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PRE-FEASIBILITY REPORT FOR
THE EXPANSION OF ALUMINIUM SMELTER PRODUCTION
CAPACITY FROM 5.75 LTPA TO 10.85 LTPA AT VILLAGE
RISDA, TEHSIL - KORBA, DISTRICT - KORBA, CHHATTISGARH
Submitted to:
Ministry of Environment, Forest and Climate Change New Delhi
Prepared by:
M/s Bharat Aluminium Company (BALCO) Korba, Chhattisgarh
August 2017
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-1
1.0 EXECUTIVE SUMMARY
1.1 Introduction
Bharat Aluminium Company (BALCO) was established at Korba, Madhya Pradesh
(presently Chhattisgarh) as a Government of India undertaking with integrated
smelter capacity of 1 LTPA (1,00,000 tonnes per annum) with Soder berg
technology employing 100 kA cells and Alumina Refinery capacity of 2 LTPA. The
plant started in 1973. BALCO was taken over in 2001 by Sterlite Industries, an
associate of Vedanta Resources, PLC.
Vedanta is having a total revenue of more than 13 billion US$ sustaining global
leadership of nonferrous metals and optic fibre business. Vedanta has a growing
interest in copper aluminium, zinc, silver lead, iron ore, gold & optical fibre cable
in India, Australia, North America, Zambia and the UK.
Since 2001, BALCO modernized & expanded the plant in the following manner:
(i) Setting up a 2,50,000 TPA pre-baked technology smelter and 540 MW
captive power plant employing GAMI – China 320 KA technology;
(ii) Expanding further by installation of 3.25 LTPA aluminium and 1,200 MW
(4X300 MW) captive power plant employing GAMI China 340 KA) pre baked
anode technology. While installing 3.25 LTPA smelter, original 1 LTPA
Soderberg smelter was dismantled favoring environmental friendly pre
baked technology. 3.25 LTPA smelter included 336 no 340 KA pots and
ingot casting capacity of 1.50 LTPA & wire rod of 2.00 LTPA capacity.
(iii) The previous expansion was undertaken based on the EC which was granted
by MOEF vide Lr J-11011/123/2007-IA-II(1), Dated 16.09.2008 for the
expansion of aluminium smelter plant from 3.5 LTPA to 9.0 LTPA. Under the
said EC smelter plant of 3.25 LTPA was constructed and 1 LTPA Soderberg
smelter was dismantled. However the remaining capacity of 3.25 LTPA was not
constructed due to prevailing economic scenario at that point of time. The said
EC expired in September, 2015. Now Balco is expanding its existing aluminium
production capacity by 5.1 LTPA in the area earmarked for balance 3.25 LTPA
smelter capacity by incorporating advanced state of the art environment
friendly technology.
BALCO is presently contemplating to undertake brown field expansion of the
smelter by installing 5.10 LTPA (5,10,000 TPA) by employing 500 KA cell
technology. It is proposed that the said smelter shall be constructed at the
designated area, earlier proposed for 3.25 LTPA aluminium smelter.
1.2 Project at a Glance
The proposed expansion project at a glance is given in Table-1.
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-2
TABLE-1
PROJECT AT A GLANCE DETAILS
General Description
Type of Project Expansion of aluminium smelter capacity from 5.75
LTPA to 10.85 LTPA by addition of 5.10 LTPA capacity
Owner M/s. Bharat Aluminium Company Limited
BALCO Nagar, village Risda, tehsil Korba, district
Korba, Chhattisgarh
Location of Plant The site is located within existing BALCO Complex at,
village Risda, tehsil Korba, district Korba,
Chhattisgarh
Technology Energy efficient pre- baked technology, state of art
500 KA pot line technology with Pre-baked anodes.
Inputs to Aluminium Smelter
Alumina About 1.94 T of Alumina / Tonne of Metal (or
about 9,89,400 TPA)
Calcined Petroleum
Coke, cryolite as
Na3AlF6 Aluminium
Fluoride (AlF3), CT
Pitch
Calcined Petroleum Coke: 2,04,000 TPA;
Cryolite: 1,020 TPA;
Aluminium fluoride: 7650 TPA
CT Pitch: 39,500 TPA
Land requirement 39.66 ha (98 acres). The land is already available
Power requirement About 850 MW (including auxiliary power) based
on average 12,500 Kwh/tonne (DC Power) for Pot
Line from the Captive Power Plant of BALCO
Water requirement About 2,400 m3/day (100 m3/hr) from Hasdeo
Barrage around 10 km from plant.
Manpower requirement 1,050 persons
2.0 INTRODUCTION OF THE PROJECT/ BACK GROUND INFORMATION
2.1 Identification of Project Proponent and Project
BALCO is a group company of M/s. Vedanta Aluminium Limited and Sterlite Industries
India Ltd. VEDANTA is having a total revenue of more than 13 Billion US$ with clear
focus on achieving and sustaining global leadership in non-ferrous metals (with mining
also) and Optic Fibre business. VEDANTA has a growing interest in copper, aluminium,
zinc, silver, lead, iron ore business, Gold and Optic Fibre Cable in India, Australia, North
America, Zambia and the U.K.
BALCO is proposing for expansion of aluminium smelter capacity from 5.75 LTPA to
10.85 LTPA by addition of 5.10 LTPA capacity in an area of 39.66 ha (98 acres) in
the existing BALCO integrated aluminium complex, which is located at village Risda,
tehsil Korba, district Korba, Chhattisgarh.
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-3
2.2 Brief Description of Nature of the Project
The existing BALCO integrated aluminium complex comprise 2 smelter units totaling
5.75 LTPA (5,75,000 TPA) smelter (2,50,000 TPA + 3,25,000 TPA) along with all
auxiliary facilities, captive power plants totaling 4 x 67.5 MW (270 MW near in
NTPC Jamanipali, Korba) , 4 x 135 MW (540 MW) and 4 x 300 MW (1200 MW) .
Now BALCO intends to install 5.10 LTPA (5,10,000 TPA) aluminium smelter and
associated facilities in the factory premises at Balco plant where in the general plant
layout, it is designated as “Brownfield Smelter” with associated facilities. Power
requirement for smelter expansion shall be met from the existing power plants.
The estimated project cost of aluminium smelter is about Rs. 7,927.04 Crores.
2.3 Need and Justification for the Project
BALCO has been the first in the Indian Aluminium Industry to produce the Alloy
Rods, which is a Feedstock for all Aluminium Alloy Conductors, needed for today’s
power transmission lines. BALCO contributes to about 20% of the country's
aluminium production. BALCO has the distinction of being the sole provider of
aluminum for Indian Defense Missiles like Prithvi, Akaash, Agni, Agni-II.
BALCO was the first major Public Sector Organization which went through the
economic reforms and disinvested to Sterlite Group in 2001. BALCO is a partially
integrated aluminium company with captive bauxite mines, captive power plants,
refineries and smelters.
In the last 44 years, BALCO has built-up a production capacity of 2,50,000 TPA of
alumina production capacity; 5,75,000 TPA of smelting capacity and expanded its
fabrication facility to include three Properzi Rod Mills, three pig casting machines,
integrated hot and cold rolling mills, and captive power plants of 270 MW + 540 MW
+ 1200 MW capacity. BALCO has received ISO-9001:2000 certification for
manufacture and supply of calcined alumina, aluminium ingots/billets, aluminium
rods and aluminium rolled products.
Present day power demand and supply scenario for BALCO plant is given in following
Table-2 & 3.
TABLE-2
EXISTING POWER GENERATION DETAILS
Sr. No Power Plant Capacity
(MW)
Total Capacity
(MW)
Net output after
Aux Consumption
(MW)
1 CPP-1 4X67.5 270 240
2 CPP-2 4X135 540 486
3 CPP-3 4X300 1200 1100
4 Total 2010 1826 Source: DPR
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-4
TABLE-3
EXISTING SMELTER PLANT POWER REQUIREMENT DETAILS
Bauxite ore requirements are being met from Mainpat mine is about 53 lakh tonnes
(5.3 million tonnes) of Bauxite reserves and Bodai-Daldali mine is about 63 lakh
tonnes (6.3 million tonnes) of Bauxite reserves.
BALCO is interested in further expansion of their aluminium production capacity by
5.10 LTPA with the available surplus power from the existing captive power plant for
meeting power demand. The power requirement for the proposed smelter plant shall
be about 850 MW.
2.4 Employment Generation
The proposed expansion project will be operated with skilled and semi-skilled personal.
The total employment for smelter complex will be 1,050 persons, direct employment of
400 persons and indirect employment of 650 persons.
3.0 PROJECT DESCRIPTION
3.1 Type of the Project
The proposed expansion project deals with the expansion of aluminium smelter
capacity from 5.75 LTPA to 10.85 LTPA by addition of 5.10 LTPA capacity to the
existing capacity in an area of 39.66 ha (98 acres) in the existing BALCO integrated
aluminium complex.
3.2 Details of Alternative sites
There is no alternative sites examined for installation of aluminium smelter plant as it is
an expansion project and will be implemented within the existing land.
3.3 Location of the Project
The proposed expansion project site is within the premises of BALCO integrated
aluminium complex at village Risda, which falls in tehsil Korba, district Korba in
Chhattisgarh state. The index map of the project site is shown in Figure-1.
Similarly, the study area showing topographical features within 10 km radius from
the project site boundary is shown in Figure-2. The Google image of proposed
expansion project site and 10 km radius are shown in Figure-3(A) & 3(B)
respectively.
Sr. No. Smelter Plant Requirement in Smelter Plant
1 Potline-1 420 MW
2 Potline-2 530 MW
3 Proposed Expansion 850 MW
4 Total 1,800 MW
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-5
3.4 Size or Magnitude of Operation
The proposed aluminium smelter plant for production of primary aluminium metal is
given in Table-4. The overall layout plan is shown in Figure-4.
TABLE-4
PROJECT DETAILS FOR ALUMINIUM SMELTER
Sr. No. Description Details
1 Aluminium production
capacity
5.10 LTPA Aluminium Ingots
2 Land requirement 39.66 ha (98 acres)
3 Water consumption and
source
2,400 m3/day
Water is drawn from Hasdeo river.
4 Power consumption About 850 MW (including auxiliary power)
based on average 12,500 Kwh/tonne (DC
Power) for Pot Line from the Captive Power
Plant (CPP) of BALCO
5 Alumina requirement About 1.94 T of Alumina / Tonne of Metal
(or about 9,89,400 TPA)
6 Fuel requirement
Furnace Oil
15,000 KLPA
7 Manpower requirement 1,050 persons
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-6
FIGURE-1
INDEX MAP OF THE PROJECT SITE
Balco Project Site
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-7
FIGURE-2
STUDY AREA MAP (10 KM RADIUS)
Pre-Feasibility Report for the Expansion of Aluminium Smelter Production Capacity from 5.75 LTPA
to 10.85 LTPA at Village Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-8
FIGURE-3(A)
GOOGLE IMAGE MAP OF PROPOSED EXPANSION PROJECT SITE
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-9
FIGURE-3(B)
GOOGLE IMAGE MAP (10 KM RADIUS)
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-10
FIGURE-4
OVERALL LAYOUT PLAN
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-11
3.5 Project Description with Process Details
The process adopted for production of aluminium is the process of electrolytic reduction
of alumina to metallic aluminium as being practiced in present age advanced aluminium
smelting plant globally. The aluminium production flow sheet is shown in Figure-5.
3.5.1 Process Description of Aluminium Smelter
The process of reduction is the well known and commercially established Hall – Heroult
process of electrolysis and will employ State of Art 500 KA cell technology. Electrolytic
operations are proposed to be carried out at a cell amperage of 500 KA. Generally
speaking, higher cell amperages are conducive to more economical production &
tendency over time has been to achieve higher current intensities.
The anode system proposed to be used is prebaked centre feed type. Aluminium metal
is deposited in molten form on the cathode under the electrolyte layer and is tapped
under vacuum. As the operation is continuous, alumina is charged at suitable intervals
after breaking the crust that is formed at the top of electrolyte layer.
Fume liberated at the anode during the electrolytic process consists primarily of oxides
of carbon & fluorine compounds. The former are obtained by chemical reaction of the
anode mass whereas the later result from the dissociation of fluorides in the cell bath.
Additionally entrained fluorides, alumina dust are also included in liberated gases. The
gases are vented through dry scrubber type gas cleaning system.
FIGURE-5
ALUMINIUM PRODUCTION FLOW SHEET
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-12
3.5.2 Process Related Facilities
Electrolysis
Because of solubility of aluminium oxide in molten cryolite, it is possible to complete the
electrolysis of oxide at a temperature of 9500C – 9800C. Aluminium oxide has a melting
point of 20500C but is soluble in cryolite bath upto 10% by weight. The basic equation
describing the chemical decomposition of aluminium oxide is:
2Al2O3 4Al + 3O2
Earlier electrolyte cells were small with current intensities of only several thousand
amperes. Prebaked anodes made of pitch and Calcined Petroleum Coke weighing
approximately 100 kg were used. Cathodes were mostly monolithic rammed
construction. With larger sized cells being built, self baking soderberg anodes started to
become popular. Horizontal stud & vertical stud soderberg reduction cells became more
common. Main advantage of continuous Soderberg Electrode was that the plant is very
simple affair with no provision of anode forming, baking & rodding. Soderberg
technology necessitated change to meet new demands of improved working conditions,
emission control both inside & outside pot lines and higher degree of automation.
Prebaked anode in place of Soderberg technology became the trend. Some of the major
factors influencing usage of baked anodes are:
It allows higher current densities (presently cells with 500 KA rating or more are in
Vogue);
Distribution of magnetic flux is better & gas flow becomes favourable;
Possibility of better thermal balance;
Working area is comparatively free of obnoxious fumes; and
Higher Metal Purity.
The original BALCO Plant was designed based on 100 KA technology employing
continuously self-baked soderberg technology. Because of inherent suitability prebaked
anode was selected for 2,50,000 TPA expansion. The same was also envisaged for
325000 TPA expansion carried out by BALCO.
Electrolytic cell consists of a box shaped steel shell which contains the cathode and
anode assembly. Bottom of steel shell is lined with refractory bricks which support the
cathode assembly. The cathode assembly consists of blocks and cathode bar which
extends over the entire width of the cell & is externally connected to the bus bars with
flexible connectors. Anode assemblies consist of anode block and anode rods. These are
clamped to anode beam. Electrical & mechanical connection between blocks & rods is
made by means of cast iron stubs, which are locked in stub holes of anode blocks.
A total of 376 electrolyte cells, or pots are envisaged. Cells are arranged in four pot
rooms in one pot line.
Pot is placed side by side in the room, completely enclosed by sheet metal hoods,
serviced by multipurpose overhead pot tending machines (PTM), fully controlled by a
process computer, connected though a central hyperdense phase pneumatic transport
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-13
system to alumina & fluoride supply & vented through a duct system to the central dry
scrubbing waste gas cleaning installation.
Process and Plant Characteristics of High Amperage Cells (500 KA and above)
BALCO, in their proposed expansion is planning to set up 5.10 LTPA smelter 500 KA cell
technology. Besides expansion by 5.10 LTPA by 500 KA cells, there will be billet & rolled
products together with saleable “Sow ingot’ and liquid metal.
BALCO shall be partnering with suitable technology provider and EPC Contractor for 500
KA smelter technology.
As per published information, the following KA cells are operating in India.
Hindalco: Mahan 3,60,000 TPA (AP36 Technology 360 KA)
Lapanga 3,60,000 TPA (AP36 Technology 360 KA)
NALCO : 4,75,000 TPA (180 KA to 220 KA)
2,45,000TPA (GP-320 KA, 320 KA)
Vedanta: VAL, Jharsuguda – 5,00,000 TPA (GP-320 KA, 320 KA) & (1,250,000 TPA
(GP – 340 KA, 340 KA)
BALCO – 2,50,000 TPA (GP-320 KA, 320 KA) & 3,25,000 TPA (GP – 340,
340 KA)
The above shows that maximum cell amperage operating in India is of the range of 360
KA.
The higher KA cell ratings will have the following advantages:
(i) Lowers specific energy consumption;
(ii) It reduces capital expenditure;
(iii) Requires lesser man power;
(iv) Less cell maintenance costs, control, fume treatment facilities; and
(v) Assists in faster recovery of investment.
As per published records, there are presently four (4) different super high amperage
cell technologies operating at 550-660 KA in worldwide aluminium industry.
The following Table-5 and Table-6 highlight pertinent details of 500 KA cells
technology being contemplated by BALCO.
TABLE-5
PERTINENT TECHNICAL DETAILS OF 500 KA CELLS
Sr. No. Items Units GP500-376
1 Anode Size mm 1770x770x645
2 No. of anodes piece 48
3 Operating current kA 500
4 Current density of A/cm2 0.764
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-14
Sr. No. Items Units GP500-376
anode
5 Avg current efficiency % 94.5
6 Avg voltage V 3.950
7 Stable and efficient ACD mm 44.00
8 Bath type CaF2%6.8 + MgF2%0.4 + CR2.2
9 Alumina quality India and Australia
10 Cathode resource 50% semi graphitic cathode
11 Avg. DC consumption Kwh/t.Al 12553
12 Installed nos. of pots in potline
Pots 376
13 Nos. of operating pots Pots 370
14 Daily tapping volume
per pot
Kg/p.d 3804
15 Annual tapping volume per pot
t/a 1388
16 Annual tapping volume per potline
t/a 513560
17 No. of potline 1.00
18 Total capacity t/a 513560
19 Anode requirement 24 groups/48 pieces/32 days
TABLE-6
PERTINENT TECHNICAL DETAILS OF CARBON PLANT ANODE SIX (MM)
Sr. No. Items Units GP-500-376
1 No. of anodes piece 48
2 Operating current kA 500
3 Anode requirement 24 groups/48 pieces/32 weeks
4 Daily quantity demand of anode in Potline pieces/day 564
5 Annual quantity demand of anode in Potline
pieces/day 205860
6 Annual anode rodding capacity pieces/day 207939
7 Capacity of anode rodding line piece/hour 51.27
8 Annual anode baking capacity piece/year 210040
9 Capacity of each firing system for baking furnace
piece/year 52560
10 Nos. of firing system for baking furnace
- 4.00
11 Capacity compaction of anode vibrating pieces/year 213238
12 Capacity of anode vibrating compaction by
hour
piece/hour 33.50
13 Unit weight of green anode kg/piece 1366.91
14 Capacity of mixing kneader by hour
t/h 46.49
15 Unit weight of baking anode kg/piece 1271
16 Gross volume of anode Kg/t.Al 498.42
Carbon Plant
Smelter will be self-contained for anode requirement. Anode production facility will
comprise:
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-15
Green anode plant comprising paste preparation, green anode formation;
Baking; and
Rodding facility.
The process flow sheet of carbon plant is shown in Figure-6.
Green Anode Plant
Raw material used in the manufacture of anode is calcined petroleum coke and the
binder such as coal tar pitch.
The following material processing circuits will be encountered in the paste plant:
Calcined petroleum coke;
Butts and green scrap;
Ball milling of coke;
Pitch; and
Paste preparation.
Through different unit operations in the above circuits, different size fractions of coarse
butts, medium & fine coke, mill & filter dust are weighed, heated & mixed with green
scrap & liquid pitch & paste is made by kneading. Anode is formed by vibrating forming
machine. The process flow sheet of green anode plant is shown in Figure-7.
FIGURE-6
CARBON PLANT FLOW SHEET
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-16
FIGURE-7
GREEN ANODE PLANT FLOW SHEET
Baking
The following processing will be done after the anode is formed:
Cooling & storing;
Baking; and
Baked anode cleaning & storage.
The above processing requires extensive storage & movement area for materials. From
the green anode storage area, green anodes are transported by crane and roller
conveyor in suitable package to anode baking furnace.
Rodding
Subsequent to baking, anodes are subjected to cleaning operation and the rods which
have been removed from butts are cleaned, inspected, and reused. The rods are
positioned & secured in place with molten cast iron & used after quality check. The
anode rodding and cleaning process flow sheet is shown in Figure-8.
Casting and subsequent Operation
A casting house is envisaged to produce “Value Added Products (VAP)” by installations
of suitable furnaces and casting machines.
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-17
Anode Production Process
As the 500 KA cell technology will have different anode formation, a complete new
dedicated plant shall be installed to cater the expansion project.
Raw materials for anode manufacturing are calcined petroleum coke and liquid coal
pitch plus recycled materials (butts and green scraps) reclaimed from the process. They
are crushed, screened, ground, proportioned, preheated, mixed, compacted and baked
etc. until they are made into qualified prebake anodes.
Heavy Fuel Oil (HFO) will be utilized for baking purpose.
In the anode production process, the baked anode manufacturing is divided into the
three production sections. Raw materials preparation, Green anode manufacturing and
Anode baking. The raw materials preparation section includes storage and
transportation of calcined petroleum coke and liquid coal pitch and treatment of
recycled materials etc.; The green anode manufacturing section includes intermediate
crushing and screening of calcined petroleum coke & recycled materials, grinding,
mixing, compacting, green anode cooling and conveying and heat transfer oil heating
station etc.; and the anode baking section includes storage and transportation of
carbon blocks, anode baking, and baking fume treatment etc.
FIGURE-8
ANODE RODDING AND CLEANING FLOW SHEET
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-18
GIS Vs AIS Switchyard
Space required for per bay (Bus 1 & Bus 2 arrangement scheme) 220 kV Air
Insulated switchyard is around 17 meters per bay, 220 kV AIS is considered.
Further, the power from the proposed 220 kV AIS is evacuated to GRID through
220/400 kV rated Interconnecting Transformer (ICT). Necessary 400 kV transmission
line shall be considered for evacuating the power to grid.
3.6 Requirement and Resources
3.6.1 Land Requirement
The aluminium smelter plant and captive power plant including greenbelt is around
39.66 (98 Acres). Land breakup of facility is given in Table-7.
TABLE-7
ITEM WISE BREAK-UP OF LAND
Sr. No Plant Unit Area (Acres) Area (ha)
1 Smelter Plant 98 39.66
2 Greenbelt 35 14.17
Total for Aluminium Smelter Plant (A) 133 53.83
3.6.2 Raw Material Requirement
The details of raw material requirement of project is presented in Table-8.
TABLE-8
DETAILS OF RAW MATERIAL REQUIREMENT
Sr. No. Description Quantity
1 Alumina 9.89 LTPA
2 Calcined Petroleum Coke 2,04,000 TPA
3 Coal Tar Pitch 39,500 TPA
4 Aluminum Fluoride 7,650 TPA
5 Heavy Diesel Oil (HDO) 40,000 KLPA
Details of raw materials chemical analysis is presented in Table-9.
TABLE-9
DETAILS OF CHEMICAL ANALYSIS OF RAW MATERIALS
Sr. No Details of Chemical Constituents Results
I Alumina
a Code AL2O3 Contents >%
Impurities <%
SiO2 Fe2O3 Na2O Loss on Ignition
AL2O3-1 98.6 0.02 0.03 0.50 0.8
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-19
Sr. No Details of Chemical Constituents Results
AL2O3-2 98.5 0.04 0.04 0.55 0.8
AL2O3-3 98.4 0.06 0.04 0.55 0.8
AL2O3-4 98.3 0.08 0.04 0.60 1.0
AL2O3-5 98.2 0.10 0.05 0.60 1.0
b Other Metal Impurities Limits
TIO2 <0.005 %
V2O5 <0.003 %
P2O5 <0.003 %
ZnO <0.005 %
c Physical Characteristics
Specific surface area >35 m2/g
Α-Alumina Maximum 10%
(-) 325 mesh Maximum 10%
II Calcined Petroleum Coke
1 Moisture (max) 0.3%
2 Volatile matters (max) 0.5%
3 Ash content 0.35%
4 Iron (max) 350 ppm
5 Silicon (max) 350 ppm
6 Nickel (max) 250 ppm
7 Vanadium (max) 300 ppm
8 Sulfur 2.5 – 3.5%
9 Sodium + Calcium (max) 200 ppm
10 Real density 2.05 -2.10 g/cm3
11 Apparent density >1.70 g/cm3
12 Bulk density >0.8 g/cm3
13 Resistivity <600
14 Hardness index 32 – 46
III Pitch
1 Softening point (R & B) 105oC – 113oC Coking value
2 (Conardson) 54% (min)
3 QI 6 – 10%
4 TI 30 – 37%
5 resin 20 26%
6 Density 1.15 1.30 g/cm3
7 Ash content 0.5% (max)
8 Moisture 0.5% (max)
9 Sodium 400 ppm (max)
10 Iron 200 ppm (max)
11 Sulfur 0.7% (max)
12 Viscosity 2x104 cps
13 (1600C) 3x104 cps
IV Aluminium Fluoride Special grade 1 Special grade 2
1 Fluorine as F 61 60
2 Aluminium as Al 30 30
3 Sodium as Na 0.5 0.5
4 Sulphate + Iron as SO3 + Fe2O3 0.38 0.43
5 SO4 0.5 0.8
6 Phosphorus as P2O5 0.04 0.04
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Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
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Bharat Aluminium Company Limited (BALCO) PFR-20
Sr. No Details of Chemical Constituents Results
7 Loss on ignition at 550oC for 30 Min. 0.5 1.0
V Fuel Oil
Heavy Diesel Oil (HDO)
1 Total Sulphur content 4.5% (Max.)
2 Gross Calorific Value (Kcal/kg) 10,000
3 Flash Point (Min.) 66 oC
4 Water content by Volume (Max.) 1.0%
5 Sediment by weight (Max.) 0.25%
6 Asphaltene content by weight (Max.) 2.5%
7 Kinematic Viscosity in Centistokes at 50o C (Max.)
370
At 98.90 C 20 – 30
8 Ash Content by weight (Max.) 0.1%
9 Acidity (in inorganic) Nil
10 Pour Point (Max .) 50 oC
11 Sodium Content --
12 Vanadium Content 25 ppm
13 Specific heat (kCal/kg. Deg. C) 0.5
14 Relative density at 15oC 0.89 (Approx)
VI Light Diesel Oil (LDO)
1 Pour Point (Max) 12 Deg.C & 21 Deg.C for Summer and Winter respectively
2 Kinematic viscosity in centistokes at 38
Deg.C
2.5 to 15.7
3 Water content, percent by volume (Max.) 0.25
4 Sediment Percent by Mass (Max) 0.10
5 Total Sulphur percent by Mass (Max) 1.8
6 Ash percent by Mass (Max) 0.02
7 Carbon Residue (Rans bottom) percent by Weight (Max)
1.50
8 Acidity in organic Nil
9 Flash point (Min) (Pensky Martens) closed cup
66oC
10 Acidity Total, mg of KOH/g (Max) Nil
11 Copper strip corrosion for 3 hours at 100 oC
Not worse than No.2
12 Relative density at 15oC 0.82 – 0.86
3.6.3 Water Requirement
The total water requirement (fresh and recycled) of the smelter is about 2,400 m3/day
(100 m3/hr). Out of this, the fresh water requirement is 1400 m3/day and balance
quantity of 1000 m3/day is treated wastewater from effluent treatment plant.
Recirculating cooling water system using wet evaporative cooling towers are deployed
for the existing station. It is used for the condenser and auxiliary equipment cooling in
a semi-open cooling water circuit.
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
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Bharat Aluminium Company Limited (BALCO) PFR-21
3.7 Waste Generation and Management
3.7.1 Wastewater Management
The total water requirement for aluminium smelter plant is 2,400 m3/day. The major
consumptive units and wastewater generation units in the smelter are cooling towers
and domestic waste from canteen and toilets is generated in the plant. The
wastewater is treated and reused for fire protection, dust suppression and gardening.
The water system flow diagram of smelter plant is given in Figure-9.
3.7.2 Storm Water Management
During first showers in monsoon season, the fugitive emissions of fluorides, which
get deposited on roof top and other areas, is washed out and this rainwater is
collected in storm water pond. The necessary drains are constructed within the plant
area to collect the run-off water. Storm water collection pond is constructed with
appropriate lining to prevent contamination of ground water. The stored storm water
is utilized in smelter operation. This is help to conserve the fresh water sources to
comply our zero discharge policy before reusing, water is treated in ETP to bring
back in the process.
3.7.3 Solid Waste
Solid Waste Generation in Aluminium Smelter Plant
The major categories of solid waste expected during aluminium smelter operation is
from Spent Pot Lining (SPL) and impregnation from electrolysis unit, coke fines
(burnt) and refractories from bake oven, sundry waste from plant, ladle cleaning
refractories, cast house refractory’s, effluent treatment plant sludge and domestic
solid waste etc.
In pots, solid waste is generated in the form of butts. Butts are cleared from the
various waste material attached to it and utilized in anode plant. The waste material
from the butts is reused in bath preparation in pot. The major solid waste generated
in the smelter plant is Spent Pot Lining in reduction plant, used oil from various units
and dross from cast house. Quantitative estimation of solid waste generation from
the above units is presented in Table-10. The cathode consists of carbon blocks with
refractory material lining for insulation. The life of these cathodes is approximately
72 month (1800 days working days). Over this period of time, the carbon in blocks
gets graphised and impregnated with fluoride salts resulting in reduction of pot
efficiency.
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-22
TABLE-10
SOLID WASTE DETAILS FROM SMELTER
Name of the
Residue / Waste
Brief Composition
[of major chemical
(metal etc.) constituents
in %]
Current rate of
generation per annum
Generation rate post current
expansion (if any)-
Altogether
Current Stocks (as on 31.07.2017)
Current disposal strategy
(Disposal on land, in SLF,
sold to registered recyclers,
etc.)
Potential Values
(for reuse,
recovery of metal,
etc.)
Spent Pot Lining
Carbon, Ammonia, Sodium Fluoride
12,000 T 22,000 T 53,600 T Co Processing/
SLF/ DeToxification
NIL
Used oil/Spent oil
Hydro Carbon 300 KL 500 KL 30 KL Authorized recyclers
-
ETP Sludge
Oil, Soil 17 T 30 T 0 SLF -
Anode Butt
Carbon 1,00,000 T 2,00,000 T 8,000 T Internally recycled
-
Dross Aluminium 10,000 T 20,000 T 1,200 T Authorized recyclers
0.7 Lac/T
These spent linings contain 5% to 6% fluoride. These are designated as hazardous
wastes as per the schedule of Hazardous Wastes Rules. The quantity of SPL
generated depends upon number of pot failures and hence is a function of smelter
operation. The failure of one pot generates approximately 120 tonnes of SPL.
Disposal Mechanism
Spent Pot Lining is temporarily stored under covered sheds on concrete floor to prevent
any contamination with water or land. BALCO is also promoted the use of SPL in
cement / steel industries by supplying SPL to authorised parties. A secured landfill is
constructed for the disposal of any unused SPL.
Pre-Feasibility Report for the Expansion of Aluminium Smelter Production Capacity from 5.75 LTPA
to 10.85 LTPA at Village Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-23
FIGURE-9
WATER BALANCE DIAGRAM FOR SMELTER PLANT
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-24
4.0 SITE ANALYSIS
4.1 Connectivity
The proposed expansion project is well connected with road network, the nearest road
is National Highway-149B (connecting Champa to Katghora) in a distance of 1 km in
west direction from the proposed expansion project site. The nearest railway station is
Korba Railway Station in a distance of 6 km in South West direction from the proposed
expansion project site.
4.2 Land Form, Land Use and Land Ownership
The total land requirement for the aluminium smelter plant including greenbelt is
around 53.83 ha (133 acres) within the existing BALCO integrated aluminium
complex. The overall land for proposed expansion project is in industrial use, which
is under the possession of BALCO.
4.3 Topography
The land in the plant site is plain with gentle slopes with a general elevation of about
250 m to 300 m above MSL and no water streams present in the site area.
The plant site comprises of industrial area and no agriculture land is involved in the
plant site. The plant area is under possession of BALCO and displacement of population
and Rehabilitation and Resettlement issues are not involved in the proposed expansion
project.
4.4 Existing Land Use Pattern
The existing land use is already under industrial category. The proposed expansion
will be carried out within the existing premises of BALCO integrated aluminium
complex.
4.5 Environmental Setting of the Site
The environmental setting of the existing and proposed expansion project site is given
in Table-11.
TABLE-11
ENVIRONMENTAL SETTING OF THE SITE
Sr. No. Particulars Details
1 Latitude & Longitude a) Latitude: 22°23'24.5"N to 22°23'49.73"N
b) Longitude: 18°43'32.4"N to 18°44'09.5"N
2 General elevation above MSL 300 m
3 Present land use at the site Industrial land
4 Nearest highway NH-149B (1.0 km, W)
5 Nearest railway station Korba (6.0 km, SSW)
6 Nearest airport Raipur (220 km, SW)
7 Nearest town/City Korba (5.2 km, SSW)
8 Hills/valleys Nil in 15 km radius
9 Topography Plain
Pre-Feasibility Report for the Expansion of Aluminium Smelter
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Bharat Aluminium Company Limited (BALCO) PFR-25
Sr. No. Particulars Details
10 Archaeologically important places
Nil within 15 km radial area
11 National Parks / Wildlife Sanctuaries
Nil within 15 km radial area
12 Reserved/ Protected Forests Dense mixed Jungle, Risda (1.3 km, ESE) Protected Forest near Bhalumara (6.5 km, SSE) Protected Forest near Naktikhar (6.6 km, SE)
Protected Forest near Rampakharra (7.2 km, S) Protected Forest near Bhargaon (7.2 km, N) Protected Forest near Bundeli (9.7 km, SE)
13 Seismicity Seismic Zone-II as per IS 1893 (Part I): 2002
14 Streams/Rivers Belgari nala (0.1 km, NW) Dhengu nala (0.1 km, S) Hasdeo river (1.5 km, W)
15 Defence Installations Nil
Industrial Development in the Study Area
The region is industrially developed with many major power plants and coal mines
operating in the study area besides existing aluminium smelter of BALCO. The list of
industries in 10-km radius is given in Table-12.
TABLE-12
LIST OF INDUSTRIES IN 10-KM RADIUS
Sr. No.
Name of Industry Location (Village)
Distance (km) from Plant Site/ Direction
1 Aluminium Smelter of BALCO 5.75
LTPA
Adjacent -
2 Captive Power Plant of 540 MW & 1200 MW BALCO
Adjacent -
3 2x250 MW Power Plant of Chhattisgarh State Electricity Board – Korba (East)
Korba 0.2 km, SSW
4 Dr. SPM Thermal Power Plant (2x250 MW)
- 1.0 km, SSW
5 2600 MW (200x3 + 500x4) MW Power Plant of National Thermal
Power Corporation
Gerwan 3.2 km, W
6 2x250 MW Power Plant of Chhattisgarh State Electricity Board – Korba (West)
Darri 4.0 km, NW
7 500 MW Power Plant of
Chhattisgarh State Electricity Board – Korba (West)
Darri 4.0 km, NW
8 Existing Coal Fields of South Eastern Coal Fields (SECL)
- 6.0 km, SW
9 Captive Power Plant of 270 MW of BALCO
Balghikhar 4.4 km, WSW
10 Industrial explosives plant of IOCL Gopalpur 8.2 km, NW
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-26
4.6 Climatic Data from the Secondary Sources
The meteorological data is collected from the IMD-Ambikapur, which is the nearest
IMD station to the existing plant site area. The data collected from IMD includes wind
speed, temperature, relative humidity, atmospheric pressure; rainfall and cloud
cover over a period of 10 years. The monthly maximum, minimum and average
values are collected for all the parameters except wind speed and direction. The
collected data is presented in Table-13.
TABLE-13
CLIMATOLOGICAL DATA-STATION: IMD, AMBIKAPUR
Month Atmospheric
Pressure (mb) Temperature (0C) Relative
Humidity (%) Rainfall (mm)
0830 1730 Max. Min. 0830 1730
January 947.9 945.2 27.6 4.4 75 48 26.1
February 946.3 943.5 31.4 6.7 66 39 22.8
March 944.7 941.2 36.9 11.1 49 26 18.5
April 941.8 937.9 40.7 16.5 39 22 13.3
May 938.4 934.6 42.7 20.7 41 26 24.2
June 934.7 931.7 41.5 21.6 66 55 251.1
July 934.6 932.2 33.9 21.4 86 81 460.9
August 935.4 933.1 32.4 21.4 88 83 389.9
September 939.5 936.7 32.4 19.8 85 78 230.5
October 944.2 941.5 32.3 13.4 78 63 62.4
November 947.2 944.5 29.5 8.6 73 54 15.6
December 948.7 945.9 26.5 5.5 75 51 11.6
Total 1,526.9
Source: India Meteorological Department, Pune
4.7 Infrastructure Facility
Infrastructure facilities near the site are available for the transportation of material
and equipments. The fresh water requirement of the plant is meeting from the
Hasdeo river, which is located at 1.5 km NW from the project site. The nearest town
is Korba, which is well connected by road and rail and all the basic facilities are
available.
5.0 PLANNING BRIEF
5.1 Existing and Proposed Land Use Details
The existing and proposed plant land use details are given in Table-14.
TABLE-14
EXISTING AND PROPOSED PLANT LAND USE DETAILS
Sr. No. Land description Area
Acres Hectares
A Integrated aluminium smelter complex 948 383.63
1 Proposed smelter (old plant / brownfield /area) 98 39.66
2 Existing smelters, power plant and ancillary plant 585 236.73
3 Old Alumina plant 85 34.40
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Sr. No. Land description Area
Acres Hectares
4 Road & open space 55 22.26
5 Green belt inside plant boundary 125 50.58
B Ash pond (outside plant complex) 375 151.75
C Township land (outside plant complex) 650 263.04
D Balance other land (outside plant complex
boundary, encroachment etc.
745 301.49
Grand Total ( A+B+C+D) 2,718 1099.91
The greenbelt area or green coverage in township, ash dyke and other areas is
161.87 ha (400 acres).
5.2 Brief Description of Main Process and Equipment of Different Anode
Production Facilities
5.2.1 Raw Materials Preparation
a) Storage and Transportation of Calcined petroleum coke
Calcined petroleum coke will be transported to the plant by truck or by Railway
Wagon. The coke is transferred to calcined petroleum coke silos by conveying
and lifting devices. Each existing silo has a storage capacity of 4,000 t. 2 nos.
additional silos are envisaged for the increased requirement.
b) Storage and Transportation of Liquid Coal Pitch
Liquid coal pitch transported to the plant by truck is sent to the two liquid pitch
storage tanks via pitch pump with jacket. Each storage tank has a storage
capacity of 1,000 t. 2 nos of tanks of same capacity shall be added along with
heating arrangements.
c) Recycled Material Treatment
The recycled materials treatment section treats the reject paste, reject green
anode, and reject baked anode from mixing, compacting, anode baking and
anode rodding sections etc., as well as the recycled butts from pot room. The
recycled materials are sent by the bridge crane to suitable crushing equipment
for primary and secondary crushing, and then they are sent respectively to the
green scraps or butts silo bucket elevator and belt conveyor. The pre-crushed
butts from pot room are crushed by suitable crusher and then sent to the butts
silo via conveyors. For the recycled materials treatment, it will be stored in two
butts silos and one green scraps silo. The existing butt storage capacity would
be augmented by installing more butt silos with butt unloading facility.
d) Intermediate crushing and screening of petroleum cokes and
recycled materials
The intermediate crushing and screening system of petroleum cokes treats
calcined petroleum cokes, while the intermediate crushing and screening
system of recycled materials treats butts, baked scraps and green scraps. The
main equipment of the two systems are similar, consisting of one speed-
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variable impact crusher, two (for the petroleum cokes system) or one (for the
recycled materials system) horizontal vibrating screen(s).
All kinds of calcined petroleum cokes stored in the calcined materials silos are
sent to the impact crusher through volumetric feeder, belt conveyor and electro-
magnetic separator etc. Then they are sent to the two-stage horizontal
vibrating screen by the bucket elevator for being separated as the required four
kinds of grain sizes: 12 – 6 mm, 6 – 3 mm, 3 – 0.8 mm, 0.8 - 0 mm.
Remaining materials larger than 6mm and cokes larger than 12 mm are
recycled to the crusher for re-crushing. For the remaining materials smaller
than 6mm, part are sent to the feeding silo for grinding in the ball mill and part
are stored in the packing materials silo for baking. The packing cokes are sent
to the anode baking furnace by truck.
Green scraps, baked scraps and butts stored in the green scraps and butts silos
enter into the middle crushing and screening system of recycled materials.
Green scraps which are crushed to be smaller than 12 mm enter into the green
scraps proportioning silo while those larger than 12 mm are recycled to the
crusher for re-crushing. Butts are divided into two grain sizes: 12 – 3 mm and 3
– 0 mm. They are sent respectively to different proportioning silos while butts
larger than 12 mm are recycled to crusher for re-crushing. Butts and green
scraps share one set of system that operates by turns.
e) Grinding
Petroleum cokes stored in the silo are fed into the ball mill. The oversize coarse
particles are recycled to the ball mill for re-grinding while the required fine
materials are collected by the cyclone precipitator and bag filter and then sent to
the fine materials proportioning silo.
f) Pre-heating, mixing, paste cooling, compacting, green anode cooling &
Conveying
Petroleum coke particle materials, fine materials and butts particle materials
stored in different proportioning silos are sent continuously and volumetrically to
the preheating screw by their own continuous proportioning scales as per the
required recipes for being preheated to about 17oC, then they are sent together
with the green scraps weighed by the continuous proportioning scale according
to the ratio and the liquid pitch from the liquid pitch proportioning system to the
continuous mixer. The paste of required quality from the continuous mixer is
cooled in the paste cooler and then sent to the vibro-compactor. The compacted
green anodes are measured with height, calculated with bulk density and printed
with marks and then enter into the overhead conveyor which transports the green
anodes to the cooling tank. The cooled tested green anodes are sent to be stored
in the carbon transfer station via chain conveyor, while the reject blocks are sent
to the recycled materials treatment section via roller conveyor and fork lifts. The
reject paste is sent by bucket loader to the recycled materials treatment section.
g) Anode Baking Facility
The green anodes sent from the green anode manufacturing shop are collated by
the collating conveyor in the carbon blocks transportation station, and stacked by
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the tacking crane. In addition, the stacking crane is equipped with single anode
clamp for handling single anode. According to the baking requirement, the green
anodes stored in the station are sent by the chain conveyor to the anode baking
shop.
h) Baking Furnace Fume Treatment
The baking furnace fume contains tar, dust, and small amount of fluoride. Dry
type pollution control measure to contain tar, dust and fluoride contents of the
fume will be considered. The baking furnace fumes are conditioned, cooled and
subjected to dust collection system by bag dust collectors. The purified fume is
sent by the exhaust fan to the stack for emitting to the atmosphere.
i) Power Distribution of Anode Production System
The green anode manufacturing unit will be equipped with suitable transformers,
which can meet with the power supply requirements of various sections of green
anode manufacturing, and circulating water system of anode compacting.
The baking plant is equipped with transformers, which can meet with the power
supply requirements of baking unit and various auxiliary systems.
5.2.2 Pot Room Control
Operation of pots will be fully automatic and computer controlled. Two level
control is envisaged:-
a) Supervision Level of Potroom: Industrial PCs will be used for the
monitoring and supervision of computer control system of pot lines.
b) Control Level: pot controllers will be used for controlling production
process of pots.
Data communication between supervision level and control level will be through
Local Area Network bus constituted by intelligent communication boards.
Description of Control Functions
a) The following major functions shall be realized by the Pot Control System:-
Data collection & treatment
Pot resistance (voltage) control (lifting anode and lowering anode)
Normal Feed Control
Anode Effect inspection, alarm and treatment control
Anode Effect forecast and feeding control
Bus bar raising tracing
Alumina concentration control
Tapping inspection and control of pot resistance after tapping
Anode changing inspection & control of pot resistance after anode
changing
Voltage fluctuation inspection and control of pot resistance after
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voltage fluctuation inspection
Aluminium fluoride feed control
Pot control during start-up
b) Main functions of master computers
Setting & modification of parameters
Preparing & printing of shift-wise, day & month-wise report data and
work order for the next shift
Displaying & printing comprehensive historical curves
Automatic annunciation / alarm of important information
5.3 Existing Facilities within Balco Integrated Aluminium Complex
5.3.1 Lightning Protection System
Adequate lightning protection facilities are provided as per the applicable Indian
codes of practice.
5.3.2 Fire Protection System
Adequate fire protection system is provided as per the applicable Indian codes of
practice and Tariff Advisory Committee (TAC) guidelines. Also an appropriate On-site
Disaster Management Plan (DMP) is implementing for the plant which is included in
this report.
5.3.3 Road and Site Drainage
Adequate circular and other roads are provided for smooth operation and effective
emergency response. The drainage network is constructed to prevent water
accumulation in the plant area and to avoid mixing of plant effluent with storm
water.
5.3.4 Communication
Independent telephone exchange is provided to cater to the requirement of the
smelter plant complex. Intercom network is served as the main communication link
for internal communication of the plant & township.
5.3.5 Water Receipt & Storage System
Raw water is received from water reservoir through pipe lines. The drinking water
pumped and stored in overhead tank located at smelter. From overhead tank the
drinking water is supplied at various points of smelter. However, for fire water
system, separate lines are to be laid from CPP and water is pumped from CPP.
For cooling water system, only filtered water as make-up water is provided at the
battery limit of cooling towers. For the distribution of make-up water, one overhead
tank is provided at the smelter and this is filled from CPP through separate line.
Cooling Water System
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The cooling system is provided for the station is natural draft type cooling towers.
Circulating cooling water flow including dissipation of the heat load of auxiliary
equipment. As per the water quality of Hasdeo water reservoir, the Total Dissolved
Solid (TDS) in water is reasonably low. Hence softening process is not considered in
the designing. Based on the source water quality the cooling tower is designed for
five Cycles of Concentration (COC), which is attainable in the cooling circuit. The
blow down from the cooling towers is utilized for ash disposal, water spray in coal
handling system, miscellaneous requirement etc.
Among chemical dozing requirements in the water system, shot chlorination in CW
circuit to contain algae growth, lime and alum dozing in pre-treatment section for
effecting coagulation and use of acid and alkali for regeneration of resin in
demineralization plant and condensate polishers are considered.
Drinking Water System
Filtered water in underground storage tank is chlorinated through gravity feed type
chlorinator to directly dose chlorine into the water. This is done at CPP. The
distribution of drinking water is done by gravity from the overhead storage tank
through a network of G.I. pipe lines laid underground/over ground to cater the
requirement of all units, plant and non-plant buildings.
Fire Water System
The basic philosophy of the fire protection system design is centred on water as the
main fire extinguishing medium, although other types of firefighting devices are
provided. The system is designed to provide adequate quantity of water at a
specified pressure. The clarified and filtered water received from power plant is used
for fire water and sprinkler system.
However, since the process for the aluminium smelter plant is based on the
electrolytic reduction, the use of water for extinguishing fire in the following
sections/units of the plant is absolutely prohibited for safety reasons:
Pot rooms including all buildings in that area;
Cathode assembly area (cast iron furnace area);
Cast house;
Baking furnace;
Rodding shop (cast iron furnace and spraying furnace area); and
Sub-stations and control rooms.
The system consists of storage, pump station and the fire water main ring with
hydrants installed along the road side at regular intervals in the off-site areas, and
rising main is provided with landing valves inside the buildings. There are two fire
water pumps, one electric driven and one diesel driven. In addition there is a jockey
pump to maintain the pressure in the fire hydrant.
Sprinkler Water System
The system consists of storage, pump station, sprinkler and piping manifolds etc.
and it covers following areas:
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Paste Plant;
Solid pitch storage & handling building; and
Green Anode Storage.
5.3.6 Compressed Air
Compressed air system is used as plant air for the service applications, and as
instrument air for plant instruments. The system is consists of four compressors out
of which three are power driven and one is diesel driven. Three air dryers are
provided to supply dry air to the distribution network.
6.0 PROPOSED INFRASTRUCTURE
6.1 Industrial Area (Processing Area)
The existing BALCO aluminium smelter and captive power plant area is 271.13 ha (670
acres) and proposed expansion of smelter plant area is about 39.66 ha (98 acres). The
total industrial area after proposed expansion will be 310.79 ha (768 acres).
6.2 Residential Area (Non processing Area)
The existing township caters to the proposed expansion project employment
requirement. It is developed with a state of art combined township for employees
including security personnel and supporting staff of smelter and thermal power plant. It
have other amenities such as schools, community centre, guest house, health centre,
hospital, shopping complex, post office, bank etc.
6.3 Greenbelt
The greenbelt area in the integrated complex is 50.58 ha (125 acres). The greenbelt
area or green coverage in township, ash dyke and other areas is 161.87 ha (400 acres).
6.4 Connectivity
The proposed expansion project is well connected with network, the nearest road
network is National Highway-149B (connecting Champa to Katghora) in a distance of 1
km in west direction from the proposed expansion project site. The nearest railway
station is Korba railway station in a distance of 6 km in South South West direction from
the proposed expansion project site.
6.5 Drinking Water Management (Source & Supply of Water)
The total water requirement (fresh and recycled) of the smelter is about 2,400 m3/day
(100 m3/hr). Out of this, the fresh water requirement is 1,400 m3/day and balance
quantity of 1,000 m3/day is treated wastewater from effluent treatment plant. The
water is sourced from Hasdeo barrage. The raw water is treated in clarifier and filter
beds.
6.6 Sewage System and Industrial Waste Management
Expected quality of wastewater generated is given in Table-15.
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-33
TABLE-15
EXPECTED QUALITY OF WASTEWATER
Sr.
No.
Parameter Unit Raw
wastewater
Treated
Wastewater
Permissible Limits as
per GSR 422 (E) for On-land Discharge
(Irrigation)
1 pH - 5.5 to 9.0 6.0 to 8.5 5.5 to 9.0
2 Suspended Solids mg/l 100 to 500 <100 200
3 Oil & Grease mg/l 10 to 200 <5 10
4 Total Dissolved Solids
mg/l 500 to 10000 <1000 --
5 BOD mg/l 250 to 350 <30 100
6 COD mg/l 450 to 600 <100 -
ETP and STP has been designed suitably capacity. Treated sewage is conformed to the
standards for land application. Oil and Grease removal system is provided. Regular
monitoring of ground water (one sample at the solid waste dump) and surface water as
part of the post-project monitoring is carried out.
Oily waste water generated due to oil spills is collected in separate tanks which is
having skimmers. The skimmed waste oil from each of these areas is sent back to the
oil storage tank and the oil free waste water is pumped to ETP.
6.7 Solid Waste Management
The major categories of solid waste expected during aluminium smelter operation is
from Spent Pot Lining (SPL) and impregnation from electrolysis unit, coke fines
(burnt) and refractories from bake oven, sundry waste from plant, ladle cleaning
refractories, cast house refractory’s, ash from captive power plant, effluent
treatment plant sludge and domestic solid waste etc.
Spent Pot Lining is temporarily stored under covered sheds on concrete floor to prevent
any contamination with water or land. BALCO is also promoted the use of SPL in
cement / steel industries by supplying SPL to authorised parties. A secured landfill is
constructed for the disposal of any unused SPL.
6.8 Power Requirement & Supply/Source
The power requirement of the proposed smelter plant is about 850 MW (including
auxiliary power) based on average 12,500 Kwh/tonne (DC Power) for Pot Line.
The power requirement is met from Captive Power Plant (CPP).
The 2 nos. of additional power evacuation line at 400 kV level is considered. Necessary
space is considered for location of additional lines and further connecting it to the
nearest Grid in smelter switch yard design.
7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN
The land allocated for the proposed expansion project is within the existing BALCO
intergraded complex. Hence, no R&R issues involved in the proposed expansion project.
Pre-Feasibility Report for the Expansion of Aluminium Smelter
Production Capacity from 5.75 LTPA to 10.85 LTPA at Village
Risda, Tehsil Korba, District Korba, Chhattisgarh
Bharat Aluminium Company Limited (BALCO) PFR-34
8.0 PROJECT SCHEDULE & COST ESTIMATES
The estimated capital cost is Rs. 7,927.04 Crores for 5.10 LTPA aluminium smelter.
The proposed expansion project construction activities start after obtaining all
necessary statutory clearances from concern authorities and construction will be
completed within the 24 months.
9.0 ANALYSIS OF PROPOSAL
The proposed expansion project is likely to generate direct employment opportunities
during the operation of plant and indirect employment opportunities in the field of
transportation of employees, transportation of raw material & product to nearest port,
development of ancillary units and canteen services and greenbelt development work
etc.
The major advantage in planning the proposed expansion of aluminium smelter plant
is summarized below:
The land available is in possession of BALCO and within their plant.
Water required will be availed at site from Barrage on Hasdeo river.
Existing Captive Power Plant (CPP) and other infrastructural facilities are
available.
As part of the Corporate Social Responsibility (CSR), BALCO is taken steps in
developing education, health, infrastructure development, women empowerment,
sports and vocational training facilities actively seeks opportunities to share its success
with the communities in areas where it operates. The Company has a long way to go in
this area and is determined to make a difference in the lives of the less fortunate.
The fields of its activities are:
Women and child care;
Direct and indirect employment of the people particularly the downtrodden;
Promotion of education;
Relief and rehabilitation;
Rural development;
Promotion and preservation of culture;
Water harvesting;
Agricultural development; and
Animal care.