Environmental Impact Assessment For the Proposed Copper Smelter Plant-II (1200 TPD Copper/ 4.38 LTPA Copper) in the SEZ at SIPCOT Industrial Complex, Therkku Veerapandiapuram Village, Ottapidaram Taluka, Thoothukudi District, Tamil Nadu FINAL REPORT Environmental Consultant: Vimta Labs Limited 142, IDA, Phase-II, Cherlapally, (Approved Consultant) Hyderabad–500 051, www.vimta.com (NABL/ISO 17025 Certified Laboratory, Recognized by MoEF, New Delhi) January, 2015 PREFACE Sesa Sterlite Limited Tuticorin, Tamil Nadu ENVIRONMENTAL IMPACT ASSESSMENT FO R THE PROPOSED COPPER SMELTER PLANT-II (1200 TPD COPPER/4.38 LTPA COPPER) IN THE SEZ AT SIPCOT INDUSTRIAL COMPLEX, THERKKU VEERAPANDIAPURAM VILLAGE, OTTAPIDARAM TALUKA, THOOTHUKUDI DIST RICT, TAMIL NADU For and on behalf of VIMTA Labs Limited Approved by : M. Janardhan Signed : Position : Head & Vice President (Env) Date : 10th January 2015 The report has been prepared inline with the prescribed TORs issued vide letter J-11011/431/2008-IA II(I) dated 25.6.2014 of the Ministry of Environment and Forests (MoEF), New Delhi This report has been prepared by Vimta Labs Limited with all reasonable skill, care and diligence within the terms of the contract with the client, incorporating our General Terms and Conditions of Business and taking account of the resources devoted to it by agreement with the client. Environmental Impact Assessment for the Proposed Copper Smelter Plant-II (1200 TPD Copper/ 4.38 LTPA Copper) in the SEZ at SIPCOT Industrial Complex, Therkku Veerapandiapuram Village, Ottapidaram Taluka, Thoothukudi District, Tamilnadu Table of Contents Table of Contents _______________________________________________________________ Chapter # Title Page # _______________________________________________________________ Table of Contents TC-1 List of Figures TC-4 List of Tables TC-6 1.0 Introduction 1.1 Identification of Project and Project and Proponent C1-2 1.2 Brief description of the Project C1-3 1.3 Scope of the Study C1-8 1.4 Methodology of the Study C1-8 1.5 Organization of the Report C1-9 2.0 Project Description 2.1 Type of Project C2-1 2.2 Salient Features of the Project C2-3 2.3 Project Description C2-8 2.4 Precious Metal Recovery Plant C2-26 2.5 Sources of Pollution C2-40 2A CTO Compliance Status 3.0 Baseline Environmental Status 3.1 Introduction C3-1 3.2 Geology, Hydrogeology & Drainage C3-1 3.3 Land Use Studies C3-9 3.4 Soil Characterisitics C3-19 3.5 Meteorology C3-24 3.6 Ambient Air Quality C3-34 3.7 Water Quality C3-40 3.8 Noise Level Survey C3-46 3.9 Ecology and Biodiversity C3-50 3.10 Demography and Socio-Economics C3-64 4.0 Anticipated Environmental Impacts and Mitigation Measures 4.1 Impacts during Construction Phase C4-1 4.2 Impacts during Operational Phase C4-3 5.0 Analysis of Alternative Sites and Technology 5.1 No Project Scenario C5-1 5.2 Site Selection C5-1 VIMTA Labs Limited, Hyderabad TC-1 Environmental Impact Assessment for the Proposed Copper Smelter Plant-II (1200 TPD Copper/ 4.38 LTPA Copper) in the SEZ at SIPCOT Industrial Complex, Therkku Veerapandiapuram Village, Ottapidaram Taluka, Thoothukudi District, Tamilnadu Table of Contents Table of Contents (contd.) _______________________________________________________________ Chapter # Title Page # ______________________________________________________________ 6.0 Environmental Monitoring Program 6.1 General C6-1 6.2 Environmental Monitoring C6-1 6.3 Monitoring and Reporting Procedure C6-3 6.4 Implementation Schedule of Mitigation Measures C6-6 6.5 Infrastructure for Environmental Protection C6-7 6.6 Greenbelt Development C6-7 7.0 Additional Studies 7.1 Risk Assessment and Disaster Management Plan C7-1 7.2 Approaches to the Study C7-1 7.3 Hazard Identification C7-1 7.4 Hazard Assessment and Evaluation C7-3 7.5 Visualization of MCA Scenarios C7-8 7.6 Disaster Management Plan C7-15 8.0 Project Benefits 8.1 Copper Production C8-1 8.2 Improvement in the Physical Infrastructure C8-1 8.3 Improvement in the Social Infrastructure C8-1 8.4 Employment Potential C8-2 8.5 Corporate Social Responsibility Policy C8-3 9.0 Administrative Aspects 9.1 Organizational Structure C9-1 9.2 Environmental Management System C9-1 10.0 Summary and Conclusion 10.1 Introduction C10-1 10.2 Type of Project C10-1 10.3 Baseline Environment C10-2 10.4 Anticipated Environmental Impacts & Management plant C10-3 10.5 Environmental Monitoring Program C10-7 10.6 Disaster Management Plan C10-7 10.7 Project Benefits C10-8 10.8 Conclusions C10-8 11.0 Disclosure of Consultants 11.1 Introduction C11-1 11.2 Vimta Labs Limited- Environment Consultant C11-1 VIMTA Labs Limited, Hyderabad TC-2 Environmental Impact Assessment for the Proposed Copper Smelter Plant-II (1200 TPD Copper/ 4.38 LTPA Copper) in the SEZ at SIPCOT Industrial Complex, Therkku Veerapandiapuram Village, Ottapidaram Taluka, Thoothukudi District, Tamilnadu Table of Contents Table of Contents (contd.) _______________________________________________________________ Chapter # Title Page # ______________________________________________________________ Annexures Annexure-I Earlier EC Letter Annexure-II TOR Letter Annexure-III Exemption for Public consultation Annexure-IV Methodology for Sampling and Analysis Annexure-V SEZ Approval Letter and Additional Land Requisition Letter Annexure-VI Water Allocation Letter Annexure-VII Hydrogeological Studies Annexure-VIII Land Use Pattern Annexure-IX Sodar Studies Annexure-X Ambient Air Quality Levels Annexure-XI Demographic Details VIMTA Labs Limited, Hyderabad TC-3 Environmental Impact Assessment for the Proposed Copper Smelter Plant-II (1200 TPD Copper/ 4.38 LTPA Copper) in the SEZ at SIPCOT Industrial Complex, Therkku Veerapandiapuram Village, Ottapidaram Taluka, Thoothukudi District, Tamilnadu Table of Contents List of Figures _______________________________________________________________ Figures # Title Page # _______________________________________________________________ 1.1 Index Map C1-6 1.2 Study Area Map C1-7 2.1 Process Flow Diagram of Copper Smelter Plant-II C2-2 2.2 Overall Plant Layout C2-4 2.3 Water Balance C2-7 2.4 Pictorial Diagram of Isa Smelter and Settling Furnace C2-9 2.5 Flow Diagram of Electrolytic Refinery Process C2-15 2.6 Flow Diagram of Continuous Copper Rod Plant Process C2-18 2.7 Pictorial Diagram of Gas Cleaning Plant C2-19 2.8 Process Flow Diagram of Sulphuric Acid Plant C2-20 2.9 Process Flow Diagram of Phosphoric Acid Plant C2-24 2.10 Proposed Flow Diagram of Copper Telluride Recovery Plant C2-28 2.11 Process Flow Diagram of Bismuth Recovery Plant C2-29 2.12 Process Flow Diagram of Nickel Sludge Plant C2-32 2.13 Process Flow Diagram of Nickel Plant C2-33 2.14 Process Flow Diagram of Copper Sulphate Preparation C2-34 2.15 Process Flow Diagram of Precious Metal Extraction C2-35 2.16 Process Flow Diagram of Selenium Recovery Plant C2-36 2.17 Process Flow Diagram of Dore Metal Processing Plant C2-39 2.18 Wastewater Treatment Plant-1 C2-42 2.19 Wastewater Treatment Plant-2 C2-42 2.20 Wastewater Treatment Plant-3 C2-43 2.21 Secured Landfill Design C2-53 3.2.1 Drainage Map of the Study Area C3-3 3.2.2 Geology of the Study Area C3-6 3.2.3 Hydrogeological Map of Study Area C3-8 3.3.1a Satellite Image Study Area C3-14 3.3.1b Landuse/Land Cover Map Based on Satellite Data C3-15 3.3.2a Satellite Image – SIPCOT Industrial Area (2014) C3-17 3.3.2b Satellite Image – SIPCOT Industrial Area (1998) C3-18 3.4.1 Soil Sampling Locations C3-20 3.5.1 Seasonal Windroses – Tuticorin C3-27 3.5.2 Seasonal Windroses – Tuticorin C3-28 3.5.3 Annual Windrose C3-29 3.5.4 Site Specific Wind Rose (July to September 2014) C3-32 3.5.5 Graphical Mixing Heights at the Project Site C3-33 3.6.1 Air Quality Sampling Locations C3-36 3.7.1 Water Sampling Locations C3-41 3.8.1 Noise Monitoring Locations C3-47 3.9.1 Ecological Sampling Locations C3-52 4.1 Incremental Concentrations for PM C4-7 4.2 Incremental Concentrations for SO C4-8 2 6.1 Greenbelt Development Plan C6-10 7.1 Radiation Contour Layout for Furnace Oil Storage Tank C7-12 7.2 Radiation Contour Layout for HSD Storage Tank C7-13 7.3 Radiation Contour Layout for LPG Bullet C7-14 7.4 Off-Site Emergency Plan C7-59 VIMTA Labs Limited, Hyderabad TC-4 Environmental Impact Assessment for the Proposed Copper Smelter Plant-II (1200 TPD Copper/ 4.38 LTPA Copper) in the SEZ at SIPCOT Industrial Complex, Therkku Veerapandiapuram Village, Ottapidaram Taluka, Thoothukudi District, Tamilnadu Table of Contents List of Figures (Contd…) _______________________________________________________________ Figures # Title Page # _______________________________________________________________ 8.1 CSR Activities – Photographs C8-6 9.1 Organizational Chart of Environmental Cell C9-2 9.2 Environmental Policy C9-7 VIMTA Labs Limited, Hyderabad TC-5 Environmental Impact Assessment for the Proposed Copper Smelter Plant-II (1200 TPD Copper/ 4.38 LTPA Copper) in the SEZ at SIPCOT Industrial Complex, Therkku Veerapandiapuram Village, Ottapidaram Taluka, Thoothukudi District, Tamilnadu Table of Contents List of Tables _______________________________________________________________ Tables # Title Page # _______________________________________________________________ 1.1 Details of Project Cost C1-2 1.2 Details of Production Capacity C1-3 1.3 Environmental Setting of the Plant Site (10 KM Radius) C1-5 1.4 Environmental Attributes and Frequency of Monitoring C1-8 2.1 Land Utilization Pattern C2-3 2.2 Major Design Parameters of Proposed Plant C2-3 2.3 Design Details of Isasmelt Furnace C2-5 2.4 Raw Material Requirement C2-5 2.5 Water Requirement for Copper Smelter Plant-II C2-7 2.6 Details of Converter C2-12 2.7 Details of Anode Furnace C2-13 2.8 Input and Output Details for Copper Telluride Recovery Process C2-27 2.9 Input and Output Details for Bismuth Recovery Process C2-30 2.10 Analysis of Anode Slime C2-35 2.11 Input and Output Details for Selenium Recovery Plant C2-37 2.12 Details of Stack Emissions - Proposed Plant C2-40 2.13 Wastewaters Treated and Recycled to Process C2-41 2.14 Wastewaters Recycled to Process without Treatment C2-41 2.15 Details of Wastewaters Treatment Plants C2-41 2.16 Characteristics of Wastewater C2-43 2.17 Permeate Water Quality from RO C2-46 2.18 Hazardous Waste Generation Details C2-48 2.19 Lime Grit, Scrubber & ETP Cake Composition C2-50 2.20 Composition of ESP/Gas Cooler Dust C2-50 2.21 Spent Catalyst Composition C2-50 2.22 Spent Oil and Oil Sludge Composition C2-51 2.23 Details of Hazardous Waste Handling and Management C2-54 2.24 Noise Levels from the Proposed Plant C2-56 3.3.1 Landue Pattern in the Study Area C3-9 3.3.2 Landuse / Land Cover Classification System C3-11 3.3.3a Landuse Breakup Details in 10 Km radius C3-13 3.3.3b Changes in Landuse of SIPCOT Industrial Area C3-16 3.4.1 Details of Soil Sampling Locations C3-19 3.4.2 Soil Analysis Results C3-22 3.4.3 Soil Analysis Results C3-23 3.4.4 Standard Soil Classifications C3-24 3.5.1 Climatological Data C3-25 3.5.2 Predominant Wind Pattern C3-30 3.5.3 Summary of the Meteorological Data Generated at Site C3-30 3.5.4 Mixing Heights at the Project Site C3-33 3.6.1 Details of Ambient Air Quality Monitoring Locations C3-35 3.6.2 Summary of the Ambient Air Quality Results C3-39 3.7.1 Water Sampling Locations C3-42 3.7.2 Surface Water Quality C3-43 3.7.3A Ground Water Quality C3-44 3.7.3B Ground Water Quality C3-45 3.8.1 Details of Noise Monitoring Locations C3-46 VIMTA Labs Limited, Hyderabad TC-6 Environmental Impact Assessment for the Proposed Copper Smelter Plant-II (1200 TPD Copper/ 4.38 LTPA Copper) in the SEZ at SIPCOT Industrial Complex, Therkku Veerapandiapuram Village, Ottapidaram Taluka, Thoothukudi District, Tamilnadu Table of Contents List of Tables (contd.) _______________________________________________________________ Tables # Title Page # _______________________________________________________________ 3.8.2 Noise Levels in the Study Area C3-49 3.9.1 Ecological Sampling Locations C3-51 3.9.2 Plantation at Copper Smelter Plant C3-54 3.9.3 Plantation at Copper Smelter Plant C3-54 3.9.4 Lifeform and Economic Importance of the Plant Species in Study Area C3-55 3.9.5 Class Wise Distribution of Plant Species in the Study Area C3-58 3.9.6 Details of Importance Value Index and Diversity Index C3-59 3.9.7 Fauna of the Study Area C3-60 3.9.8 Phytoplankton group Abudance from the Study Area C3-61 3.9.9 Zooplankton Group Abundance from the Study Area C3-62 3.9.10 Meiobenthic Group Abundance from the Study Area C3-63 3.9.11 Macrobenthic Group Abundance from the Study Area C3-63 3.9.12 Year Wise Fish Production at Tuticorin C3-64 3.10.1 Distribution of Population C3-65 3.10.2 Distribution of Population by Social Structure C3-66 3.10.3 Distribution of Literate and Literacy Rates C3-66 3.10.4 Occupational Structure C3-68 4.1 Model Set-Up C4-5 4.2 Details of Proposed Stack Emissions C4-5 4.3 Predicted Short-Term Modelling Results C4-6 4.4 Resultant Ground Level Concentrations C4-6 4.5 Additional Traffic Due to the Proposed Project C4-12 4.6 Emission Factors C4-12 4.7 Peak Hourly Prediction Results C4-13 4.8 Existing and Additional Traffic C4-13 4.9 Recommendations on Traffic Capacity-IRC C4-13 4.10 Noise Levels from the Proposed Plant C4-18 6.1 Environmental Monitoring During Project Construction Phase C6-3 6.2 Environmental Monitoring During Project Operation Phase C6-5 6.3 Implementation Schedule C6-6 6.4 Cost Provision for Environmental Measures C6-7 6.5 Recommended Species for the Greenbelt Development C6-9 7.1 Category Wise Schedule of Storage Facilities after Copper Smelter Plant-II Operation C7-2 7.2 Properties of Fuels Used at the Plant C7-3 7.3 Applicability of GOI Rules to Fuel Storage C7-3 7.4 Preliminary Hazard Analysis for Storage Areas C7-4 7.5 Preliminary Hazard Analysis for the Proposed Plant in General C7-4 7.6 Fire Explosion and Toxicity Index C7-6 7.7 Fire Explosion and Toxicity Index for Storage Facilities C7-6 7.8 Damage due to Incident Radiation Intensities C7-8 7.9 Radiation Exposure and Lethality C7-8 7.10 Scenarios Considered for MCA Analysis C7-9 7.11 Properties of Fuels Considered for Modeling C7-9 7.12 Occurrence of Various Radiation Intensities- Pool Fire C7-9 7.13A Thermal Radiation Levels due to Failure of LPG Bullet C7-11 VIMTA Labs Limited, Hyderabad TC-7 Environmental Impact Assessment for the Proposed Copper Smelter Plant-II (1200 TPD Copper/ 4.38 LTPA Copper) in the SEZ at SIPCOT Industrial Complex, Therkku Veerapandiapuram Village, Ottapidaram Taluka, Thoothukudi District, Tamilnadu Table of Contents List of Tables (contd.) _______________________________________________________________ Tables # Title Page # _______________________________________________________________ 7.13B Explosive over Pressure Levels due to Failure of LPG Bullet C7-11 7.14 Anticipated Accident Scenarios C7-17 7.15 Anticipated Emergency Situations C7-20 7.16 Off-Site Action Plan C7-58 8.1 Action Plan for CSR Programs C8-4 10.1 Cost Provision for Environmental Measures C10-7 VIMTA Labs Limited, Hyderabad TC-8