DETAILED ENVIRONMENTAL IMPACT ASSESSMENT (DEIA)
ENVIRONMENTAL FRAMEWORK FOR THE
METAL INDUSTRY IN MALAYSIA
CHEMSAIN KONSULTANT SDN BHD
Presented By: Ir. Brian Chong
Outline of Presentation
1 • Environmental Legislations &
Requirements for the Metal Industry
2 • Ferro Alloy Industries and Challenges
Faced
IMni Seminar: Manganese Science and Regulatory Issues
ENVIRONMENTAL QUALITY
ACT, 1974 (FEDERAL)
Gazetted : 14 March 1974
Enforced : 15 April 1975
Prevention, abatement,
control of pollution and
enhancement of the
environment in Malaysia
Natural Resources & Environment
Ordinance (Sarawak) 1993
Environment Protection Enactment
(Sabah) 2002
IMni Seminar: Manganese Science and Regulatory Issues
FEDERAL AGENCY The Department of Environment (DOE)
• Under the Ministry of Natural Resources and Environment (MNRE)
& maintain offices in all States
• Industrial Projects, Waste Management Projects and Offshore
Petroleum Projects
STATE AGENCY The Natural Resources and Environment Board (NREB),
Sarawak
The Environment Protection Department (EPD), Sabah
• State Government
• Land and Natural Resources Projects (Land Clearing, Agriculture
Projects, Mining, etc.)
IMni Seminar: Manganese Science and Regulatory Issues
Department of Environment (DOE)
•Natural Resources and Environment Board (NREB), Sarawak • DOE
• Environment Protection Department (EPD), Sabah • DOE
IMni Seminar: Manganese Science and Regulatory Issues
ENVIRONMENTAL
MANAGEMENT TOOL
EIA IS A STUDY TO IDENTIFY,
PREDICT, EVALUATE AND
COMMUNICATE
INFORMATION ABOUT THE
IMPACTS ON THE
ENVIRONMENT OF A
PROPOSED PROJECT AND
TO PROVIDE DETAILS ON
THE MITIGATING MEASURES
PRIOR TO PROJECT
APPROVAL AND
IMPLEMENTATION
IMni Seminar: Manganese Science and Regulatory Issues
Under the EQA 1974 and associated
regulations, Industrial Activities are required to
obtain approval from the Director General of
Environment Quality prior to implementation.
Among the approval required is that of an
Environmental Impact Assessment (EIA).
In Malaysia, EIA is required under Section 34A,
Environmental Quality Act (EQA) 1974.
IMni Seminar: Manganese Science and Regulatory Issues
Agriculture
Mining
Ports Infrastructure
Industrial Housing
Forestry Drainage & Construction Fisheries Land Reclamation
Quarries
Airport
Power Generation & Transmission
Railways
Transportation
Resort & Recreational Development
Waste Treatment & Disposal
Water Supply
IMni Seminar: Manganese Science and Regulatory Issues
Petroleum
• EIA report must be:
Prepared in accordance with the guidelines
issued by the DOE.
Prepared by Registered EIA Consultants
• EIA is also legislated in Sabah and
Sarawak under the respective state
legislations.
IMni Seminar: Manganese Science and Regulatory Issues
DEIA
PEIA
DEIA
• Submission of TOR
• Public Display
• Stakeholder Engagement
• Independently Review by
an Expert Panel
IMni Seminar: Manganese Science and Regulatory Issues
1. Iron and steel Industry
2. Pulp and paper mills
3. Cement plant
4. Construction of coal fired power plant
5. Construction of dams and hydroelectric power schemes
6. Land reclamation
7. Incineration plant (scheduled waste & solid waste)
8. Sanitary landfill
9. Project involving land clearing where 50% of the area or more having slopes exceeding 25 degrees (except quarry)
10. Logging involving an area exceeding 500 hectares
11. Development of tourist or recreational facilities on islands in surrounding waters which are gazetted as national marine parks.
12. Construction of recovery plant (off-site) for lead-acid battery wastes
13. Scheduled wastes recovery or treatment facility generating significant amount of wastewater which is located upstream of public water supply intake; and
14. Non-ferrous - Primary smelting
15. Petrochemicals-all sizes
16. Construction of oil refineries
17. Prescribed activities using radioactive material(s) and generating radioactive wastes
IMni Seminar: Manganese Science and Regulatory Issues
Environmental
Impact Assessment
What might happen
What can be done
Environmental Management Plan
Actions to be taken
Project Planning Construction and Implementation
Environmental
Monitoring Report
(EMR)
Compliance
Environmental Audit
Compliance
Written Notifications
Compliance
IMni Seminar: Manganese Science and Regulatory Issues
• DETAILED ENVIRONMENTAL IMPACT ASSESSMENT (DEIA)
• A Prescribed Activity under the Environmental Quality (Prescribed
Activities) (Environmental Impact Assessment) Order 1987
– Item 8(c) Non-Ferrous
Primary Smelting
Others – Producing 50 tonnes/day of product
• The DEIA needs to be submitted to the DOE, Putrajaya for approval
before any commencement of work
IMni Seminar: Manganese Science and Regulatory Issues
Consultants / Specialists must
be registered with the DOE
IMni Seminar: Manganese Science and Regulatory Issues
Dominated by the Iron and Steel Industry
Ferro- Alloy Industries in Malaysia is
relatively new
IMni Seminar: Manganese Science and Regulatory Issues
IMni Seminar: Manganese Science and Regulatory Issues
Name Location Product
Pertama FerroAlloy (Ph 1) – under construction
Samalaju, Bintulu, Sarawak Silicon Manganese (~125,000 t/y) MCFeMn (~60,000 t/y) FeSi (~72,000 t/y) Sinter (200,000 t/y)
OM Material (Sarawak) – started operation Q4 2014
Samalaju, Bintulu, Sarawak SiMn (~190,000 t/y) HCFeMn (~60,000 t/y) M/LCFeMn (~36,000 t/y) FeSi (~300,000 t/y) Sinter (300,000 t/y)
Sakura Ferroalloy – under construction
Samalaju, Bintulu, Sarawak HCFeMn (~107,000 t/y) SiMn (~70,000 t/y)
Elpion Silicon Sdn Bhd Banting, Selangor Metallurgical grade silicon (MGS) - ~55,000 t/yr
Dongbu Metal Sarawak Sdn Bhd– (project and DEIA on hold)
Samalaju, Bintulu, Sarawak Metallurgical grade silicon – 100,000 t/y
Asia Advanced Materials (in planning stage – DEIA approved, construction pending)
Samalaju, Bintulu, Sarawak Metallurgical grade silicon – 33,000 t/y
Confirmed
industries in
SIP
Mn Ore Coke Fluxes
Ferromanganese Silicomanganese
+/- 2300 kWh
MnOre / Sinter Quartzite Coke Iron Ore
+/- 4500 kWh
Slag Dump
Slag Crushing
HCFeMn Crushing Saleable Product
SiMn Crushing Saleable Product
Ferro / Silico Managanese: Production Process
18 IMni Seminar: Manganese Science and Regulatory Issues
Dust
Source:
Sakura
Ferroalloy
Scheduled waste are substances that are:
Corrosive
Explosive
Flammable
Ignitable
Toxic
Reactive
Irritant
Carcinogenic
Infectious
IMni Seminar: Manganese Science and Regulatory Issues
Regulation 2: Scheduled waste = any waste falling within
the categories of waste listed in the First Schedule.
First Schedule (Regulation 2)
Metal and metal-bearing wastes SW101-110 (10 categories)
• Used Lead Acid Battery – SW102
• Aluminium dross - SW 104
• Metal smelting slag/ dust - SW 104
• Galvanic sludges – SW105
IMni Seminar: Manganese Science and Regulatory Issues
Ferroalloy Slag Ferroalloy Dust
IMni Seminar: Manganese Science and Regulatory Issues
• Slag and dust
Slag is from the Ferroalloy smelting process, the impurities of
raw materials generated in the smelting furnace.
Dust is from also from the smelting process –captured in the
bag filters
Descriptions of SW104 from the First Schedule of the
Environmental Quality (Scheduled Wastes) Regulations 2005
– Dust, slag, dross or ash containing aluminium, arsenic,
mercury, lead, cadmium, chromium, nickel, copper,
vanadium, beryllium, antimony, tellurium, thallium or selenium
excluding slag from iron and steel factory.
IMni Seminar: Manganese Science and Regulatory Issues
Industry Ferroalloy Slag (t/yr) (SW 104)
Ferroalloy Silicon Dust
(t/yr) (SW 104)
Spent Pot Lining (t/yr)
Sludge (t/yr) (SW
316)
OM Materials (Swak) S/B 264,000 77,500 - -
Pertama Ferroalloys S/B 141,000 - - 175,800 (EMM)
Press Metal Bintulu 8,000 - 9,600 -
Tokuyama (Phase I & II) - - - 25,500
Dongbu Metal 3,960 39,600 - -
Asia Advanced Materials 1,036 14,515 - -
SAKURA Ferroalloy 131,400 - - -
TOTAL 549,396 131,615 9,600 201,300
These contribute to about 21% of the total volume of SW generated in the whole of
Malaysia in year 2013.
IMni Seminar: Manganese Science and Regulatory Issues
Under the Environmental Quality (Scheduled Waste) Regulations
2005, Scheduled Waste can be managed as follows:
Dispose to a licensed disposal facility
Recovered / recycled by a licensed recovery facility
SW generator can initiate special waste management
application to recover / dispose the waste to a non-
licensed facility
Export to overseas after the requirement of BASEL has
been fulfilled and Government to Government
agreement is met
SW generator can also choose to recycle the waste in-house if the
waste can be used raw material for other production line usage.
IMni Seminar: Manganese Science and Regulatory Issues
For example:
• Sludge generated from a facility can be used as alternative
raw materials as clinker feed;
• Slag generated from a ferroalloy smelting plant can be used
as additives in cement or aggregates for concrete
manufacturing;
• Fly ash from power generation plant which is a suitable
material for cement additives, etc.
Note:
Cement plant, clinker plant and ready mix concrete facility is not
prescribed premises for SW treatment and disposal facilities.
IMni Seminar: Manganese Science and Regulatory Issues
• As pozzolanic material in Portland cement. Addition of 5-15%
of slag in blended cement has shown improvement in cement
strength (slag cement).
• It is possible for metal slags to be used in road pavement
construction and also in making glass-ceramic materials.
• Usage in other countries includes:
a) The U.S.: Used as aggregate in asphaltic concrete fill;
unconfined bases; shoulder stabilization; berm construction;
railroad sub-base; base for walkways and rock wool insulation
b) China: used extensively for hollow blocks for construction use
(Shianxi Jiaocheng Yiwang Ferroalloy Works)
c) Japan, 99% of slag is useful construction material and employed by
national agencies such as the Ministry of Land, Infrastructure and
Transport and by local government
IMni Seminar: Manganese Science and Regulatory Issues
As additives in concrete are as listed below:
• Construction of the Petronas Twin Towers in Kuala Lumpur, used 4,800
tons of ferro silicon dust in their construction, all delivered by
Finnfjord AS, a leading ferro silicon producers in Europe;
• Construction of Burj Dubai / Dubai Tower in Dubai uses 350,000 m3 of
high strength concrete with ferro-alloy dust as additives;
• Construction of the Tsing Ma Bridge in Hong Kong which also uses >80
MPa high strength concrete with ferro silicon dust additives;
• Construction of the East Sea Bridge, Shanghai which spans a total
length of 32.5 km including a over-sea part, harbour and bridge
connection to the on-land part;
• Construction of the Nordhordland bridge in Norway which uses Light
Weight Composite Concrete of 60 -70 MPa ferro silicon additives; and
• Construction of the extension project of the Dubai airport has used up to
2 million cubic meter of microsilica concrete for durability reasons in sub-
terrain concrete and in high strength structural concrete elements.
IMni Seminar: Manganese Science and Regulatory Issues
• The cement industry has started looking into option of using alternative raw
material (ARM).
• In Europe, the cement industry is reusing waste material for fuel and raw
materials – also known as co-processing under the EU regulation.
• The World Business Council for Sustainable Development under its Cement
Sustainability Initiative (CSI) 2002 recognised that many industrial by
products and waste materials can be recovered in cement manufacture.
• Participated by many International cement producers (Lafarge, CEMEX,
RMC Group, Siam Cement Industry, Taiheiyo Cement).
• The Cement Producers in Malaysia which recycle SW.
• Potential SW for recovery in the cement industry:
Sludges, metal slags, dusts with calcium / silica content, fly ash from
power plant etc.
IMni Seminar: Manganese Science and Regulatory Issues
The slag generated must meet ALL the following conditions:
• Does not exhibit –corrosivity, ignitability, reactivity, toxicity
(Appendix I in the Special Management Guidelines)
• Has been proven (scientific studies / tests) does not have
hazardous effects on human or other life forms (Appendix II in
the Special Management Guidelines)
• Generator to substantiate / support the proposed recovery
process by research papers and other countries practices to
DOE.
• Generator shall submit form (Appendix IV) in the guidelines
and processing fee of RM 300 to DOE for Special
Management Application
IMni Seminar: Manganese Science and Regulatory Issues
The generator must have the following information for application of
special management:
• A potential waste recovery facility who is willing to accept the quality
and quantity of SW the generator produced;
• An MOU between the generator and receiver on the SW to be
generated and recovered by both parties
• The technology and potential impacts of waste recovery activities.
• Supporting documents (research papers, overseas practices, feasibility
reports) to support the recovery activity if it is new to Malaysia.
• The waste acceptance criteria by the receiver and the QC practices of
both parties of ensuring each batch of SW meets the set criteria.
IMni Seminar: Manganese Science and Regulatory Issues
• Cement raw material;
• Road stone material;
• Aggregate for concrete;
• Land reclamation, ground fill, ground improvement
and other civil engineering uses;
• Filter media;
• Land-filling.
IMni Seminar: Manganese Science and Regulatory Issues
IMni Seminar: Manganese Science and Regulatory Issues