Vedanta gets go-ahead for Tuticorin expansion - but with conditions attached

Last week UK-listed Vedanta Resources was forced to halt its illegal bauxite mining of the Kolli Hills in Tamil Nadu, India [see "Indian High court halts Vedanta's bauxite mining", posted this week].

However, this welcome news was somewhat over-shadowed by a decision, made in August by India's Expert Appraisal Committee (Industry), but only just announced, that the company may double the capacity of its notorious Tuticorin copper smelter in the same state. Vedanta has also gained exemption from the holding of a public hearing, ostensibly because the expansion is within an existing industrial estate.

Whether the expansion will go ahead in the near future is open to question. The copper market has been one of the worst to suffer from the commodity down-turn. Morever,
the permit is hedged about with conditions which the company may find difficult to meet - as is made clear in the last paragraphs of the Committee's judgment:

" The Committee found the final EIA/EMP report inadequate and observed that :

1. Data presented regarding continuous ambient air quality monitoring appears to be improper since minimum value can not be "zero" and suggested to recheck the data.

The committee also desired submission of the existing ambient air, stack emission and fugitive emission data collected by TNPCB's, approved laboratory and PAs [Project Authorities] own data generated in their lab.

2. SO2 values also momentarily go high which PAs were unable to explain.

3. NOX values are also high.

4. Ground water quality monitoring data was also not satisfactory.]

Based on the unsatisfactory explanation, the Committee desired that PAs should submit the above mentioned data which will be reconsidered by the Committee as and when submitted.

The proposal is differed (deferred) till the above information is submitted."

Vedanta's plan to expand Tuticorin - the official decision

11.2 Expansion of Copper Smelter Plant (Phase II) at SIPCOT Industrial Complex, Madurai Bypass Road, Tuticorin, Tamil Nadu by M/s Vedanta [Sterlite] Industries (India) Limited. (EC)

The project authorities and their consultant gave a detailed presentation on the salient features of the project and proposed environmental protection measures to be undertaken as per Draft Terms of References (TORs) awarded during the 84th Meeting of the Expert Appraisal Committee (Industry) held during 19th-21ST August, 2008 for preparation of EIA/EMP. All the Primary metallurgical industries have been kept at S.N. 3(a) under Primary metallurgical industry under category A.

PAs informed to the Committee that M/s. Vedanta (M/s. Sterlite Industries (India) Limited) has proposed to set up a Copper Smelter Plant (Phase II), SIPCOT Industrial Complex, Madurai Bypass Road, Tuticorin, Tamil Nadu. The total land acquired from SIPCOT, Govt. of Tamil Nadu is 92.5 ha instead of 124 ha earlier mentioned. Gulf of Mannar National park is at a distance of 12 km in the North-East direction. Bay of Bengal is at a distance of 10 km in North East and East direction. Thoothukkudi falls within the 15 km periphery of the proposed site. Total cost of the proposed unit will be Rs. 2,400.00 Crores. Rs. 465.00 Crores are earmarked for environmental protection measures.

The existing plant comprises of Copper smelter (1,200 TPD), Sulphuric acid plant (4200 TPD), Phosphoric acid plant (800 TPD), Refinery (875 TPD), Rod Plant (410 TPD). Another Copper smelter of capacity (1,200 TPD) will be installed in the proposed expansion.

PAs have earlier proposed that the main products from the proposed Copper smelter-II will be as follows:

S. No Products Proposed Production
Capacity (TPD)

I Main Product
1 Copper anode 1200
2 Copper cathode (from anodes produced) 1200
3 Phosphoric acid 800
II Intermediate Product
1 Anode slime (refinery) 7.20
III By-Product
1 Sulphuric acid 4500
2 Ferro sand 3200
3 Gypsum 4000
4 Hydrofluro- Silicic acid 50

Now, PAs have informed that the following products will be manufactured from the proposed Copper smelter-II.

S. N. Products Proposed Production (TPD)
I Main Product
1 Copper anode 1,200
2 Copper cathode 1,525
3 Phosphoric acid 800
4 Continuous Copper rod 800
II Intermediate Product
1 Anode slime 3.0
2 Dore Metal 0.65
3 Selenium 1.2
4 Bismuth Bi-sulphate 1.8
5 Copper Telluride 0.6
6 Nickel Sludge 30
7 Nickel 1.5
III By-Product
1 Sulphuric acid 4,500
2 Ferro sand 3,200
3 Gypsum 4,000
4 Hydrofluro- Silicic acid 50

PAs gave a detailed presentation of existing and proposed production details and is as follows:

S. N. Products Quantity (TPD)
Existing Expansion Total
I Main Product
1 Copper anode 1,200 1,200 2,400
2 Copper cathode 875 1,525 2,400
3 Phosphoric acid 410 800 1,210
4 Continuous Copper rod 800 800 1,600
II Intermediate Product
1 Anode slime 1.75 3.0 4.75
2 Dore Anode -- 0.65 0.65
3 Selenium -- 1.2 1.2
4 Bismuth Bi-sulphate -- 1.8 1.8
5 Copper Telluride -- 0.6 0.6
6 Nickel Sludge -- 30 30
7 Nickel -- 1.5 1.5
III By-Product
1 Sulphuric acid 4,200 4,800 9,000
2 Ferro sand 2,400 3,000 5,400
3 Gypsum 3,200 4,200 7,400
4 Hydrofluro- Silicic acid 25 80 105

It is also informed that the environmental clearance has been accorded for all Intermediate products.

Main raw material for the production of Cu metal is Sulphidic Copper concentrate containing about 25-35% copper, 28-35% Sulphur, Iron 25-30% and 7-10% moisture. Raw materials required will be Copper concentrate, Furnace oil, Liquid Oxygen, Silica, Quartz, LPG, HSD, Limestone, Coke, Copper Anodes, Hydrochloric acid, Thio-urea, Glue, Lime, Caustic Lye, Ferric sulphate, Sodium sulphide, Flocculent, Sulphuric acid, Rock phosphate, Active Silica, Defoamer, Caustic lye solution.

Copper anodes will be produced from the imported copper concentrates through pyro-metallurigical smelting process. The SO2 generated during the smelting of Cu will be converted into H2SO4 by Double Conversion Double Absorption (DCDA) process. Part of H2SO4 will be used for the production of Phosphoric acid from the imported rock phosphate using a Hemi-hydrate Di-Hydrate process. The casted Cu anodes will be dispatched to the refinery unit for further electrolytic refining to about 99.99% purity. The major steps in Cu extraction will include:

1. Blending of different grades of concentrates
2. Smelting of concentrate in ISASMELT furnace to produce an intermediate copper rich product known as "matte" containing 50-65% copper and eliminate Iron silicate (Ferro sand) by adding Silica.
3. Converting liquid matte to blister copper (98-99% Cu) in a Pierce- Smith Converters (PS Converter).
4. Fire refining of blister copper to produce anode copper (99.5% Cu) in anode furnace and casting of the anodes
5. Electrolytic refining of anodes to produce copper cathodes (99.99% Cu)

In the process of extraction of Copper metal from Sulphidic concentrates, Sulphuric acid will be recovered as a by-product from smelter & furnace.

WHRB will be provided to ISA. ESP will be provided to WHRB. ESP dust will be recycled back into ISA furnace. The primary gas from the ISA smelter and converter will be sent to proposed Sulphuric acid plant. Fugitive emissions from rotary holding furnace, secondary emissions from converter will be connected to the scrubber followed by a stack (175 m) provided to Smelter, Sulphuric acid plant and various other furnaces. Stack of height 60 m will be provided to the Phosphoric acid plant. Multi-stage scrubbing system will be installed to treat the secondary gases from smelter particularly Fluorine. Existing air emission from the Sulphuric acid plant is 1 kg/T of Sulphuric acid produced.

Total water requirement for the existing smelter is 1.7 MGD and for proposed smelter is revised from 1.8 MGD to 2.4 MGD and will be sourced from Tamirabarani River and supplied by TWAD board through dedicated pipelines. In addition, Desalination plant (5,000 m3/day) now revised to 10,000 m3/day capacity will be installed to meet peak demands. During presentation, PAs informed that existing water requirement of 1.8 MGD will be supplied from TWAD board. Proposed expansion requires 2.25 MGD of water, which will be supplied from Desalination Plant. Existing water consumption is 5.9 m3/T of product.

The entire wastewater generated will be treated and reused. The liquid effluent generated from Sulphuric acid plant, Refinery section will be reused in the plant after treatment. The other effluents generated from Phosphoric acid, cooling towers, boiler blow down and ETP raw water does not require any treatment for reuse/recycle. Similarly, the scrubbers bleed off, which is in slurry form and will be filtered for solids only. Gas cleaning effluent and secondary gas scrubber effluent will be treated in ETP. "Zero discharge" will be adopted.

Domestic effluent will be treated in sewage treatment plant (STP) and the treated water will be used for green belt. Leachates are also collected and used in the process. Regarding ground water quality, it is observed that Ph and Fluoride levels are high.

Scrap from stores / workshop will be sold to authorized recyclers. Lime grit generated from Milk of Lime preparation plant will be recycled back into ISA furnace in place of flux material. ETP cake, ETP slime, Spent Catalyst, Scrubber cake, Resin from Bismuth plant and toxic metal containing residue from Ion exchange material in water purification will be stored in secured land fills designed as per CPCB guidelines. ESP, WHRB and Gas coolers dust will be recycled back into Smelter. Metal slag from TROF converted of DORE process will be recycled to smelter. Regarding storage of gypsum, PAs informed to the Committee that out of 52 Lakhs, 42 Lakhs gypsum is already dispatched to the concerned organizations and remaining 10Lakhs will be sent in 2009. Spent oil, oil sludge and non-ferrous scrap will be sold to CPCB registered recyclers.

During presentation, PAs informed that 39.35 ha of land will be afforested in addition to existing 33 ha. green belt. Proper noise, vibration and heat arrester will be provided at the generation point itself. Vibration isolators will be provided to all ID fans and Compressors. Personal Protective equipment will be ensured in high noise areas. Total power requirement will be 60 MW and sourced from existing CPP (120 MW). Now, PAs informed that an additional cpp (75 MW) will be required for proposed expansion. Fuels required for the proposed unit will be LPG, HSD, Fuel oil and Coke.

PAs informed to the Committee that environmental clearance was accorded for the the Copper Smelter Plant (Phase?II) at SIPCOT Industrial Complex, Madurai Bypass Road, Tuticorin, Tamil Nadu and may be kept in abeyance since further expansion will be carried out in the existing and new area acquired in the near vicinity. Part of the new area acquired will be overlapping. PAs have requested for the use of data for EIA/EMP collected in 2006-07 (Winter season) and exemption from public hearing due to location in notified SIPCOT industrial estate. The Committee agreed for the use of same data as well as exemption for public hearing as per Section (iii), Stage (3), Para (i)(b) of EIA Notification, 2006 due to location of the project in notified SIPCOT.

After detailed deliberations, the Committee agreed for the exemption for public hearing as per Section (iii), Stage (3), Para (i)(b) of EIA Notification, 2006 due to location of the project in notified SIPCOT. The Committee found the final EIA/EMP report inadequate and observed that :

1. Data presented regarding continuous ambient air quality monitoring appears to be improper since minimum value can not be "zero" and suggested to recheck the data. The committee also desired submission of the existing ambient air, stack emission and fugitive emission data collected by TNPCB, approved laboratory and PAs own data generated in their lab.
2. SO2 values also momentarily go high which PAs were unable to explain.
3. NOX values are also high.
4. Ground water quality monitoring data was also not satisfactory.

Based on the unsatisfactory explanation, the Committee desired that PAs should submit the above mentioned data which will be reconsidered by the Committee as and when submitted. The proposal is differed till the above information is submitted.