Indian Aluminium Company Limited, Alupuram Smelter Eloor.

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120 Findings 1. The factory situates by the river side at about 60m away from the river. There is no direct intake from Periyar River. The Water requirement of 200 to 250 m 3 /day is met by M/s FACT (80%) and three nos ground wells in the factory premises 2. The company authorities reported that the hazardous waste generated since 1997 is stored in the roofed concrete storage tank (without lining) and the quantity of waste stored till date is 169 tonne. The capacity of the tank is 225 m3. The unit has got valid consent under the Water (Prevention and Control of Pollution) Act 1974, Air (Prevention and Control of Pollution) Act 1981 and authorization under Hazardous Waste (Management and Handling) Rules 1989. The company authorities have informed that they have requested for Board’s permission to use the newly constructed R.C.C tank of 10.5 x 21 x 2.4 m after providing polythene lining. The sources of emissions are Boilers (2nos) band driers (2nos) ammonia scrubber stack (30 m high), box driers (2nos), tableting machines (2nos), generator (2nos, 500 KVA and 100 KVA) Effluent and emission monitoring reports as stipulated in the consent order and environmental audit report are submitted to the Board periodically. The company authorities informed that there is a proposal for installing sulphuric acid catalyst manufacturing plant. 3. The effluent treatment plant was working during the inspection. The effluent generated from the factory are passed through oil taps for removing oil and collected in equalization tank. The wastewater from the canteen is taken to the equalization tank after removing the suspended solids. The effluent is then taken to the flash mixer for chemical treatment, settled and passed through sand filters. The treated effluent is discharged into the river Periyar. The underflow from the settling tank is fed through a plate and frame filter press and the dewatered sludge is disposed in the hazardous waste storage tank. The filtrate from the filter press is taken to sand filter after pH correction. The pH of the effluent from the filter press was noted as 6.5 during inspection. 4. The sludge pump used for pumping the sludge to the filter press is kept in a roofed tank. Solid wastes from the canteen are collected in a roofed tank provided with a grilled cover. 5. The spillage from furnace oil storage tanks are collected inside the dyke wall, passed through oil traps and recovered. Considerable spillage was noticed near the storage tanks. The waste water discharged from the oil trap is taken to the ETP.Used oil is collected in drums for final disposal to authorized dealers. The quantity of used oil as reported by the company is 150 litre in 90 days. Scrap is stored separately. 6. A Delay pond is provided in storm water drain. 7. During the inspection of the factory the surrounding areas of effluent treatment tanks were seen covered with crushed metals. Over all housekeeping is satisfactory. The cooling water (20m 3 /day) after passing through cooling towers (2nos) is recirculated 8. The raw material FeSo 4 is stacked in a partially roofed yard. An underground cement plastered pit with tin sheet roofing is provided for collecting the leakage from old wooden pit, which was used for collecting the spillage from FeSo 4 storage area.
121 9.Greenbelt provided is inadequate. During the subsequent inspection conducted it is noticed that the company have taken positive steps for planting more trees and more trees and developing greenbelt . 10. Effluent and water samples are collected for analysis. The report of analysis of the effluent collected from the authorized outlet of the factory on 20-11-04 and 15-7-05 are noted below. Parameters Analyzed Parameters Tolerance limits in the consent book 1. PH 7.1 pH - 6.70 5.5-9.0 2. BOD 0.9 mg/l 3. COD 3.2 ,, 4. SS 6.0 ,, SS - 9.0 100 5. Zinc 0.04 ,, Zinc - 0.12 5 6. Iron 0.11 ,, 7. Lead 0.88 ,, 8. Mercury ND 9. Cadmium 0.07 ,, 10. Copper 0.068 ,, copper - ND 3 11. Nickel 0.03 ,, Nickel - ND 3 12. Chlorides 34.0 ,, 13. Cyanides ND ,, 14. Phenolic compounds ND ,, 15. Hexavalent Chromium ND ,, Hexavalent Chromium- 0.1 mg/l 16. Total Chromium 0.03 ,, Total Chromium- 2mg/l 17. Manganese 0.15 ,, 18. Oil and grease ND ,, Oil and grease -10 mg/l 19. Titanium ND ,, 20. Free available Chlorine ND ,, The analysis report of the hazardous waste collected from the waste storage tank on 12-1-05 is given below. A/R no;1131 The report shows the presence of copper, Chromium compounds II exceeding the limits specified in class B schedule II and also high content of Zinc. Recommendation: 1. A decision is to be taken by the Board on the company’s proposal to use the newly constructed hazardous waste storage tanks after providing required lining. 2. Effluent treatment plant should be augmented for complete recycling of treated effluent. 3.Chromium bearing effluent should be segregated and treated separately. 4. Chromium recovery plant should be installed. 5. Test wells are to be provided near the effluent treatment plant and hazardous waste storage tank. 6. Greenbelt is to be improved.
Page 1 and 2: 77 INDIAN ALUMINIUM COMPANY LIMITED
Page 3 and 4: 79 8. The industrial plant was not
Page 5 and 6: 81 5. Industry has obtained consent
Page 7 and 8: 83 Heat Exchangers. The gas then go
Page 9 and 10: 85 1. Concentration and crystalliza
Page 11 and 12: 87 Petro chemical Division is conce
Page 13 and 14: 89 7. The scrubber stack for IVth a
Page 15: 91 the faulty nature of manual anal
Page 18 and 19: 94 Source : FACT - UD Date of sampl
Page 20 and 21: 96 FACT- PETROCHEMICAL DIVISION Nam
Page 22 and 23: 98 scrubbing with ammonia water whe
Page 24 and 25: 100 5. Delay ponds shall be provide
Page 26 and 27: 102 Products : Rare Earths Chloride
Page 28 and 29: 104 recovered. Ammonium di uranate
Page 30 and 31: 106 M/S KEMO GRAVURES , EDAYAR Name
Page 32 and 33: 108 Raw materials : Name Quantity (
Page 34 and 35: 110 The Effluent treatment system c
Page 36 and 37: 112 Date of Sampling 08/06/05. Sl.
Page 38 and 39: 114 Waste: Sources of liquid waste
Page 40 and 41: 116 Date of Sampling 29-11-04 N o D
Page 42 and 43: 118 Raw Materials: Name of material
Page 46 and 47: 122 Consented Parameters and limits
Page 48: 124 Source : Sud Chemie India Pvt.

Indian Aluminium Company Limited, Alupuram Smelter Eloor.

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