pfr for increasing the production capacity of blast...

PRE-FEASIBILITY REPORT

FOR

ENHANCEMENT IN THE PRODUCTION CAPACITY

of EXISTING BLAST FURNACE

From 4,50,000 TPA to 5,40,000 TPA

By

PROCESS OPTIMIZATION & EFFICIENCY

LOCATION

Village: Navelim (Amona Navelim (Bicholim) Industrial Area

Taluka: Bicholim Dist: North Goa

APPLICANT

Vedanta Limted (Formerly Sesa Goa Limited)

(Formerly Sesa Industries Limited)

GOA

JUNE 2015

PFR for enhancement in the production capacity of blast furnace from 4,50,000 TPA to 5,40,000 TPA by process optimization and efficiency

Vedanta Limited, Goa

CONTENTS

Title Page

1. Executive Summary (with Pollution Load Statement) 3

2. Introduction of the project/ Background information 6

3 Project Description. 10

4 Site Analysis 14

5. Planning Brief. 15

6 Proposed Infrastructure 16

7. Rehabilitation and Resettlement (R & R) Plan. 17

8. Project Schedule & Cost Estimates 18

9. Analysis of Proposal (Final Recommendations) 19

A-1 Location Map 20

A-2 Map Showing Plant Site & Surrounding 10 km Area 21

A-3 General Plant Layout Showing Blast Furnace Location 22

A-4 Project Description, Process Details and Schematic

Flow Chart

23-28

A-5 List of Raw Materials and Material Balance 29

A-6 Climate Data 30

A-7 Photographs of Existing Plant and Greenbelt 31

A-8 Stack Emissions & Air Quality Data of Existing Plant 32-33

A-9 Copy of EC, Change of Name and EC Amendment 34-42

A-10 Point-wise Compliance to EC Conditions 43-48



1. Executive Summary:

Vedanta Limited (formerly Sesa Industries Ltd. and Sesa Goa Limited) got Environmental

Clearance (EC) F. No.J-11011/946/2007-IA-II(I) from MOEF on June 03, 2009 for following:

Sl. No. Facility Production Capacity

1 Mini Blast Furnace 9,00,000 TPA

2 Sinter 20,00,000 TPA

3 Coke Oven 6,00,000 TPA

4 Power Plant (Waste Heat Recovery) 60 MW

Amendment in EC was granted by MOEF on 25th April 2012, with comments:

Project will be implemented in two phases (with exactly half the production capacity in

each phase) and

Change in the plant configuration with particular reference to stack dimensions with

reference to height and diameters without change in production capacity.

Consent to Establish (NOC) was obtained from Goa State Pollution Control Board (GSPCB)

for following:

Sl. No. Description Quantity

1 Mini Blast Furnace 0.45 Million Tons/annum

2 Sinter 01 Million Tons/annum

3 Coke Oven 0.3 Million Tons/annum

4 Power Plant (Waste Heat Recovery) 35 MW

Accordingly, all the units mentioned in CTE/ NOC were commissioned and Consent to

Operate for respective units with production quantities were obtained from GSPCB

Six monthly EC compliance reports were submitted on regular basis which were verified by

MOEF (SZO) & GSPCB officials periodically.

In 2014-15 hot metal production of 376947 tons was achieved, which is the highest since

commissioning of Blast Furnace in August 2012



With in-house experiences in operating the blast furnace and experience gathered from other

similar BF operating in India, it has been inferred that hot metal production can reach upto

0.54 MTPA with the existing Blast Furnace.

The 450 m

3 Blast Furnace was designed for foundry grade production having around 2% Si,

primarily catering to auto industry for different castings manufacturing. Due to sudden fall of

demand in automotive sector, foundry grade pig iron market shrunk drastically. Also Ferro

silicon prices got affected due to fall in steel market. To reduce cost of production many of the

manufacturers have started using semi-foundry or basic grade pig iron having lesser Si% and

explored addition of ferro silicon to metal after melting of pig iron in cupola or induction

furnaces. Current market scenario has favored the auto industry to optimize cost of

manufacturing the castings.

Since there was over all shortage of demand and China has started dumping steel in India

which was cheaper option for different consumers in India. This resulted in pushing primary

steel producers to produce pig iron as there was stiff competition in steel production cost and

Indian steel producers were not competitive against the imported steel from other countries.

This resulted in heavy inventories of pig iron in India. Looking in to the scenario and taking

advantage of strategic location where in sea transport is viable option, management has

taken decision of exporting basic grade pig iron in big way. Although there was competition

from primary steel producers, Goa being very close located to sea and good water bound

logistic infrastructure in place was an advantage there by making Sesa / Vedanta compete

with big steel manufacturers.

The process optimization will not add to the cost of the BF project. The cost of blast furnace is

about Rs.400 Crores. Therefore without spending any extra CAPEX, annually around 90, 000 to

1,00,000 tons of hot metal could be produced.

The cost of production of foundry grade pig iron by Indian Producers is more than the sale

price of China. In order to remain sustainable, profitable and socially viable, the company

decided to produce basic grade pig iron. The demand of basic grade pig iron at competitive

cost exists in the domestic and international market.



The proposal will save direct employment for about 150 people and add another 25 direct

employment. It will also add about 100 indirect employment in the transportation sector.

The existing Blast Furnace of 450 m3 volume and 4,50,000 TPA production capacity is already

operating. The production capacity enhancement to 5,40,000 TPA through process optimization

could be done without stopping the BF. It will be completed within 1 month of getting EC

amendment.

This production increase can be achieved through increased injection of wind volume, oxygen

enriched blast, charging sinter feed upto 90%, better process control in operations, etc.

without any change in Blast Furnace nor any modernization or change of product mix.

With increase in production capacity from 0.45 MTPA to 0.54 MTPA, there will be no increase

in stipulated water consumption, neither the pollution load on air, water and land environment

will increase.

POLLUTION LOAD STATEMENT

Environmental

Component

Pollution Load discharged to environment after capacity

enhancement

1 Land Area There will be no increase in land area (no physical expansion)

2 Plant Layout There will be no change in plant layout.

2 Water Consumption No additional water will be required. Cooling tower blowdown

water is used for slag granulation.

3 Power Consumption The additional power will be met from CPP

4 Air Environment The existing Bag Filters, ESP and Gas Cleaning Plant have

sufficient capacity to take care of additional load.

Entire dust collected from air pollution control equipment’s

will be reused in the sinter plant

Please see calculation of PM load in page 32

5 Water Environment Plant operates on Zero Liquid Discharge (ZLD). Entire water

is Recycled & Reused in the system.

6 Solid Wastes Entire slag will be granulated and sold to cement plants

Entire dust will be reused in the sinter plant.



2. Introduction of Project / Background Information:

(i) Identification of Project and Project proponent.

Name of Project: Production Capacity Enhancement of Existing Blast

Furnace from 4,50,000 TPA to 5,40,000 TPA.

Category of Project: “A” Category.

Project Proponent: Vedanta Limited (Formerly Sesa Industries Ltd /

Sesa Goa Limited)

(ii) Brief description of nature of the project:

The volume of existing blast furnace is 450 m3. The licenced production

capacity is 4,50,000 TPA. Technology supplier of the BF is China. The

maximum hot metal production achieved in a single day is 1476 tons.

It has been observed from the existing BF as well as similar BF

technology installed at other plants in India (by MCC Overseas China)

that through appropriate process optimization the production capacity

could be increased by 20% to 5,40,000 TPA. This could be achieved by

increasing the hot blast volume, by increasing oxygen blowing and

increasing the Fe content in sinter burden.

There will be no change in the process technology, general layout and

water consumption. The plant area will remain same. Technically, the

pollution load discharged into the environment will also remain same.



(iii) Need of Project and Importance to the Country or Region:

The existing BF produces foundry grade pig iron for automobile sector.

Hot metal is tapped into ladle and poured in the Pig Casting Machine.

Productivity rate of foundry grade pig iron using BF is low as compared

to productivity of basic grade pig iron using the same blast furnace. This

is mainly because of strict process control requirement in making

foundry grade pig iron.

The automobile sector is experiencing slowdown in India as well as in

other countries. Therefore the sale price of foundry grade pig iron is low

thereby affecting the sustainability / economic viability of the project.

Presently China started dumping low cost foundry grade pig iron in India

and other international market. The cost of production of foundry grade

pig iron by Chinese suppliers is lower than Indian Producers.

In order to remain competitive in the domestic as well as international

market, Vedanta Limited decided to start making basic grade pig iron

from the existing blast furnace.

This will make the project sustainable, profitable and socially viable. The

general product will meet the demand of India as well as international

market.



(iv) Demand – Supply Gap:

The automobile sector is experiencing slowdown in India as well as in

other countries. Therefore the demand of foundry grade pig iron for use

in automobile sector has reduced.

Presently China started dumping low cost foundry grade pig iron in India

and other international market. The cost of production of foundry grade

pig iron by Indian Producers is more than the sale price of China.

In order to remain sustainable, profitable and socially viable, the

company decided to produce basic grade pig iron. The demand of

general grade pig iron at competitive cost exists in the domestic and

international market.

(v) Imports Vs Indigenous production:

The cost of production of foundry grade pig iron by Indian Producers is

more than its counterparts in China. The Indian Government is not

considering any additional import duty to be levied on steel/scrap

imported into India.

(vi) Export Possibility:

The project is located close to Major Port. This will enhance the export

chance by remaining cost competitive.

(vii) Domestic / Export Markets:

Railway line exists till Madgaon in Goa. This will make the product

competitive in domestic market like Maharashtra and Karnataka.

The project is located close to Major Port. This will enhance the export

chance by remaining cost competitive.



(viii) Employment Generation (Direct & Indirect) due to project:

The company decided to produce basic grade pig iron from the existing

blast furnace. The raw material consumption would increase. Slag

generation would also increase proportionately.

Handling and transportation of additional raw materials and slag would

attract additional employment, both direct as well as indirect. The

additional direct employment would be about 25. The additional indirect

employment would be about 100, most of them in the material (raw

materials, product and slag) transportation sector.



3. Project Description:

(i) Type of project including interlinked and interdependent

projects, if any:

This is a stand-alone project

(ii) Location (map showing general location, specific location, and

project boundary & project site layout) with coordinates:

General Location / Specific Location of Project Site: Annexure 1

Project Boundary on 10 km SOI Toposheet: Annexure 2

General Plant Layout: Annexure 3

(iii) Details of alternate sites considered and the basis of selecting

the proposed site, particularly the environmental conditions

gone into to be highlighted:

This is an existing project. Land area and general layout remains

unchanged. Hence not applicable

(iv) Size and Magnitude of Operation:

It is „A‟‟ Category Project as per EIA Notification 2006.

The cost of Blast Furnace complex is about Rs.400 Crores.



No additional expenses will be incurred for production capacity

enhancement using process optimization.

(v) Project description with process details (a schematic

diagram/flow chart showing the project layout, components of

the project etc. should be given:

Attached as Annexure 4

(vi) Raw Material required along with estimated quantity, likely

source, marketing area of final product / s, Mode of transport

of raw material and finished product:

Attached as Annexure 5

(vii) Resource Optimization / recycling and reuse envisaged in the

project, if any, should be briefly outlined:

Entire dust collected in Bag Filter, ESP, Gas Cleaning Plant of BF and

Scales of Cast House / PCM will be recycled in Sinter Plant.

Slag generated from BF will be granulated and 100% sold to cement

making plants.

Plant operates on Zero Liquid Discharge (ZLD), as all water is recycled

and reused in the system. Same will be followed.

BF gas shall be partially reused in stoves for making hot blast and

balance shall be used along with coke oven gas to generate power using

Waste Heat Recovery Boiler based Power Plant (existing 30 MW CPP).



In this manner the BF project will technically continue to remain as zero-

discharge project.

(viii) Availability of water it’s source, Energy / power requirement

and source should be given:

There is no change in source of water and its quantity.

Water requirement for the entire project has been designed as

Integrated System. The entire project consumes 16632 kl/day of water.

10000 kl/day water is taken from Mandori estuary (somewhat saline

water). 6700 kl/day fresh water is supplied by Government from nearby

Bhandara.

There is no change in source of power. Power requirement for BF and

the entire project shall be met from the 30 MW CPP.

(ix) Quantity of Wastes to be generated (liquid or soild) and scheme

of their management / disposal: (Total after capacity

enhancement)

Wastewater: Plant is Zero Discharge as all water is Recycled & reused.

Slag: 221400 TPA, which will be 100% granulated and sold to cement

makers

Dust from air pollution control equipment: 9180 TPA, which will be

100% reused in the Sinter Plant.

Spent oil and lubricants: 10 KL/Year, which will be 100% auctioned to

authorized re-processors



(x) Schematic representations of the feasibility which give

information of EIA purpose:

There is no change in pollution load. No additional land or water is

required. The production capacity enhancement is about 20% of the

original plan. Therefore no TOR points for undertaking detailed EIA is

proposed for this project.

The company is submitting 6-monthly compliance report of all points

mentioned in the environmental clearance (EC) to MOEF, its Regional

Office located at Bangalore and CPCB on regular basis.

The company is generating environmental data on regular basis; related

to stack emissions, ambient air quality, wastewater quality before and

after treatment, and keeping records of use of solid wastes like slag,

dust, spent oil, etc.



4. Site Analysis:

(i) Connectivity: The project is well connected by road.

(ii) Land Form, Land use and Land Ownership:

Land area: 104 hectares

The land form is now graded to suit the project establishment. 33%

land has been earmarked as Greenbelt.

The existing landuse is industrial land

Vedanta Limited owns the land.

(iii) Existing Infrastructure:

i. Boundary wall

ii. Plant civil structures, blast furnace & auxiliaries, oxygen & nitrogen

plant, sinter plant, coke oven & power plant

iii. Internal and external roads

iv. Water reservoir

v. ESP, Bag Filters, GCP, ETP, STP

vi. Raw material Stock Yard

vii. Finished products Stock Yard

viii. Administration building and general offices of each units

ix. Security Cabins

(iv) Soil Classification:

The soil is lateritic type. The area falls under Seismic Zone III.

(v) Climatic Data from secondary sources:

Climatological Data attached as Annexure 6.

(vi) Social Infrastructure available:

Temples, Schools



5. Planning Brief

(i) Planning Concept (types of industries, facilities, transportation

etc) Town and Country planning/Development authority

Classification:

This is A Category Project as per EIA Notification 14-9-2006and

requires EC.

(ii) Population Projection:

The additional manpower is 25 direct and about 100 indirect.

(iii) Land use planning (breakup along with green belt etc):

Out of 104 ha land taken 33 ha land is being developed as greenbelt.

Photographs of Greenbelt attached as Annexure 7.

(iv) Assessment of infrastructure demand (Physical as well as

social):

No additional infrastructure is required for capacity enhancement.

(v) Amenities / Facilities:

No additional amenities / facilities is required for capacity enhancement.

The existing amenities / facilities are adequate for the BF production

enhancement.



6. Proposed Infrastructure

There is no change in the land area, greenbelt area and general layout

plan of the project.

(i) Industrial Area (Processing Area): No change

(ii) Residential Area (Non Processing area): No change

(iii) Green Belt: No change (33 ha area already is being developed as

green)

(iv) Social Infrastructure: No change

(v) Connectivity(Traffic and Transportation Road/ Rail/Metro/

water ways etc): No change

(vi) Drinking Water Management (Source and supply of water): No

change

(vii) Sewerage System: No change

(viii) Industrial Waste Management: Changed as per additional handling

of raw materials, dust from air pollution control devises and slag from blast

furnace. Generation of spent oil and lubricants will remain more or less

same. The existing EMP is adequate for the marginal increase in waste.

(ix) Solid waste Management: Changed as per additional handling of raw

materials, dust from air pollution control devises and slag from blast

furnace.

(x) Power requirement supply and source: CPP will meet the power

demand



7. 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 laborers (a brief outline to be given):

Not applicable because no additional land will be required for the

production enhancement of blast furnace



8. Project Schedule and Cost Estimates

(i) Likely date of start of construction and likely date of completion

(time schedule for the project to be given):

The existing Blast Furnace is already operating. The process

optimization could be done without stopping the BF. It will be

completed within 1 month of getting EC amendment.

(ii) Estimated project cost along with analysis in terms of

economic viability of the project:

The process optimization will not add to the cost of the BF project.



9. Analysis of Proposals (Final Recommendations)

(i) Financial and social benefits with special emphasis on the

benefit to the local people including tribal population, if any in

the area:

Financial Benefit

The process optimization will not add to the cost of the BF project. The cost of blast

furnace is about Rs.400 Crores. Therefore without spending any extra CAPEX,

annually around 90,000 to 1,00,000 tons of hot metal could be produced.

Social Benefit

The automobile sector is experiencing slowdown in India. Therefore the demand

of foundry grade pig iron for use in automobile sector has reduced. Presently

China started dumping low cost foundry grade pig iron in India. The cost of

production of foundry grade pig iron by Indian Producers is more than the sale

price of China. In order to remain sustainable, profitable and socially viable, the

company decided to produce basic grade pig iron. The demand of general grade

pig iron at competitive cost exists in the domestic and international market.

The proposed project will save direct employment for about 150 people and add

another 25 direct employment. It will also add about 100 indirect employment in

the transportation sector.

The existing Blast Furnace of 450 m3 volume and 4,50,000 TPA production capacity

is already operating. The production capacity enhancement to 5,40,000 TPA through

process optimization could be done without stopping the BF. It will be completed

within 1 month of getting EC amendment.



ANNEXURE 1 : LOCATION MAP



ANNEXURE 2 : MAP SHOWING PLANT SITE AND SURROUNDING 10 KM AREA



ANNEXURE 3 : GENERAL PLANT LAYOUT SHOWING LOCATION OF BLAST

FURNACE



ANNEXURE 4 : PROJECT DESCRIPTION, PROCESS DETAILS & SCHEMATIC

FLOW CHART

Project Description Transportation of raw material from storage yard to the stock house is done by closed belt

conveyors. The raw materials are distributed into the respective bunkers through shuttle

conveyors located at the top of the stock house bunkers. All materials, stored in different

weigh hoppers is charged sequentially into collecting conveyors which is discharged into

common charging conveyor which in turn feed the material to the blast furnace top charging

equipment. The hot blast stoves are designed for a blast temperature of 1250°C. Combustion

air and combustion gas is pre-heated by heat recovery system using BF gas from the stoves.

A blast furnace (BF) is an enclosed vertical furnace into which the raw materials enter at

the top, while the products (molten iron and slag) are tapped from the bottom (the

hearth).The raw material mixture of iron bearing materials (iron ore lump and sinter) and

additives (slag former, such as limestone) is called the “burden”. The burden and coke are

fed into the top of the furnace via a sealed charging system to prevent furnace gases from

escaping. Coke reduces iron ore to iron and also supplies heat. Iron ore gets converted to

iron and impurities are converted to slag. The solid burden moves downwards, counter

current of a rising stream of hot reducing gas. The hot reducing gas is provided by hot

stoves and is needed to transfer heat to the solid burden in order to raise the

temperature for reaction. The BF gas with residual calorific value is collected from the top of

the furnace for treatment and use.

The blast furnace is periodically tapped to remove the hot metal iron and slag from the

earth. For this purpose a tap-hole is opened in the side wall of the hearth. The tapped metal

has a temperature of approximately 1440-1500 °C. The slag and hot metal from the furnace

flows along the refractory or low cement covered runners and they are subsequently

separated at the skimmer in the cast house, after which each continues in a separate

runner. Liquid Hot metal is poured into ladles or torpedo cars. Slag flows in runners to a

granulation plant. At the end of casting cycle, the tap hole is closed by injecting a heat

resistant tap hole clay mixture, using a so-called “mudgun”.

Blast furnace gas is reused as fuel in the blast furnace stoves. The molten iron is converted to

pigs in Pig Casting Machine.



The process flow of blast furnace is shown below:

Process Flow Chart of Blast Furnace

Sinter from Sinter

Plant Coke from Coke

Oven

Oven

Lump Iron Ore +

Limestone

Hot Blast Stoves

Hot Blast

Blower House

Cold Blast

Gas Cleaning

Plant

Dirty Gas

Clean Gas

Clean Gas

Clean Gas

Flue Gas

Chimney

WHRPP/other

units in Plant

Liquid Metal + Slag

Metal to PCM

Slag to SGP

Blast Furnace



Production Capacity Enhancement Process Details

In 2014-15 the hot metal production from the 450 m3 blast furnace was 376947 tons, which is

the highest since commissioning of Blast Furnace in August 2012. With in-house experience

in operating the blast furnace and experience gathered from similar blast furnaces (Uttam

Galva, Jindal Steel, etc), it has been confirmed that the hot metal production can go upto

5,40,000 TPA.

This production increase can be achieved through increased injection of wind volume, oxygen

enriched blast, charging high Fe sinter feed upto 90% and better process control in operations

(without any change in Blast Furnace structure or change of product mix).

It is possible to enhance the productivity of existing blast furnace in five steps, described

below:

i. Production enhancement from 4,50,000 TPA to 4,62,143 TPA can be done by

producing only basic grade material. Production of foundry grade material will be

stopped / reduced.

ii. Production enhancement from 4,62,143 TPA to 4,76,007 TPA can be increased after

charging 2% increased Fe from current level of 54.25% to 56.25% (Fe can be

increased upto 60% in the same blend mix.).

iii. Production from 4,76,007 TPA to 5,30,487 TPA can be increased after increasing

wind volume from current level of 75000 Nm3/h to 85000 Nm

3/h. (Wind Volume can

be increased upto 90000 Nm3/h) as per design capacity of existing blowers in blast

furnace)

iv. Production from 5,30,487 TPA to 5,33,987 TPA can be increased by increasing

gaseous liquid Oxygen availability from current level of 3000 Nm3/h to 3200 Nm

3/h by

vaporizing current available liquid oxygen.

v. Production from 5,33,987 TPA to 5,40,000 TPA can be increased after improving plant

OEE from current 93.29% to 94.50% (OEE can be increased upto 97%)



When producing basic grade pig iron suitable for export it has also helped in increasing

production from usual level of 33000-34000 TPM to around 37000-38000 TPM. This

production level is almost close to our EC limit of 45000 TPA. The BF have potential to push

another 10000-15000 Nm3/hr. wind in blast furnace through optimization of burden

distribution, better quality of raw material usage and better process control. With this

additional 6000-7000 TPM production could be achieved. In the design given by technology

provider there were bottlenecks in hot metal evacuation which were resolved by putting up an

additional PCM and some modifications in ladle placement and handling schemes. With all

process improvements / optimization in place, the BF could produce around 45000 TPM or

5,40,000 TPA Metal.

After starting the plant as mentioned above there were restrictions on wind volume till October

2014 and also there were other teething issues in various equipment’s like conveyors, break

downs of equipment’s, frequent leakages in blowing systems etc. thereby dragging the

availability of plant below 90%. After stabilization of plant we have improved the availability of

plant to 94% and few projects in hand will improve it further to >97%. Thus there will be

another boost in production on this account.

There is no requirement of any additional facility per say for achieving this but improvements/

modifications in existing systems. Equipment’s available are having enough cushion to

support this higher production volume.

Pollution control devices are capable enough to handle this additional production level and

there will be no impact on environment on this account.

Blower which is main equipment decisive for augmenting the production level was selected

slightly on higher side during finalization stage itself, so this higher production is possible and

there no additional equipment cost coming for us. The Blower is designed for pushing around

100000 Nm3/h of wind.

Tomorrow when market becomes better we may switch over back to foundry grade

production but till that time it is paramount important for us to sustain in the market. This is

possible only buy controlling cost of production which comes through basic grade production



wherein fuel rate come down by 10% from that of foundry grade and export through sea route

gives freight benefit.

With current EC limit we will not be able to compete with primary steel producers, hence we

propose to increase our EC from current 45000 MTPA to 540000 MTPA from the 450 m3

effective volume Blast Furnace.

The Fe balance of the existing blast furnace (production: 4,50,000 TPA) and that of blast

furnace producing 5,40,000 TPA metal is shown in two different Figures shown below.



ANNEXURE 5 : LIST OF RAW MATERIALS AND MATERIAL BALANCE

Material Balance of 4,50,000 TPA and 5,40,000 TPA Production

Raw

Materials

(INPUT)

Quantity

for Quantity for Product

(OUTPUT)

Quantity for Quantity for

0.45 MTPA 0.54 MTPA 0.45 MTPA 0.54 MTPA

Sintered

ore

631,080 757,296 Hot Metal 450,000 540,000

Lump iron

ore

157,770 189,324 Slag, 184,500 221,400

Coke

208,350 317,520

LOI, BF gas,

losses, etc 411,300 561,060

Pulverised

Coal (PCI)

56,250 67,500

Dust &

sludge 7,650 9,180

Total

1,053,450 1,331,640 Total 1,053,450 1,331,640

Source of Raw Materials and Transportation:

Iron ore shall be purchased/sourced from mines located in Goa and Karnataka. It

will be transported by road/rail network

Coal for PCI shall be imported It will be transported from Port to plant by road.

Coke and Sintered ore is available inhouse.



ANNEXURE 6 : CLIMATE DATA



ANNEXURE 7 : PHOTOGRAPHS OF EXISTING PLANT & GREENBELT



ANNEXURE 8 : AIR MONITORING DATA OF EXISTING PLANT Blast Furnace: Stack Emission Monitoring Data

Month Parameter Location

Hot Blast

Stove

PCM Cast

House

Dedusting

Stock House

Dedusting

Pulverised

Coal

Injection

August 2014 to

October 2014

PM (mg/Nm3) 28 47 35 48

SO2 (mg/Nm3) 25 NA NA NA

NOx (mg/Nm3) 41 NA NA NA

November’ 14 to

January 2015

PM (mg/Nm3) 30 42 45 46

SO2 (mg/Nm3) 29 NA NA NA

NOx(mg/Nm3) 42 NA NA NA

Blast Furnace: Stack Parameters & Existing Pollution Load

Stack

Location

Stack

Height

Stack

Diamete

r

Exit Gas Temp Exist Gas

Velocity

PM Emission

Limit

PM Emission

Load

BF Stove 60 m 3 m 130-190 deg C 5 m/s 30 mg/Nm3 0.7 g/s

Cast House 30 m 2.8 m 40-80 deg C 10 m/s 50 mg/Nm3 2.6 g/s

Stock House 30 m 2.8 m 40-80 deg C 5/s 50 mg/Nm3 1.5 g/s

PCI 37.5 m 1.02 m 80-180 dg C 7 m/s 50 mg/Nm3 0.23 g/s

Total PM

Load

5.03 g/s

17.6 kg/h

The PM emission load will be maintained within 17.6 kg/hour by increasing the efficiency of Bag Filter and Gas Cleaning Plant



Ambient Air Quality Results (µg/m3)

17/03/2015

Location PM10 PM2.5 SO2 NO2

Amona Gate 74.85 29.11 13.97 18.03

Opposite BSNL Exchange 92.39 34.1 14.13 17.84

Near Dispatch Gate 75.95 33.68 13.81 17.91

Compound wall Towards Navelim 61 31 13.73 18.05

Nr. Sateri Temple 80.14 33.67 14.13 18.27

19/03/2015

Amona Gate 83.48 31.19 13.89 18.15



Compound wall Towards Navelim 79.1 29.11 13.97 18.08

Nr. Sateri Temple 86.78 33.68 14.78 19.29

24/03/2015

Amona Gate 85.22 30.35 13.24 17.91




Nr. Sateri Temple 88.84 33.27 14.05 18.56

26/03/2015

Amona Gate 77.78 35.56 14.45 16.63




Nr. Sateri Temple 82.64 32.42 15.1 18.29

31/03/2015

Amona Gate 82.11 34.48 14.13 17.79




Nr. Sateri Temple 85.69 31.19 14.78 19.46



ANNEXURE 9 : COPY OF EC dt 3-6-2009 & EC AMENDMENT dt 25-4-2012



ANNEXURE 10 : 6-MONTHLY COMPLIANCE STATUS OF EC CONDITIONS

6 Monthly Compliance Report to Conditions Of Environmental Clearance

Issued By MOEF, Govt. of India, for Blast Furnace (0.90MTPA), Sinter Plant

(2MTPA), Coke Plant (0.6MTPA), Waste Heat Recovery Power Plant (60MW)

by Vedanta Limited (earlier known as Sesa Sterlite Ltd./ Sesa Goa Limited) *

12th Compliance Report to EC No: F. No. J-11011/946/2007-IA-II(I)

PERIOD : October 2014 to March 2015

Sr.

No. Condition of clearance Status of compliance

A. Specific Conditions

(i)

Electrostatic precipitator (ESP) shall be

provided to Sinter plant and WHRB based

Power Plant to control gaseous emissions

from all the vents/stacks within 100

mg/Nm3. Gas Cleaning Plant along with

Ventury scrubber shall be provided to

blast furnace. On-line stack monitoring

facilities for all the stacks shall be

provided to ensure particulate emissions

below 100 mg/Nm3 and data submitted to

the Ministry’s Regional Office at

Bangalore, CPCB and Goa Pollution

Control Board. Efforts shall be made to

reduce RSPM levels in the ambient air and

a time bound action plan should be

submitted.

Electrostatic Precipitator (ESP) provided to the Sinter

Plant at Head End & Tail End of Sinter Machine. Dry

Gas Cleaning Plant (GCP) with a dust catcher & bag

filters, provided to Blast Furnace. Online stack

monitoring instrument is installed at 100m high main

stack of Sinter machine at Sinter plant. Other

conditions complied subject to letter dated 15 Sep

2009 addressed to MOEF, which clarifies areas of non

applicability of the conditions. Regular Stack

Monitoring & Ambient Air Quality Monitoring is

conducted and monthly reports are submitted to

GSPCB. Also half yearly reports are submitted to

CPCB & MOEF.

(ii)

Pulse jet bag filters shall be provided to

coal crusher, product house, raw material

handling areas, transfer point etc. Bag

filters shall be provided at the crusher,

screening and transfer points. The Coke

Oven gases shall be fully utilized for

power generation. Water sprinkling system

and dry fog system shall be provided to

control fugitive emissions at the coal

handling area and work zone

Complied. Pulse jet bag filters are provided for coal

crusher house, coke screening towers, transfer points,

raw material handling sections, etc. Also rain gun

sprinklers are provided at raw material yard. Coal is

stored in the enclosed shed. Wind screens are installed

along the raw material storage yard. Baghouse

dedusting system provided for proportioning bin,

sinter screening building, flux and fuel crushing and

small dedusting units for various transfer stations.

Coke Oven Flue Gas (COFG) is fully utilised for

Clean Power Generation, save an except situation

which require statutory shut downs of waste heat

recovery boilers (WHRBs), etc.



(iii)

Data on ambient air quality stack emission

and fugitive emissions shall be uploaded

on the company’s website and also

regularly submitted online to Ministry’s

Regional office at Bangalore, Goa

Pollution Control Board (GPCB) and

Central Pollution Control Board as well as

hard copy once in six months. Data on

SPM, SO2 and NOx shall also be displayed

prominently outside the premises at the

appropriate place for the general public.

Ambient Air quality & source emission data is

submitted on regular basis to GSPCB. Also six

monthly data on stack emission & ambient air quality

is submitted to GSPCB, CPCB, MOEF & in hard

copy and through e-mail and also uploaded on

company website.Display of PM10, PM2.5,SO2 &

NOx is done prominently outside the premises for the

general public.

(iv)

Secondary fugitive emissions from all the

sources including Blast Furnace, Coke

Oven and Sinter Plant shall be controlled

within the latest permissible limits issued

by the Ministry and regularly monitored.

Guidelines/Code of Practice issued by the

CPCB shall be followed.

There are no specific permissible limits,

guidelines/code of practice issued by CPCB/MOEF for

Non Recovery Coke Oven Plants. Rain guns have been

installed at raw material yard. Bag filter dedusting

systems are used to control dust. Wind screen/wind

shields are installed at prominent locations as per the

instructions of GSPCB. The monitoring is done

regularly.

(v)

Total water requirement shall not exceed

16632 m3/day. The effluent from generated

utilities shall be treated in the effluent

treatment plant and recycled and reused in

the process in blast furnace, sinter plant,

dust suppression, ash moistening, fire

fighting and green belt development

etc.No effluent shall be discharged outside

the premises and ‘zero’ discharge shall be

followed.

Total water requirement does not exceed

16632m3/day. All Process water from Coke, Blast

Furnace, Sinter Plant is recycled and reused after

appropriate treatment.Blow down from Cooling Tower

of Power Plant is let out into Mandovi river after

temperature & pH monitoring.

(vi)

Regular monitoring of influent and

effluent water shall be ensured and treated

wastewater shall meet the norms

prescribed by the Goa State Pollution

Control Board or described under the E(P)

Act whichever are more stringent and

reports shall be submitted six monthly to

the Ministry’s Regional Office at

Bangalore, GPCB and CPCB.

Blow down from Cooling Tower of Power Plant is let

out into Mandovi river after temperature & pH

adjustment. Monthly monitoring is carried out as per

Consent conditions. Reports are submitted to GSPCB

every month and to MOEF(RO) , CPCB, every six

monthly



(vii)

All the blast furnace slag shall be

granulated and provided to cement

manufacturers for further utilization. All

the dust from the air pollution control

equipments shall be recycled and reused in

the Sinter plant. All the other solid wastes

shall be disposed off in the environment-

friendly manner or provided to authorized

recyclers/ reprocessors. Used oil shall also

be provided to authorized recyclers only.

An action plan for the disposal of fly ash

and granulated BF & SMS slag shall be

submitted to the Ministry and its Regional

Office at Bangalore within 3 months

Granulated BF slag is disposed to cement industries .

Dust from air pollution control equipments is recycled

& reused in Sinter Plant. All other solid wastes is

disposed off in the environment-friendly manner or

provided to authorized recyclers/ reprocessors. Used

oil is disposed off to the authorized recyclers

only.Disposal of Fly Ash & SMS slag is not applicable

as the fascility is limited to ironmaking throngh blast

furnace and there is no steel making provision and the

power plant is based on waste heat hence thermal coal

is not used for power generraion. The non applicability

of fly ash & SMS slag is mentioned in letter to MoEF

dated 15 September 2009.

(viii

)

All the fly ash shall be utilized as per Fly

Ash Notification, 1999 and amended in

2003.

Not Applicable as explained above.

(ix)

Vehicular pollution due to transportation

of raw material and finished product shall

be controlled. Proper arrangements shall

also be made to control dust emissions

during loading and unloading of the raw

material and finished product.

Vehicular pollution due to transportation of raw

material and finsished product is controlled. Rain

Guns(Sprinkling system) have been installed in the

raw material yard and water tankers are used for dust

suppression. Sprinklers for dust suppression have been

installed at Pig Iron Dispatch yard

(x)

Green belt shall be developed in 33 % area

within and around the plant premises as

per the CPCB guidelines in consultation

with DFO.

Green belt is developed in phases with plantation

drives during the Monsoons. Plantations in co-

ordination with Goa Forest Development Corporation

is carried out. Around 3500 saplings were planted

during 2014 monsoons which included fruit bearing

as well as flowering trees. Geotextile of around 15000

square Meters is layed on tthe slopes and grass and

trees are planted on these slopes to cover the area.

Total 10000+ trees are planted till date.

(xi)

All the recommendations made in the

Charter on Corporate Responsibility for

Environment Protection (CREP) for the

Steel Sector shall be strictly implemented.

The Project is not a Integrated Iron & Steel Plant and

hence the CREP guidelines of steel sector are not

applicable however, whatever CREP conditions are

applicable for blast furnace and nonrecovery coke

plant have been complied, proactively.



(xii)

The company shall provide housing for

construction labour within the site with all

necessary infrastructure and facilities such

as fuel for cooking, mobile toilets, mobile

STP, safe drinking water, medical health

care, crèche etc. The housing may be in

the form of temporary structures to be

removed after the completion of the

project.

Complied. All temporary housing structures have been

decommissioned after the completion of project.

B General Conditions

(i)

The project authorities must strictly

adhere to the stipulations made by the Goa

Pollution Control Board (GPCB) and the

State Government.

Stipulations made by GSPCB are strictly adhered to.

Reports are sent to Goa State Polution Control Board

(GSPCB) . Regular site visits are made by GSPCB

personnel to check the compliance status.

(ii)

No further expansion or modifications in

the plant should be carried out without

prior approval of the Ministry of

Environment and Forests.

No expansion or modification in the plant shall be

carried out without prior approval of MoEF. We have

found that hot metal capacity can be increased to 540-

600 KTPA from existing 450 KTPA by process

efficiency/optimisation like increasing Fe rich burden,

higher wind volume, etc. without change in product

mix, technology, modernisation, physical expansion.

For same application for amendment in EC is moved

(iii)

The gaseous emissions from various

process units shall conform to the

load/mass based standards notified by this

Ministry on 19th May, 1993 and standards

prescribed from time to time. The state

Board may specify more stringent

standards for the relevant parameters

keeping in view the nature of the industry

and its size and location. At no time, the

emission level shall go beyond the

prescribed standards. On-line continuous

monitoring system shall be installed in

stacks to monitor SPM and interlocking

facilities shall be provided so that process

can be automatically stopped in case

emission level exceeds the limit. NOX

burners shall be installed to control NOX

levels.

Whatever applicable to our type of industry is

complied. Online stack monitoring instrument is

provided for 100m high main stack of Sinter plant, tail

stack of sinter plant, HBS stack and both WHRB

stacks of Power Plant to track TPM.



(iv)

At least four ambient air quality-

monitoring stations shall be established in

the downward direction as well as where

maximum ground level concentration of

SPM, SO2 and NOX are anticipated in

consultation with the GPCB. Data on

ambient air quality and stack emission

shall be regularly submitted to this

Ministry including its Regional Office at

Bangalore / GPCB / CPCB once in six

months.

AAQM locations approved by GSPCB and the

monthly reports are submitted to GSPCB . Two

Continuous Ambient Air Quality Stations have been

set up. Data on Air Quality, Stack emissions is

submitted once in a six months to MOEF (RO) & SZO

of CPCB. Monthly AAQM reports are submitted to

GSPCB

(v)

In-plant control measures for checking

fugitive emissions from all the vulnerable

sources like Sinter plant, Blast Furnace

area etc. shall be adopted. Further, specific

measures like water sprinkling shall be

carried out at the stock piles of raw

material, stacker, reclaimer, transfer points

etc. Dust extraction system and bag filters

shall be provided to the sinter plant, stock

house and blast furnace. Centralized de-

dusting system i.e. collection of fugitive

emissions through suction hood and

subsequent treatment through bag filter or

any other device and finally emitted

through a stack of appropriately designed

shall be provided. Fugitive emissions shall

be controlled, regularly monitored and

records maintained.

Individual Pulse Jet Bag Filters are provided for Cast

House, Stock House of Blast Furnace and Flux & Fuel

House, Proportioning House, Sinter Screening House

of Sinter Plant. These Pulse jet bag filters cover

various capture points such as screening, transfer

stations, etc. Electrostatic precipitators (ESPs) are

provided at Head & Tail end of Sinter Machine aof the

Sinter Plant. Rain gun sprinklers are provided &

operated at the Raw material yard of the Sinter Plant &

Blast Furnace. Windscreens are also installed along

the raw material boundary wall. Windshields are

installed at the Pig Iron dispatch yard. All the stacks

are are of adequate height as per the design. Fugitive

emissions are controlled, monitored & records

maintained. Dust supression system installed at raw

material hoppers.

(vi)

Industrial wastewater shall be properly

collected, treated so as to conform to the

standards prescribed under GSR 422 (E)

dated 19th May, 1993 and 31

st December,

1993 or as amended form time to time.

The treated wastewater shall be utilized

for plantation purpose.

All Process water from Coke, Blast Furnace, Sinter

Plant is recycled and reused after appropriate

treatment.Blow down from Cooling Tower of Power

Plant is let out into Mandovi river after temperature &

pH adjustment.



(vii)

The overall noise levels in and around the

plant area shall be kept well within the

standards (85 dBA) by providing noise

control measures including acoustic hoods,

silencers, enclosures etc. on all sources of

noise generation. The ambient noise

levels should conform to the standards

prescribed under EPA Rules, 1989 viz. 75

dBA (daytime) and 70 dBA (nighttime).

Overall noise levels in and around the plant area is on

an average less than 85dB(A). Enclosures, acoustic

hoods, silencers, etc. are provided wherever necessary.

The ambient noise levels conforms to the standards

prescribed under EPA Rules, 1989 viz. 75 dBA

(daytime) and 70 dBA (nighttime) at the boundary of

the plant.

(viii

)

The company shall develop surface water

harvesting structures to harvest the rain

water for utilization in the lean season

besides recharging the ground water table.

Surface rain water harvesting and ground water

recharge system implemented as per the advise of Sr.

hydrogeologist from Water Resource Department

(WRD) of Goa. Also roof top rain water harvesting is

implemented.

(ix)

Occupational Health Surveillance of the

workers shall be done on a regular basis

and records maintained as per the

Factories Act.

Occupational Health Surveillance of the workers is

carried out on a regular basis and records maintained

as per the Factories Act

(x)

The project proponent shall also comply

with all the environmental protection

measures and safeguards recommended in

the EIA / EMP report. Further, the

company shall undertake socio-economic

development activities in the surrounding

villages like community development

programmes, educational programmes,

drinking water supply and health care etc.

Environmental protection measures and safeguards

recommended in EIA/EMP is followed. We also

undretake various socio-economic development

activities in the surrounding villages like community

development programmes, educational programmes

and health care etc.



(xi)

The project authorities shall earmark

adequate capital cost and recurring

cost/annum for environment pollution

control measures and utilize judiciously to

implement the conditions stipulated by the

Ministry of Environment and Forests as

well as the State Government. An

implementation schedule for implementing

all the conditions stipulated herein shall be

submitted to the Ministry’s Regional

Office at Bangalore. The funds so

provided shall not be diverted for any

other purpose

HSE department with competent employees looks

after Environmental Management with Management

support. A earmarked bugdet has been alloted with

adequate provisions for implentation, operation and

maintainance of Environment Pollution Control

Measures.

(xii)

The Regional Office of this Ministry at

Bangalore/CPCB/GPCB will monitor the

stipulated conditions. A six monthly

compliance report and the monitored data

along with statistical interpretation shall

be submitted to them regularly.

6 monthly compliance report & monitored data is

submitted to MoEF, CPCB & GSPCB regularly on six

monthly basis.

(xii)

The Project Proponent shall inform the

public that the project has been accorded

environmental clearance by the Ministry

and copies of the clearance letter are

available with the GPCB and may also be

seen at Website of the Ministry of

Environment and Forests at

http:/envfor.nic.in. This shall be advertised

within seven days from the date of issue of

the clearance letter, at least in two local

newspapers that are widely circulated in

the region of which one shall be in the

vernacular language of the locality

concerned and a copy of the same shall be

forwarded to the Regional office.

The information about grant of Environmental

Clearance was published in 2 local newspapaers as per

the condition of EC.

(xiv)

Project authorities shall inform the

Regional Office as well as the Ministry,

the date of financial closure and final

approval of the project by the concerned

authorities and the date of commencing the

land development work

Complied

Additional Recommendations on 25/4/12, when amendment in EC was granted



i

The NAAQS issued by the Ministry vide

GSR No 826 (E) dated 16th November

2009 shall be followed.

The parameters applicable to our type of industry are

followed. Once in a year all the 12 parameters as

mentioned in NAAQS are monitored at all AAQ

stations are reports submitted to GSPCB. The 12

parameter AAQ results for year 2014 have been

submitted to GSPCB

ii

The Project Proponent shall also submit 6

monthly reports on the status of the

compliance of stipulated environmental

conditions including results of monitored

data (both in hard copies as well as by e-

mail) to respective RO of MOEF,

respective ZO of CPCB & SPCB. RO of

MOEF at Bangalore/CPCB/GSPCB shall

monitor the conditions.

Complied. This is the 12th six monthly compliance

report submitted to RO of MOEF at Bangalore with cc

to CPCB & GSPCB. Also monitored parameters are

submitted to the authorities as mentioned in above

clauses.

iii

Environmental Statement for each

financial year ending 31st March in Form

V as is mandated to be submitted by

project proponent to GSPCB as prescribed

under EPR 1986 shall also be put on the

website of the company along with the

status of compliance of environmental

conditions and shall also be sent to

respective ROs of MOEF by e-mail.

Complied. The Environmental Statement for all units,

viz, Coke Plant, Power Plant, Blast furnace and Sinter

Plant for year 2013-14 were submitted before the

deadline, i.e, 30th September 2014.

iv

The Company shall submit within 3

months their policy towards Corporate

Environment Responsibility which should

inter-alia address (i) SOP to bring into

focus any infringent/deviation/violation of

EC conditions (ii) Hierarchical system or

Administrative order of the company to

deal with environmental issues and

ensuring compliance to EC conditions (iii)

System of reporting of non

compliance/violation environmental norms

to Board of Directors of the company

or/and stakeholders or shareholders.

Company's Policy and other details on CER was

submitted.



* Vedanta Limited (earlier known as Sesa Sterlite Ltd./Sesa Goa Ltd. ) has implemented Blast Furnace

(0.45MTPA), Sinter Plant (1MTPA), Coke Plant (0.3MTPA), Waste Heat Recovery Power Plant (30MW)

vis-a-vis 50% of Environmental Clearance Capacity, as a Phase1.

With respect to Letter dated 25/4/12 from MOEF, name of Project Proponent has been changed from Sesa

Industries Ltd. to Sesa Goa Ltd. also an amendment in EC has been issued by MOEF with respect to

change in plant configuration with changes in stack dimensions. We have found that hot metal capacity can

be increased to 540-600 KTPA from existing 450 KTPA by process efficiency/optimisation like increasing

Fe rich burden, higher wind volume, etc. without change in product mix, technology, modernisation,

physical expansion. For same application for amendment in EC is moved

pfr for increasing the production capacity of blast...

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