Management and Trans boundary Movement) Rules, 2016.
Solid waste Generated by alumina refinery is given in Table-8.

TABLE-8
SOLID WASTE GENERATED BY ALUMINA REFINERY& CPP

Unit Total Quantity (TPA)

Red mud 51,00,000
Ash 5,84,000
Lime grit 43,800

3.10 Schematic representations of the feasibility drawing which give information

of EIA purpose

As per the Environment Impact Assessment (EIA) notification dated 14 th Sept. 2006
and subsequent amendments, the proposal falls under category A. EIA/EMP report
shall be prepared to get the Environmental Clearance for this project from the
MoEF&CC. The Environmental Clearance (EC) process schematic diagram presented
in Figure-5.

Earlier Environmental Clearance (EC) [Link] J-11011/141/[Link](I) dated

18.03.2006 is given in Annexure-VI. Also an EC vide [Link]-J-11011/983/[Link].
II(I) dated 04.10.2013 is given in Annexure-VII.

Also an Application for Forest Land has been filed with no FP/OR/IND/454652020
given in Annexure-VIII.

PFR-35
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

Project Concept and Site

identification*

Form 1, pre-feasibility project report

Recommendations of with proposed TOR to MoEF (EAC)
SCZMA

Scoping by EAC (site visit by sub

group of EAC, if necessary)

TOR approved by EAC EC-rejected by MoEF on the

recommendation of EAC

Draft EIA report to

SPCB/UTPCC by project Summary EIA and Form I –display
In on SPCB/UTPCC website
proponent
cas
e of
Public consultation
CRZ Display
cle process by SPCB/UTPCC
on the
ara MoEF Display at Panchayat, ZP,
nce website DM/DC/Dy. Com & on the
Proceeding of Public
SPCB/UTPCC Website
consultation

To proponent for submission of

Appraisal and final EIA report / Supplementary
recommendation by EAC report to draft EIA

Approval by MoEF Referred back to EAC under

communication to the project proponent
CRZ approval by
MoeF

Display on MoEF website &

Rejected Approved
project proponent website

Submission of the Display of

Post EC monitoring half yearly compliance
compliance report to report on
MoEF/Ro-MoEF MoEF website

FIGURE-5
ENVIRONMENTAL CLEARANCE PROCESS

PFR-36
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

4.0 SITE ANALYSIS

4.1 Connectivity

The site is well connected to SH-4 (Koraput to Rayagada, 12 km S). Nearest city is
Rayagada, 40 km, NE. Nearest Railway station is Singaram (1.5 km, SE). The
nearest airstrip Jeypore (50 km, SW). The site is well connected with
communication facilities like telephone and as such, no constraints are envisaged
in this aspect.

4.2 Land from Land Use and Land Ownership

Kansarigurha alumina refinery is about to setup in 866.28 ha, which was already
under the possession of M/s Aditya Aluminium. Topography of the land is almost
flat with minor undulation. The elevation of plant area is 840 above MSL. The Land
Use of the Proposed Project Area is given in Table-9.

TABLE-9
LAND USE PATTERN (Acres)

Private Govt. Forest

Village and Plants Land Land Land Total

Core Plant Area with Green Belt

Phuljuba 170.99 24.17 - 195.16

Kansariguda 501.09 52.53 13.48 567.10

Total 672.08 76.70 13.48 762.26

R & R colony

Podapadi 36.10 4.79 - 40.89

Biriguda - 34.72 - 34.72

36.10 39.51 - 75.61

SDC , apparel unit and green cover

Puhundi 197.65 37.82 0.56 236.03

Sub- Total 197.65 37.82 0.56 236.03

Ash pond with Green Belt

Bhalujodi 75.50 64.64 - 140.14

Singaram 109.68 38.16 0.47 148.31

Total 185.18 102.80 0.47 288.45

PFR-37
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

Red Mud Pond Area with Green Belt

Biriguda 134.93 1.77 50.795 187.495

R P guda 111.23 370.15 20.00 501.38

Total 246.16 371.92 81.01 699.09

Water Pipeline Corridor

Panchali 4.84 0.98 0.18 6.00

Punjiguma 1.64 0.63 - 2.27

Toyaput 1.36 1.25 1.46 4.07

Kapadanga 2.03 1.19 0.40 3.62

Kansariguda 1.17 - 0.37 1.54

Phulajuba 1.11 1.16 - 2.27

Sankarda 3.07 1.72 - 4.79

Sankarda RF - - 1.10 1.10

Kidripadar 1.58 0.19 0.35 2.12

Kidripadar R.F. - - 4.94 4.94

Kuntigiguda 8.11 12.34 - 20.45

Sub-Total 24.91 19.46 8.80 53.17

Ash Pond & Redmud Pond Conveyor Belt Corridor

Phuljuba 1.43 - - 1.43

Kansariguda 4.18 2.52 12.41 19.11

Biriguda 7.06 1.03 1.59 9.68

Singaram 1.20 0.09 - 1.29

Bhalujodi 4.57 0.11 - 4.68

Total 18.44 3.75 14.00 36.19

Grand Total (Acres) 1,380.52 650.488 109.569 2,140.58

.in Hectares 558.689 263.249 44.342 866.28

PFR-38
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

4.3 Topography

The topography of the land at project site is undulating with contour levels ranging
between 810 m to 900 m Relative Levels (RLs). The site is devoid of major
undulations except two spot elevations at the center of proposed plant area.
However, hilly terrain exists outside the project boundary towards west and south-
west.

4.4 Existing Land Use Pattern

Land use of the proposed land area is partly agriculture and barren land.

4.5 Existing Infrastructure

The proposed Alumina Refinery at Kansarigurha shall be self-sufficient and

independent in respect of almost all infrastructure and support facilities that are
required to operate and maintain a plant of such a magnitude. The various
infrastructural & support facilities that are required to be created for the proposed
alumina refinery are as follows:

1. Rail link;
2. Road link;
3. Power supply;
4. Port facilities;
5. And Communication.

4.6 Soil Classification

The plant site falls under Rayagada district. The area comes under Eastern ghat
region of Archean era. The hills are made up of Gneisses, Charnockites and
Khondalites. The eastern ghat is a belt of high grade metamorphism as evidenced
by the abundance of garnet and sillimanite. The Charnockites shows intrusive
relationship towards the khondalite and has itself undergone post magmatic
changes such as albitisation and myrmekitisation. The Khondalites have been
derived from rather high alumina clays, which were also fairly rich in iron.

4.7 Climatic Data from Secondary Sources

The climate of the area is dry humid and sub-tropical. It is characterized by hot
and dry summer (March to June), rainy season (July to October) and winter
(November to February). The minimum and maximum relative humidity is about
36%-90%. The temperature varies between 11.40C to34.20C.

The average rainfall observed during the monsoon season was 336.2 mm with
maximum amount of rainfall (480.5 mm) occurring in the month of August and the
minimum (135.6 mm) in the month of October respectively.

PFR-39
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

4.8 Social Infrastructure Available

Residential Area (Non-processing Area)

The proposed layout for new alumina refinery & co-generation power plant is
planned considering land availability and environment condition. Skill Development
Center and Apparel Unit is proposed for local people under CSR and CER norms.

5.0 PLANNING BRIEF

5.1 Planning concept (type of industries, facilities, transportation etc.) Town

and country Planning/Development authority Classification

Proposed industry is metal industry. Facilities required for the proposed project will
be provided as per requirement. Transportation of raw material and final product
is will be done via road and rail.

5.2 Population Projection

Direct and indirect employment will be created due to project. Temporary influx of
people will be there as the managerial and supervisory staff will generally be
outsider.

5.3 Land Use Planning

The land is already under the possession of Hindalco Industries Limited for which
Environmental Clearance was granted. The area will be occupied by various
facilities viz, refinery& associated facilities, ash pond, red mud pond area etc. The
land use breakup details are given as follows in Table-10.

TABLE-10
PROPOSED LAND USE PATTERN

[Link] Unit Area (ha)

1. Core Plant Area 220.00
2. Ash Pond 63.00
3. Red Mud Pond 210.00
4. Water Pipeline Corridor 21.52
5. Ash Pond , Red mud Pond and Conveyor Belt
14.65
Corridor
6. R&R colony 30.60
7. Skill development centre and Apparel Unit 20.24
8. Green Belt Development and Green Cover 286.28
Total 866.28

PFR-40
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

5.4 Assessment of Infrastructure Demand (Physical & Social)

Aditya aluminium has assessed the demand of infrastructure (Physical & Social) in
nearby area of the plant site and development activities are being undertaken
under corporate social responsibilities program for rural development initiatives for
the upliftment of the nearby communities from time to time.

5.5 Amenities/Facilities

Aditya aluminium will construct dispensaries, school, canteen and club etc. for the
permanent and contract employees. It is proposed to develop the amenities /
facilities in nearby area of the plant site as per requirement of local people of the
nearby area under corporate social responsibilities programme.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

The detailed plant layout area is shown in Figure-6.

The following facilities are envisaged for the production enhancement:

 Aluminium refinery -3.0 MTPA

 Captive power plant- 150 MW
 Red mud pond
 Ash pond
 Bauxite Crushing unit

PFR-41
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

FIGURE-6
PLANT LAYOUT

PFR-42
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

6.2 Residential Area (Non Processing Area)

The proposed layout for new refinery & co-generation considering is planned
considering land availability and environment condition. Skill Development Center
and Apparel Unit is proposed.

6.3 Greenbelt

An area of around 286.28 ha (33%) will be put under greenbelt and green cover .

6.4 Social Infrastructure

Employment, medical facilities, educational facilities, transportation etc. will be

further strengthened by Hindalco.

6.5 Connectivity (Traffic and Transportation Road/Rail/Metro/Water ways

etc.)

The site is well connected by all-weather road.

6.6 Drinking Water Management (Source & Supply of Water)

Apart from STP, water for domestic purpose shall be drawn from Mansi Wakal dam.

Drinking water requirement for the construction phase will be 367 KLD for about
(8000 Contract Employees and 150 nos of permanent employment). During
operation phase about 214 KLD would be required for 750 permanent and 4000
contract employees.

The refinery shall use equipment to achieve zero liquid discharge in the plant.

6.7 Sewerage System

Sewage treatment plant is envisaged to treat the domestic effluent generated. The
MBR technology is adopted to treat high quality COD, BOD and TSS.

6.8 Industrial Waste Management

The effluent generated from the process and utilities shall be categorized into three
streams viz. fluoride stream, non-fluoride stream and utility stream. The fluoride
stream is first received in reaction tank 1 and treated separately within the ETP
whereas the utility stream effluent is mainly generated from blow downs. The M/s
Aditya aluminium is adopting zero discharge.

6.9 Solid Waste Management

Red mud of about 51,00,000 TPA will be generated, which will be disposed to red
mud pond and will be used for cement making. At about 5,84,000 TPA of fly ash is
proposed to be generated, which will be sent to the ash pond will be sent to filling

PFR-43
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

of the low lying lands, brick manufacturing, mine voids filling, cement industry. The
lime grit of 43,800 TPA will be generated will be sent to brick making unit.

6.10 Power Requirement & Supply/Source

The by-product power is utilized for meeting the requirement of the process plant.
The power produced in the co-generation plant shall be synchronized with the grid
supply such that surplus power can be banked with GRIDCO (Odisha) while minor
temporary shortage or start-up requirements will be met from the grid. For short
durations, during instability of the grid, provision is made to operate the plant in
“islanding” mode also.

7.0 REHABILITATION AND RESETTLEMENT (R&R PLAN)

I. Policy to be adopted (Central/State) in respect of the project affected

persons including home oustees, land oustees and landless labourers

R&R report had already been prepared and the land has been in the possession of
M/s Hindalco Industries Limited- Aditya Aluminium Project.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

8.1 Likely date of start of construction and Completion of Project (Time

schedule for the project to be given)

Proposed Schedule for Implementation of Project:

The total project will be implemented in phases. Total project duration is estimated
to be about 60 months.

TABLE-11
MAJOR ACTIVITIES FOR FIRST PHASE

Sr. Target Completion Time

Milestone
No. form Zero date
1 Process know-how & Basic Engineering 0-4 months
2 Approval of Basic Engineering by UAIL 4-6 months
3 Detailed Engineering 6-18 months
Tendering, Procurement action, Supply
4 7-19 months
of Plant & Equipment
5 Civil & Structural Work 7-20 months
6 Erection of Equipment 14-22 months
7 Trial Run & Commissioning 22-24 months

PFR-44
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

.
8.2 Project Cost

Estimated project cost along with analysis in term of economic viability

of the project

The total investment for the proposed project works out to approximately INR
11,000 Crores. The estimated Investment Cost for the project is based on the
requirement of fixed and non-fixed assets. The details of total investment are
shown in the Table-12 below.
TABLE-12
COST BREAK-UP OF THE PROPOSED PROJECT

Description Amount (Rs cr.)

Alumina Refinery 7,500
Bauxite Residue Filtration and Storage 850
Ash Pond 100
Co-generation Power Plant 900
Mines 100
Infrastructure 600
R&R 100
Technology 300
Owner 400
Contingency 150
Total 11,000

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION)

9.1 Financial and Social Benefits

About Rs 11,000 Crore will be the capital cost of the proposed Alumina Refinery
along with the cogeneration power plant.

The proposed project will result following additional social benefits:

 Growth of the surrounding areas by increasing direct and indirect employment

opportunities in the region including ancillary development and supporting
infrastructure.
 Odisha state will get revenues in terms of taxes and local people will get direct
& indirect employment.
 Business opportunities for local community will be available like transport of
material to market, maintenance & house contract work, supply in goods, food
to people etc.
 In addition, local communities will be benefited from CSR activities to be
carried out by the company.

With the expected growth of the economy as well as the healthy trends emanating
in the, it will be prudent on the part of M/s Aditya aluminium to place itself in a

PFR-45
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

strategic position to exploit the market. Hence, it is recommended to implement

the project in Phase-1, Phase-2 and Phase-3.

10.0 Conclusion

Proposed Greenfield project will result in conservation of natural resources, growth

of the surrounding areas by increased direct and indirect employment opportunities
in the region including ancillary development and supporting infrastructure. Special
emphasis on financial and social benefits will be given to the local people.
Development of social amenities will be in the form of medical facilities, education
to under privileged and creation of self-help groups. No adverse effect on
environment is envisaged, as proper mitigation measure will be taken up for the
same.

PFR-46
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

ANNEXURE-I
INDEX MAP

Project Site

PFR-47
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

ANNEXURE-II
STUDY AREA MAP – SOI TOPOSHEET

PFR-48
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

ANNEXURE-III
STUDY AREA MAP – GOOGLE MAP

10KM

Project Boundary

PFR-49
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

ANNEXURE-IV
LEASE LAND DETAILS (First page)

PFR-50
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

ANNEXURE-V
WATER ALLOCATION LETTER

PFR-51
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

PFR-52
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

PFR-53
Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

ANNEXURE-VI
EARLIER EC for 1.0 MTPA DT 18.03.2006 (First page)

PFR-54
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

ANNEXURE-VII
EARLIER EC FOR EXPANSION FROM 1.0 to 1.5 MTPA DT 04.10.2013 (First page)

PFR-55
 Pre-Feasibility Report for Proposed Alumina Refinery of 3.0 MTPA
along with Co-Generation Power Plant of 150 MW at Kansarigurha
Village, Kashipur Tehsil, Rayagada District, Odisha

ANNEXURE-VIII
APPLICATION FOR FOREST LAND (FP/OR/IND/454652020)

PFR-56