~f@NALCONA TlONAL ALUMINIUM COMPANY LIMITED

(A GOVT. OF INDIA ENTERPRISE)SMELTER PLANT, NALCONAGAR- 759 145, ANGUL

Fax: 91-6764-220206, Tel: 91-6764 - 220645CIN:L272030R1 981GOlOO0920

No. SAN/GM(S)/3,../0/2019 Dt: 125' •. 11.2019

ToThe member Secretary,State Pollution Control Board,Parivesh Bhawan, A/11B,Nilakanthanagar, Unit - VIII,

Bhubaneswar - 751012.

Ref: Letter No. 11423/IND-I-CON (M)1377, dated 25.10.2019.

Sub: Submission of Compliances to Consent to Operate Conditions of Smelter.

Sir,

Inviting reference to the above, please find attached herewith the pointwise compliances to theconsent conditions of Smelter. As desired, copies of the audited annual balance sheet, annual

environmental statement are also attached.

Your good office is requested to renew the consent to operate (CTO) of Smelter, Nako, Angul forfurther three years period i.e. from 01.04.2020 to 31.03.2023 in line with our on line application

submitted last year with requisite fees.

Thanking you,

Yours sincerely,

~General Manager

Smelter Plant

Enclosures: As above.

Copy for kind information of:1. Chief Env. Engineer, SPCBoard, Bhubaneswar.

2. Regional Officer, OSPCB,S 3/3, Industrial Estate, Angul-759145

Status of compliance to consent to operate conditions of Smelter Plantfor the period April to October 2019

F. Special conditions of Consent to operate under section 21 of Air (P&CP) Act, 1981,under section 25of Water (P&CP) Act, 1974, vide no. 2929/1ND-I-CON-234 dated 23.03.2019 for Smelter Plant, NALCO,Angul.

Fl. Air pollution Control

SINo01

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DETAILS OF CONDITIONS

Total fluoride emission from all purposes shall notexceed 0.8 kg/ton of Aluminum produced.

HDPA (pneumatic conveymg system) shall beimplemented in old pot lines to prevent fugitive emissionduring filling alumina into the pots.

Dedicated team shall be engaged for regular cleaningof FTP floor area of pot lines and the same shall besent to the rodding shop immediately for mixing withalumina.

All the online continuous stack emission monitoringsystems (CEMS) for measurement of particulate matterand gaseous pollutants shall be operated effectively anduninterruptedly the online monitoring data so generatedshall be transmitted to SPCB and CPCB sever on acontinuous basis.

All the online continuous ambient air quality monitoringstations (CAAQMS) shall be operated effectively anduninterruptedly and the online monitoring data so generatedshall be transmitted to SPCB and CPCB server on acontinuous basis.

The digital display board at the mam gate shalldisplay real time data of stack and Ambient Air.

ACTION TAKEN

Complied.Average of total fluoride emISSIOn fromSmelter for the months from Apr 2019 toOct 2019 was 0.48kg/MT.At present HDPA system is in operation inPot line-IV. Since the same system is notimplementable in Potline I, II & III due totechnical reasons. Adequate care have beentaken by adopting improvised operation &maintenance practices to control fugitiveemission. The average fugitive emission forthe months from Apr to Oct 2019 is 0.324kg/MT which is within the norm.Complied.Regular cleaning of FTP floor area is goingon by engaging dedicated team & vacuumfloor sweeping vehicles. The same is sentregularly to rodding shop for mixing withalumina.Smelter of NALCO had already completedinstallation & commissioning of onlineemission monitoring system for PM andfluoride parameters in all the major stacks(FTP-I to 8 of potlines and FTC 1& 2 ofBake Ovens). Online monitoring datagenerated are being transmitted to OSPCB&CPCB.CAAQMS are operating continuously andthe real time data are uploaded to theOSPCB servers. Action is on the way toupload data to CPCB servers.

Complied. Real-time display of Ambient airdata and stack data are being displayed atSmelter Main gate.

07 An inventory at least 30% excess spare parts shall beavailable III the store to meet emergency need ofeffluent treatment plants/ pollution control systemsIFTPslFTCIBFs etc.

Complied.

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09

Proper housekeeping throughout the plant shall bemaintained by a dedicated team.

All fluoride contaminated solid waste i.e., dross,rejected filter bags, rejected refractories, housekeepingwaste, transport vehicle waste etc. shall be kept undershed or disposed off in secured land fill to comply withthe conditions of authorization order. In no case the wasteshall be stored open. All care shall be taken to avoid

Complied.

Complied.

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generation of surface runoff water from these wastesto prevent contamination of the surrounding area.

10 All raw material, product and waste material shall be Complied.transferred through covered vehicles without anyspillage or leakages on the way, in case any accidental ,.spillage on the road, waste shall be lifted by theindustry and suitably disposed off in designated solidwaste dumping area.

11 Care shall be taken so that the ambient noise level shall Complied.conform to the standard prescribed under EnvironmentalProtection Act, 1986.

12 In case the consent fee is revised upward during this Agreed.period, the industry shall pay the differential fees tothe Board (for the remaining years) to keep the consentorder in force. If they fail to pay the amount within theperiod stipulated by the Board the consent order willbe revoked without prior notice.

13 The Board reserves the right to revoke/refuse consent to Noted.operate/ to modify or stipulate additional conditions asdeemed appropriate at any time during period for whichconsent is granted.

F-II. Water pollution Control~I DETAILS OF CONDITIONS ACTION TAKEN!No01 All the three resin column of De-fluoridation plant shall Complied.

be operated and maintained effectively for treatment of All the three resin columns are operational.The results are well within the norms

fluoride bearing effluent. Full proof arrangement for which are regularly submitted to the officeremoval of oil and grease /emulsion from the effluent of asPCB.shall be made before the effluent is fed into De- For removal of Oil & grease, activatedfluoridation plant for its effective functions. charcoal filter columns are in line.

The Project for implementing the surfacerunoff management by Emrion NanoTechnology, was installed & is moperation.

02 The entire treated water from the de-fluoridation plant Complied.shall be taken to the re-circulation sump and the waterfrom the sump shall be pumped back for reuse. Under nocircumstances there shall be any overflow from therecirculation sump to outside.

03 The online continuous effluent quality monitoring system Complied.(EQMS) shall be operated effectively & uninterruptedly andthe online monitoring data so generated shall be transmitted.to SPCB and CPCB sever on a continuous basis.

04 The unit shall ensure all the surface runoff collected from pot Complied.room area shall reach the De-fluoridation plant for propertreatment.

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05 Rain water harvesting ponds shall be developed and thewater can be used by the industry in dry season tominimize water drawl from river and dams.

Complied.06 Necessary steps shall be taken to completely reuse thetreated effluent from STP and De-fluoridation plant forplantation/other use purpose inside premises.

Complied.Three HDPE lined holding pools havingcapacity 1,00,000 lakh cum, 51000 cumand 38000cum are developed to caterwater to Smelter in dry season thusminimizing drawl from-river.

Presently de-silting operation ofHolding pools is not required as thepools are maintaining their fullcapacity. Moreover there is no siltdeposits.

07 De-silting operation of holding pools shall be taken up atregular intervals adopting scientific procedure andprecaution to maintain its efficacy and holding capacity.

Online flow measuring device withdigital display and data recorder installedat the outlet of common drain.

08 Online flow measuring device with digital display and datarecorder shall be installed at drain -I, II, III & at thecommon drain connected to final outlet before the treatedeffluent is discharge to outside / recycled/reused. The realtime data shall be transmitted to the server of the Board overGPRS link.

Complied.Online analysis of parameter IS beingdone.

09 Necessary facilities for analysis of effluent shall be providedat the waste water treatment site for taking immediatecontrol measures.

Complied.Stored in zero discharge sump for furtheruse in firefizhtinn & horticulture.

10 Treated effluent shall be stored in a detention tank beforefinal discharge.

Complied. Results are attached atAnnexure-I.

Noted.

11 The domestic effluent generated from colony, office andcanteen shall be treated in STP and shall meet the standardsprescribed by MoEF & CC vide notification G.S.R 1265(E)dtd.13th October 2017 as follows:pH - 6.5-9.0BOD - less than 30mg/ITSS - less than 100mg/l andFecal Coliform (FC) MPN/I00ml<100.

Water consumption is reduced graduallyby adopting water recycling measureslike• Installation of Ernrion nano Defluoridation plant.• Use of recycled water in carbonanode cooling, horticulture etc.• Use of Subsoil accumulatedwater from Potline area in compressorhouse cooling tower, fire watermakeup etc.

12 Care shall be taken for safe storage of the de-silted materialto prevent any leaching.

13 The industry shall take all steps to substantially reduce waterconsumption and the waste water generation underdomestic, cooling and industrial use according to the norms.A water balance of the plant shall be submitted to the Board.

Complied.

Complied.For the period April 2019 to Oct 2019 atotal of 5011 saplings have been planted.Total 17,55,017 nos. of trees have beenplanted till date with survival rate of66.93% in Smelter and Township. Asprescribed, plantation density of 1000

14 The blow down, floor washing water shall be adequatelytreated and reused inside the plant premises.

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IS A green belt of adequate width and density preferably withlocal species along the periphery of the plant shall be raisedso as to provide protection against particulates and noise. Itmust be ensured that at least 333 of the total land area shallbe under permanent green cover. The proponent shall ensurethe maintenance of green belt throughout the year and for alltime to come. It is advised that they may engage

professionals in this field for creation and maintenance of trees per acre is.being maintained.the green belt.

16 In case the consent fee is revised upward during this period, Noted.the industry shall pay the differential fees to the Board(for the remaining years) to keep the consent order inforce. Jfthey fail to pay the amount within the period

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stipulated by the Board the consent order will be revokedwithout prior notice.

17 The Board reserves the right to revoke/refuse consent to Noted.operate/ to modify or stipulate additional conditions asdeemed appropriate at any time during period for whichconsent is granted.

18 The industry shall take steps for fulfillment of all the Complied.stipulations and necessary measures to check pollution.

19 Consent to operate is subject to availability of all other Noted.statutory clearances required under relevant Acts/Rules andfulfillment of required procedural formalities.

G. Additional Conditions/Sl DETAIL OF STATUTE / PERMIT / LICENSE ACTION TAKENlNo01 The unit shall complete installation of online continuous Online continuous laser based gaseous

laser based gaseous fugitive fluoride monitoring system at fugitive fluoride monitoring systems areall the pot rooms of the plant and connect these analyzers to installed at G & H rooms and taken intothe server of the Board by 31.05.2019. operation since May 2019. Action is

undertaken for uploading data to theserver of the board with the help ofservice provider which will be doneshortly. Procurement action for theremaining pot rooms will be done afterobserving the performance of theinstalled system at G & H rooms.

02 The industry shall complete construction of peripheral Construction of peripheral drains anddrains and concrete tanks to contain run off from the concrete tank to contain run off fromhazardous waste stock yards by 31.05.2019. the hazardous waste storage yards was

completed on 31.05.2019 and takeninto operation.

03 The industry shall install mechanized wheel washing An approved internal committee hadsystem for the material transport vehicles at the exit gate studied the feasibility of the project,and the effluent to be treated in the existing ETP to avoid prepared design & estimate. Procurementfluoride contamination of the public roads. action initiated & is expected to be

completed by May 2020.04 The unit shall take all steps to avoid contamination of Complied.

surface runoff by preventing storage of any solidi hazardous 7ili SPL shed is constructed in July 2019.wastes in open area before forthcoming monsoon. Construction of 8th SPL shed is

undertaken.

05 The industry shall strictly follow the guide line ofCPCB Noted.dated July 2018 for monitoring Online Effluent quality andAugust 2018 for online stack monitoring of PM and othergaseous parameters respectively.

06 The industry shall ensure tampered proof real time Complied.transmission of online monitoring data to the server ofCPCB and SPCB and maintain the health of the analyzersand data connectivity through valid AMC.

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Analysis result of STP{Average of Apr 2019 to Oct 2019)

S&PSmelter Complex CISF

Parameters Unit Norms Plant Township ColonypH 6.5-9.0 6.8 6.8 6.7TSS mgll 100.0 16.7 13.0 14.7BOD 3 day 27 deg-C mg/l 30.0 4.7 6.0 6.6

MPNFecal coliform Iml 100/100 69 58 65

ANNEXURE- I

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