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Choudhary Iron & Steel Industries (CISI)

PRE FEASIBILITY REPORT FOR THE PROPOSED IRON ORE, MANGANESE ORE

AND COAL BENEFICIATION PLANT

At: Village Raichhapal, Post: Kumjharia,

Dist Sundargarh, Odisha

CISI 12.08.2015

Pre Feasibility Report of Proposed Iron, Manganese Ore & Coal Beneficiation Plant of Choudhary Iron & Steel Industries, Raichhapal, Kumjharia, Sundargarh, Odisha

2 Prepared by: Environmental Research and Services (India) Pvt. Ltd., Bhubaneswar, Odisha

C O N T E N T S

CHAPTER PARTICULARS PAGE NO

1 Executive Summary 01

2 Introduction of the Project/Background Information

02

3 Project Description 14

4 Site Analysis 33

5 Planning Brief 38

6 Proposed Infrastructure 40

7 Rehabilitation and Resettlement ( R & R) Plan

43

8 Project Schedule & Cost Estimates 44

9 Analysis of Proposal (Final Recommendations)

45



Chapter - 1

Executive Summary

1. Name of the Company : M/S. Choudhary Iron & Steel Industries

2. Address of the Unit : Regd. Off : At. Utkal Automotive, Near Konark Cinema Hall, Ring Road, Rourkela – 769001, Sundergarh, Odisha, India

Sundergarh, Odisha, India

3. Proposed Location : Village : Raichhapal, P.O. : Kumjharia, District – Sundergarh - 770039, Odisha, India

4. Proposed Project : Iron Ore Beneficiation : 0.75 MTPA Manganese Ore Beneficiation : 0.10 MTPA and Coal Beneficiation : 0.65 MTPA

5. Power requirement : 1.1 MVA

6. Operating Days : 320 Days in a Year

7. Number of Shift : 2 Shift

8. Working Hours : 8 Hours

9. Water requirement : Approximately 233 m3 per day. (For the Whole Project)

10. Man Power : 30 during Operation

11. Raw Materials Requirement : Iron Ore (ROM), Manganese Ore (ROM) and Coal (ROM)

12. Estimated cost of the Project : Rs.10.30 Cr.

13. Project Schedule : 18 Months



Chapter - 2

Introduction of the Project/Back Ground Information

2.1 Identification of Project and Project Proponent The said Project is a new proposal of establishment of Iron Ore Beneficiation Plant (Wet Process), Manganese Ore Beneficiation Plant (Wet Process) and Coal Beneficiation Plant (Dry Process) at Village Raichhapal, PO: Kumjharia, Tehsil: Kuarmunda in Sundargarh district of Odisha State.

It is proposed by the proponent M/s. Choudhary Iron & Steel Industries, having its registered office at Village Raichhapal, PO: Kumjharia, Tehsil: Kuarmunda in Sundargarh district of Odisha State.

2.2 Brief Description of Nature of the Project

2.2.1 Iron Ore Beneficiation Plant

The proposed capacity of the Iron Ore Beneficiation Plant shall be of capacity 0.75 Million Tonnes Per Annum of Raw Iron Ore throughput having the following parameters: Capacity : 2 X 100 TPH

No. of operating days in a year : 320 days.

No. of operating hours in a day : 14 hours (Two shifts operation Including daily short maintenance and start/ stop).

Plant utilisation : 85%.

Annual throughput : 200 TPH X 14 hrs. X 320 X 0.85 ( % Plant utilisation) = 761600 tonnes.

Say 0.75 million tonnes.

Yield : 60 % (4.5 Lacs TPA of Beneficiated Ore)

: Balance 40 % consisting of Fines, Tailings and rejects which will be processed and sold separately.



2.2.2 Manganese Ore Beneficiation Plant

The proposed capacity of the Manganese Ore Beneficiation Plant shall be of capacity 0.10 Million Tonnes Per Annum of Raw Manganese Ore throughput having the following parameters:

Capacity : 1 X 50 TPH


No. of operating hours in a day : 7 hours (Single shifts operation Including daily short maintenance and start/ stop).




Yield : 65% (65000 TPA of Beneficiated Mn Ore)

Balance 35 % consisting of Fines, Tailings and rejects which will be processed and sold separately.

2.2.3 Coal Beneficiation Plant

The proposed capacity of the Coal Beneficiation Plant shall be 0.65 Million Tonnes Per Annum of Raw Coal throughput having the following parameters: Capacity : 1 X 200 TPH


No. of operating hours in a day : 12 hours (Two shift operation Including daily short maintenance and start/ stop).






The Beneficiation Plant shall have the following input & outputs:

Raw Coal - Ash 44%

After Beneficiation - Ash 34%, Moisture 7.50%, Yield 80%,

GCV : 4250 K Cal / Kg.

The above data are based on the quality of Ore and Mineral produced by the neighbouring mines.

All the yield figures indicated are tentative and are meant for estimation purposes only. Actual yield figures can be predicted only after full scale washability data are available.

2.3 Need for the Project and Its Importance to the Country and or Region

Huge quantity of mining reject/sub grade ore is generated during normal mining operation. Such mining rejects/sub grade ore are accumulated in the mines as a waste product having no buyers. National Mineral Policy is also promoting mineral beneficiation with an aim of converting mineral waste into national wealth.

As per National Mineral Policy 2008, conservation of mineral shall be construed not in the restrictive sense of abstinence from consumption or preservation for use in the distant future but as a positive concept leading to augmentation of reserve base through improvement in mining methods, beneficiation and utilisation of low grade ore and rejects and recovery of associated minerals. The Government is aiming for an adequate and effective legal and institutional framework mandating zero waste mining as the ultimate goal and a commitment to prevent sub-optimal and unscientific mining. Mineral Sectoral value addition through latest technique of beneficiation, calibration, blending, sizing, concentration, pelletisation, purification and general customising of product is being encouraged.

At the same time Coal is the most abundant fossil fuel. India is blessed with huge coal reserve, nearly 7% of total coal in the world. 85% of this reserve is non Coking Coal, which caters to the need of power, cement and sponge iron plants. However, most of these reserves are of very low grade coal and the reserves of good quality coal is fast depleting. On the other hand, the demand



for coal is increasing due to higher demand of steel, power and cement. The problem of inferior coal is further aggravated due to extensive mechanised mining. As a result, the users of coal are not getting desired quality necessitating beneficiation of coal for use in Sponge Iron Kiln, Power Plant, Cement Plant, etc.

Coal India Limited and its subsidiaries are the only domestic producers and suppliers of coal. The annual requirement of non-coking coal for various industrial sectors like power, steel and cement is increasing day by day. As the reserves of lower ash good coal are depleting and hence in order to fulfil industry’s demand, huge reserve of inferior grade of coal is being mined. The problem is further aggravated due to mechanised and open cast mining of coal. Due to higher demand, selective mining is not possible. The average ash of coal now being supplied by CIL is around 45%. Also, the quality varies to a great extent since the supplies are coming from various mines and coal faces.

Government of India statute prohibits transport of Coal of Ash more than 34% to Thermal Power Plants situated at a distance more than 1000 Kms from Coal Mines which shall get reduced to 500 km from the pit head from Jan 2014. In order to satisfy this statute various State Electricity Boards are looking for Coal Washery operators to supply washed coal for their Power Plants. Further, the use of beneficiated coal for the Thermal Power Plants shall have the following advantages:

1. Supply of consistent quality coal can be ensured thereby avoiding frequent adjustments in input to boiler and minimising operators’ error.

2. Higher Thermal efficiency of boiler and higher steam rate.

3. Less wear and tear of the coal grinding mills.

4. Lower capital and operating cost for installing smaller ESP.

5. Less ash handling requirement at power plant & consequently less requirement of area for ash-pond etc.

From environmental point of view Dry Process of Beneficiating Coal is more environmental friendly than Washing of Coal for beneficiation. It also help in conserving the most precious water resource.

Dry coal beneficiation has constantly lost its importance vis-a-vis hydraulic beneficiation during the last five decades, primarily because of the sharper separations achievable with the modern hydraulic beneficiation technologies, such as gravity separation and flotation for reduction of ash materials. Nevertheless, there are certain inherent advantages of dry separation methods which would give them advantages in the competitive market place to increase their thermal efficiency vis-a-vis hydraulic processes. These advantages are:

A dry product resulting in a higher calorific value per ton.



The water source problem is acute in semi-arid areas.

Hydraulic processing of coal requires large quantity of water. Water is consumed as product moisture, tailings disposal and evaporation.

Waste generated from hydraulic process after maximizing the recycle the water is unsuitable for disposal to water resources, because it contains good amount of waste solids fines, which causes the pollution of water bodies. Dry processes avoid the problems associated with treatment and storage of process waste water.

The fines generated in dry processing are suitable for ideal fuel for fluidized bed combustor.

Water demand and pollution have opened up scope of research in the development of the process for dry cleaning of coal. Significant developmental work in dry beneficiation of coal is in progress in Canada, China and India.

2.4 Demand – Supply Gap

The Steel Ministry is of the view that India will have to import iron ore in the immediate future to meet significantly increasing demand from domestic companies.

“With many projects in the pipeline, both brownfield and greenfield expansion of steel capacity, iron ore requirement will increase significantly leading to imports of iron ore in near future,” the Steel Ministry has said in a recent presentation to the Planning Commission.

The Ministry in its mid-year (2013-14) plan review has identified iron ore availability as one of the challenges to achieve the steel production target of 300 million tonnes per annum (mtpa) by 2025.

With current (FY 2013-14) production capacity of around 90 mtpa, India needs at least 140 million tonnes (MT) iron ore to meet its need. It requires 1.5-1.6 MT iron ore to produce one million tonne of steel.

“Domestic requirement of iron ore is increasing with the capacity addition in steel production. Between the 2008-09 and 2012-13 period, the demand for iron ore has gone up from 87.4 million tonnes (MT) to 124.8 MT,” as the ministry said.

India, the world’s fourth largest producer of steel after China, Japan and the US, had produced 78.31 MT steel during 2012-13. It is likely to slightly inch up in current fiscal.

During the January-October period of the current year (2013-14), India produced 66.38 MT steel.

The Steel Ministry also said iron ore production has come down from 213 MT in 2008-09 to 136 MT 2012-13 due to ban on mining in Karnataka and sharp fall in production in Odisha.



“It would require sufficient time for 200 MT plus production (of iron ore),” the Ministry said.

The government has already taken steps discourage iron ore exports by raising the duty to 30 per cent.

As per the United National Framework Classification (UNFS) of mineral resources, total resource of iron ore in the country is around 28.51 billion tonnes, as on April 1, 2010.

Coal India Ltd also said in June 2013 that, it would place orders worth Rs 2,000 crore for at least seven coal washeries by the current fiscal.

“The contract for seven coal washeries would be placed by this fiscal with washing capacity of 15-16 million tonnes (MT) of coal,” CIL General Manager (project monitoring) T K Sinha said on the sidelines of the CII-organised India-South Africa cooperation seminar.

“Agreement for two washeries had already been signed and two more would be signed shortly. The rest would be done during the year,” he said.

Asked about a low demand for washed coal from consumers, Mr Sinha said there was demand for washed coal from non-power consumers. CIL officials said the company has 17 washeries with an installed capacity of 34 million tonnes.

Mr. Sinha said Coal India would pump Rs 2,000 crore in these seven washeries, while the decision for the rest would be taken later.

The investment is over and above the Rs 5,000 crore the CIL proposes to infuse during the current fiscal for purchasing equipment, land, railway siding, etc, excluding acquisition. Coal India Limited has decided to set up 16 washeries in its various subsidiaries to reduce the quantity of ash and other un useful component from coal so as to make it competitive in comparison to imported coal. The subsidiary-wise details of these proposed coal washeries are as follows:-

Table No. 1

Sl. No.

Name of washery

Capacity (Million Tonne per annum)

Subsidiary State

1 Kusmunda 10.0 SECL Chattisgarh

2 Baroud 5.0 SECL Chattisgarh

3 Madhuband 5.0 BCCL Jharkhand

4 Patherdih 5.0 BCCL Jharkhand

5 Patherdih 2.5 BCCL Jharkhand

6 Dahibari 1.6 BCCL Jharkhand



7 Dugda 2.5 BCCL Jharkhand

8 Bhojudih 2.0 BCCL West Bengal

9 Ashoka 10.0 CCL Jharkhand

10 Konar 3.5 CCL Jharkhand

11 Karo 2.5 CCL Jharkhand

12 Chitra 2.5 ECL Jharkhand

13 Basundhara 10.0 MCL Odisha 14 Jagannath 10.0 MCL Odisha 15 Hingula 10.0 MCL Odisha 16 Ib-Valley 10.0 MCL Odisha

Total 92.10

CIL and its subsidiary companies already have 17 Coal washeries in operation which are as follows:

Table No. 2

Sl. No.

Name of coal washery

Subsidiary company

Capacity (Million Tonne per

annum) 1 Dugda-ii BCCL 2.00 2 Bhojudih BCCL 1.70 3 Patherdih BCCL 1.60 4 Sudamdih BCCL 1.60 5 Moonidih BCCL 1.60 6 Mahuda BCCL 0.63 7 Madhuband BCCL 2.50 8 Kathara CCL 3.00 9 Swang CCL 0.75 10 Rajrappa CCL 3.00 11 Kedla CCL 2.60 12 Nandan WCL 1.20 13 Dugda-I BCCL 1.00 14 Gidi CCL 2.50 15 Piparwar CCL 6.50 16 Kargali CCL 2.72 17 Bina NCL 4.50

Total 39.40



The ash content of domestic coal is 45-50 per cent. The majority of coal delivered to customers is not washed. This affects plant performance and imposes the additional burden of environmental impact, ash handling, and transportation costs.

The existing coal washing capacity of about 135 mt is inadequate as compared to the annual coal production of 570 mt. This demand-supply gap in coal washing will increase with growth in domestic coal supply. The gap will widen further with the enforcement of regulations on coal washing.

The existing norms stipulate an ash content of 34 per cent for coal transported over 1,000 km. This is being reviewed. The changes under consideration include a reduced distance of 500 km from the pithead and determination of ash content on a daily average basis instead of the current practice of annual determination. Implementation of the revised stipulations could be a key driver for augmenting coal washing capacity in the country.

Private participation is expected to play a major role in coal washing capacity addition. Coal India Limited has planned 16 new coal washeries, to be set up as explained above by private players on a build-operate-maintain basis. The potential use of washery rejects in power generation has also drawn private sector interest in coal washing capacity. Further, capacity addition could be achieved through the renovation of ageing washeries.

The case for coal beneficiation will become stronger as utilities demand for quality in their fuel supply agreements and regulations become tougher on plant efficiency and emissions. The investment opportunity is huge for the industry to meet the future demand for washed coal.

2.5 Imports Vs Indigenous Production

In order to tap India’s iron ore resources, state-run companies Steel Authority of India Limited (SAIL) and National Mineral Development Corporation (NMDC) agreed to set up an Ultra Mega Steel Plant (UMSP) in Chhattisgarh’s Bastar region.

A memorandum of understanding (MoU) was signed during January 2015 between the two companies in presence of Prime Minister Narendra Modi. The Prime Minister said the move will help India to curb its steel imports.

“…Send iron out and get steel from outside. This would go on. But now this has to stop. We will make steel from the iron ore,” Modi said, adding that by utilizing indigenous resource of iron ore, India can be able to export steel in the international market.

There has been increase in coal production and supply during 2012-13. The details of targets of coal production and supply for 2011-12 and 2012-13 and corresponding achievements are given below.



Table No. 3

(in million tonnes)

Year Production

Target Production

Ach.

in %

Supply

Target Supply

Ach.

in %

2011-12 554.00 539.950 97.5 559.00 535.299 95.8

2012-13 574.40 557.707 97.1 580.30 569.767 98.2

In 2012-13, the domestic production was 557.707 million tonnes and the total domestic supply of coal was 569.767 million tonnes. In addition to the domestic supply of coal, the country imported 137.56 million tonnes of coal in order to meet the demand. This information was given by the Minister of State for Coal, Shri Pratik Prakash Bapu Patil in a written reply in Rajya Sabha on 19th August 2013. Thus it justifies that there is huge demand of Beneficiated Ore specially Iron Ore and Coal in the coming future.

2.6 Export Possibility

The project proponent is targeting only domestic market at present.

2.7 Domestic / Export Markets

There is a huge market in both domestic and export for the high grade beneficiated Iron Ore, Manganese Ore and coal.

2.8 Employment Generation (Direct and Indirect) Due to the Project

There will be direct employment of 30 including unskilled, semi skilled and highly skilled workman and officers including managerial staff.

Table No. 4 Manpower Details

Sl. No Category No.

1 Manager Production 1 No.

2 Engineer (Mech. & Process, Electrical & Instrumentation)

1 Nos.

3 Foreman cum control room operator 2 Nos.

4 Fitter cum Operator 2 Nos.

5 Helper 4 Nos.



6 Electrician 2 Nos.

7 Instrument mechanics 1 No.

8 Unskilled Labour 10 Nos.

9 Peon 2 No.

10 Chemist 2 Nos.

11 General Majdoor 3 Nos.

12 Total 30 Nos.



Chapter - 3

Project Description

3.1 Type of the Project Including Interlinked and Interdependent Project if any

The said Project is a new proposal of establishment of Iron Ore Beneficiation Plant (Wet Process), Manganese Ore Beneficiation Plant (Wet Process) and Coal Beneficiation Plant (Dry Process) at Village Raichhapal, PO : Khumjharia, Dist. : Sundergarh in Odisha State.

It is proposed by the proponent M/s. Choudhary Iron & Steel Industries.

There is neither any interlinked nor interdependent project.

3.2 Location (Map Showing General Location, Specific Location and Project Boundary & Project Site Layout) with Coordinates

The proposed project will be set up in village Raichhapal on the left side of NH-143 running from Banarpal to Ranchi and about 14kms from Vedavyas Chhak on way to Biramitrapur. Project Site Layout is shown in Map No. 1. And Location is shown in Map No. 2 part of Survey of India Topo sheet No 73B/11.

3.3 Details of Alternate Sites Considered and the Basis of Selecting the Proposed Site, Particularly the Environmental considerations gone into should be Highlighted

No site alternatives are considered as the site for the proposed project is the same where the proponent was having an existing Iron Ore Crushing Unit. Since adequate land is available to go for the said new project it will be possible to establish the proposed plant immediately after obtaining all clearances, efficiently, quickly and optimally. The site is in the close proximity to the source of ore, Iron Ore, Manganese Ore and raw coal which requires beneficiation / washing. Attributing to the vicinity of availability of ROM it reduces the transportation of low grade ores/ minerals to larger distances. The basic infrastructure facilities are adequately present for the proposed activity at the present site.

Number of mines and industries in Sundergarh, Keonjhar and Sambalpur districts are operating in the region within 10 to 30 kms radius. The proposed beneficiation plant aligns with the mining activities of the area in line with mineral conservation plan to upgrade the existing rejected iron ore and



upgrade high ash coal and will meet the increasing demand of high grade ore and minerals as well fossil fuel in this region.

Map No. 1 Project Site Layout



Map No. 2 Location Map (Marked in the Toposheet)



The Ib Valley Coalfield would serve as source of coal which lies between latitudes 21041’N and 22006’N and longitudes 83030’E and 84008’E . It covers an area of 1,375 square kilometres (531 sq mi). According to Geological Survey of India, the Talcher Coalfield has reserves of 38.65 billion tonnes, the highest in India. Ib Valley Coalfield has reserves of 22.3 billion tonnes, the third highest in India. This coalfield forms part of the large Gondwana basin that extends across several districts in adjoining Chhattisgarh. Ib Valley Coalfield is served by South East Central Railway. The main railway station for passenger traffic is Brajrajnagar on the Tatanagar-Bilaspur section of Howrah-Nagpur-Mumbai line. The area links to NH 200. Construction of the 52 km (32 mi) long Jharsuguda-Barpalli rail line is essential for transportation of coal from the Ib Valley Coalfield with a potential of 90 million tonnes per annum. This Coalfield is a part of large synclinal Gondowna Basin of Raigarh-Hingir and Chhattisgarh Coalfields (Mahanadi Valley) and forms its South Eastern most member. Coal potentiality of this fields was investigated as early as 1871-75 by Mr.V.Ball of GSI. Some works were also done by Mr.W.King during 1884-86. During 1900-01 exposures of various seams were found while constructing bridge over IB River on the Bombay Howrah Railway line. Further work was undertaken by Geological Survey of India. During 1977 CMPDIL entrusted the Directorate of Mining & Geology (Govt. of Orissa) for detail exploration. Barakar & Karharbari measures are the major coal bearing formations. Barakar formation contains as many as twenty carbonaceous horizons with quality ranging from E to G. These horizons have been clubbed and five seams have been identified in the area, namely Belpahar, Parkhani, Lajkura, Rampur & IB Seams. Parkhani seam is erratic in quality and thickness. It is generally not found as mineable. Belpahar seam occurs in the deep side of Lakhanpur OCP and mining operation in this seam is not foreseen in near future. Karharbari formation contain only thin coal bands below IB seam. Basic considerations in deciding the location of plant site are listed below in order of its significance.

Availability of necessary infrastructure such as transportation, communication, roads, water etc.

The proposed location is having proximity of raw material.

Skilled and unskilled manpower is easily available.

Investment climate is good.

Government policies are favorable.

The siting criteria are suitably met at this location



3.4 Size or Magnitude of Operation

The proposed project will be able to produce 4.5 Lakh TPA of High Grade Iron Ore (Calibrated and Lumps), 3.0 Lakh TPA of Saleable Iron Ore Fines and Tailings, 0.65 Lakh TPA of High Grade Manganese ore, 0.35 Lakh TPA Saleable Mn Ore Fines and Tailings and 4.35 Lakh TPA of Beneficiated / washed coal and 2.15 Lakh TPA of Saleable Coal fines and Rejects.

3.5 Project Description with Process Details (a Schematic Diagram / Flow Chart Showing the Project Layout, Components of the Project etc. should be given)

Iron Ore Beneficiation

Iron ore is a mineral which is used after extraction and processing for the production of iron and steel. The main ores of iron usually contain Fe2O3 (70 % iron, hematite) or Fe3O4 (72 % iron. magnetite). Ores are normally associated with unwanted gangue material. Grade of iron ore is usually determined by the total Fe content in the ore. Run of mines ores after dry or wet sizing, if it contains normally greater than 62 % of Fe, are known as ‘natural ore’ or ‘direct shipping ore’ (DSO). These ores can be directly used in the production of iron and steel. All other ores need beneficiation and certain processing before they are used in the production of iron and steel.

Low grade iron ores cannot be used as such for the production of iron and steel and need to be upgraded to reduce its gangue content and increase its Fe content. The process adopted to upgrade the Fe content of iron ore is known as iron ore beneficiation (IOB).

However, Iron ores from different sources have their own peculiar mineralogical characteristics and require the specific beneficiation and metallurgical treatment to get the best product out of it. Also for effective beneficiation treatment, effective crushing, grinding, and screening of the ore is necessary for which suitable crushing, grinding, and screening technologies are to be employed. The choice of the beneficiation treatment depends on the nature of the gangue present and its association with the ore structure. Several methods/techniques such as washing, jigging, magnetic separation, gravity separation, and flotation etc. are used to enhance the Fe content of the Iron ore and to reduce its gangue content. These techniques are used in various combinations for the beneficiation of iron ores. For beneficiation of a particular iron ore the emphasis is usually to develop a cost effective flow sheet incorporating necessary crushing, grinding, screening and beneficiating



techniques which are necessary for the upgrading of the iron ore. A typical flow sheet for iron ore beneficiation plant is shown in Fig 1.

Fig - 1 Process Flow Chart of Iron Ore Beneficiation Plant

Crushing, grinding and screening technique

The purpose of grinding and regrinding is to reduce the ore to a size small enough to liberate and recover the valuable minerals. The crushing, grinding and screening systems of an IOB plant are to be designed taking into account the requirements of the downstream beneficiation processes. The crushing units will include primary, secondary, tertiary and quaternary crushing systems. Jaw, gyratory, cone, and roll crushers will be used for ore crushing.

Semi autogenous grinding and autogenous grinding circuits will be used for grinding the ore. Both rod mills and ball mills will be used for this purpose. Capital investment and operation costs of grinding equipment are high. Hence economics play a large part in planning for the degree of crushing and grinding performed to prepare ore for beneficiation. Other factors considered in determining the degree of crushing and grinding includes the value concentration of the ore, its mineralogy, hardness and moisture content. Closed circuit grinding minimizes over grinding of very friable ore normally found in the ore bodies of the region. The more the recirculation load the less is the over grinding of particles.



Washing and wet scrubbing

This process is primitive and widely used in lumpy iron ore processing to dislodge and remove friable and soft lateritic materials, fine materials and limonitic clay particles adhering to the ore. Wet scrubbing is useful in hard and porous ores, which invariably have cavity/pores filled with clayey material that need substantial removal.

Gravity separation

This technique is used where iron bearing minerals are free from associated gangue materials. The specific gravity of iron bearing minerals is usually higher than the specific gravity of gangue materials. Effectiveness efficiency of the gravity separation depends largely on to proper crushing and sizing of the ore so as to ensure a proper size feed to the gravity separation equipment and also removal of slime from the equipment. A large numbers of equipment/processes functioning on gravity separation principle are available. Some of them are described below.

Dense media separation – The process is also known as heavy media separation. The process is used for coarse ores (size range 3mm to 50 mm. Ground ferro- silicon of -300 mesh size is used as suspension to create a parting density of 3-3.2 which is sufficient for gangue materials to float and get separated. The suspension material is recovered by using low intensity magnetic separators (LIMS). Feed for the dense media separation must be hard and compact with non porous gangue material.

Heavy media cyclone – The process will be used for iron ore fines with size range of 0.2mm to 6 mm. The cyclone type separator utilizes centrifugal as well as gravitational forces to make separation between ore and gangue material. Ground ferro-silicon of -325 mesh size will be used as a media in cyclone.

Jigging – Jigging is a gravity concentration technique where the iron ore is separated into light density fraction, medium density fraction and heavy density fraction. Size fraction of the iron ore used for jigging will be 0.5 mm to 30mm.

Spirals – Spiral concentrators are flowing film separation devices. General operation is a continuous gravitational laminar flow down on an inclined surface. The mechanism of separation involves primary and secondary flow patterns. The primary flow is essentially the slurry flowing down the spiral trough under the force of gravity. The secondary flow pattern is radial across the trough. Here the upper-most fluid layers comprising higher density particles move away from the



centre while the lower-most concentrate layers of higher density particles move towards the centre. Spirals require addition of water at various points down the spiral to assist washing of the iron ore, i.e. transporting away the light gangue from the dense ore. The amount of wash water and its distribution down the spiral trough can be adjusted to meet the operating requirements. Point control minimizes the total water requirements by efficiently directing water into the flowing pulp at the most effective angle. Feed size applicability is in the range of 0.3 mm to 1 mm. Spirals are normally operated at a pulp density of 25 % to 30 % solids.

Tables – Tables have wide range of application in gravity treatment of iron ores. Tables are normally used in cleaning and scavenging circuits. Feed size applicability is in the range of 0.3 mm to 1 mm. Spirals are normally operated at a pulp density of 25 % to 30 % solids.

Multi gravity concentrator – They are under development stage and are designed to treat fines and ultrafine particles of iron ore. They are useful in processing of valuables from slimes and tails.

Cyclones – Cyclones used for concentration of iron ores are of several types. These include hydro-cyclone, stub cyclone and heavy media cyclone. Cyclones are cost effective and simple in their construction. The main parts of a cyclone consist of cyclone diameter, the inlet nozzle at the point of entry into the feed chamber, vortex finder, cylindrical section and cone section. They have proper geometrical relationship between the cyclone diameter, inlet area, vortex finder, apex orifice, and sufficient length providing retention time to properly classify particles. As the feed enters the chamber, a rotation of the slurry inside of the cyclone begins, causing centrifugal forces to accelerate the movement of the particles towards the outer wall. The particles migrate downward in a spiral pattern through the cylindrical section and into the conical section. At this point the smaller mass particles migrate toward the center and spiral upward and out through the vortex finder, discharging through the overflow pipe. This product, which contains the finer particles and the majority of the water, is termed the overflow and should be discharged at or near atmospheric pressure. The higher mass particles remain in a downward spiral path along the walls of the conical section and gradually exit through the apex orifice.

Magnetic separation

Magnetic separation technologies will used to take the advantage of the difference in the magnetic properties for separating iron ore from the non magnetic associated gangue materials. Magnetic separation can be conducted in either a dry or wet environment, although wet systems are more common.



Magnetic separation operations can also be categorized as either low or high intensity. Low intensity separators use magnetic fields between 1000 to 3000 gauss. Low intensity techniques are normally used on magnetite ore as an inexpensive and effective separation method. High intensity separators employ fields as strong as 20,000 gauss. This method will be used to separate weakly magnetic iron ores such as hematite, from nonmagnetic or less magnetic gangue materials. Other factors important in determining which type of magnetic separator system will be used include particle size and the solids content of the ore slurry feed.

Typically magnetic separation involves three stages of separation namely (i) cobbling, (ii) cleaning/roughing, and (iii) finishing. Each stage will employ several drums in a series to improve separation efficiency. Each successive stage works on finer particles as a result of the removal of oversized particles in earlier separations. Cobblers work on larger particles and reject substantial percent of feed as tails.

Flotation process

Flotation process uses a technique where particles of one mineral or group of minerals are made to adhere preferentially to air bubbles in the presence of a chemical reagent. This is achieved by using chemical reagents that that preferentially react with the desired mineral. Several factors are important to the success of flotation activities. These include uniformity of particle size, use of reagent compatible with the mineral, and water conditions that will not interfere with the attachment of the reagents to the mineral or the air bubble.

Flotation is primarily used to upgrade concentrates resulting from magnetic separation.

Chemical reagents used are mainly of three main groups namely (i) collectors/amines, (ii) frothers, and (iii) antifoams. Reagents will be added in a number of forms which include solid, immiscible liquid emulsion and solution in water. The concentration of reagents will be closely controlled during conditioning since adding more reagent than needed retards the reaction and reduce efficiency. Factors which affect conditioning include thorough mixing and dispersal of reagents through the pulp, repeated contact between the reagents and all of the relevant ore particles, and time for the development of contacts with the reagents and the ore particles to produce the desired reactions.

Manganese Ore Beneficiation

Beneficiation method of manganese oxide ore takes reselection as primary.. Weathering-type manganese oxide ore contains large amount of slime and fine ore, the production of washing using a method of re-election. Run-of-



mine ore after ;ore wash to remove slime, the net proceeds of mine, and some products can be used as ore, and some need to use shaker jig and re-election and so on. Overflow washing sometimes need to re-election or strong magnetic and other methods to further recovery. Some oxidation of primary sedimentary manganese ore, due to the exploitation of the poor, and the production of a heavy-medium and re-election jig remove gangue, the ore block.

Oxidation of iron manganese ore, iron mineral is limonite. Iron and manganese are difficult to re-elect, floater or strong magnetic separation, magnetic separation is needed to restore the roasting method. Ore-wash

一

Manganese carbonate

一 Re-election are adopted on industries.

Sedimentary carbonate manganese ore, the main material is manganese rhodochrosite, Ca rhodochrosite, calcite and siderite manganese such as manganese ore; gangue minerals are silicate and carbonate; has often accompanied by Health and impurities such as sulfur and iron. Ore is generally more complex, manganese complex embedded thin cloth to several micron particle size, dissociation is not easy, often difficult to get a higher grade concentrate

Carbonate manganese ore beneficiation has less production practice to study the strong magnetic separation, heavy media, such as ore dressing and flotation methods. Some of sedimentary manganese ore carbonate content, industry: the use of carbonaceous shale, pyrite, and manganese were the order of priority of the flotation process. Some hydrothermal carbonate manganese ore containing lead and zinc, used a strong magnetic flotation process. Some sulfur-rich manganese ore, manganese ore is the main sulfur manganese, roasting methods can be used in addition to sulfur. Some carbonate-rich manganese ore production roasting method used to remove volatile components, has been refined ore.

Manganese oxide and carbonate manganese ore contain ore which is difficult to select, that manganese and iron, phosphorus, or gangue are closely symbiotic, disseminated grain size is very fine, which is difficult to sort, method of smelting can be considered to treat. For example, high manganese slag method dealing with high-phosphorus and ferri manganese,ore, nitric acid leaching method producing active manganese dioxide and electrolytic method producing manganese etc. have been put into industrial production, In addition, calcium dithionate method and bacterial leaching method are under study. Fig 2 shows the Manganese Floatation Beneficiation Flow Diagram.



Fig – 2

Manganese Floatation Beneficiation Flow Diagram

Coal Beneficiation (Dry Process) :

There are different types of dry cleaning processes for coal beneficiation. Hand picking of gangue minerals or shale in coarse size is one of the simplest, oldest and labour intensive techniques of dry cleaning processes. The other dry cleaning techniques are mechanical methods (screening, classifier, gravity concentrations, heavy media separation etc.), magnetic separation, electrostatic separation, etc. These processes depend on the differences in physical properties between coal and gangue minerals such as density, size, shape, lusterness, magnetic conductivity, electric conductivity, radioactivity etc. These methods have both advantages and disadvantages. Air dense medium fluidized bed separation is one of the dry beneficiation processes that would offer benefits compared to other dry beneficiation processes. The factor used to assess the main processes under consideration is the cost per heat unit delivered to the power station. This factor takes into account the benefit of reduced transport costs due to lower moisture product.



AIR DENSE MEDIUM FLUIDIZED BED BENEFICIATION (SEPARATION) PROCESS--(ADMFB PROCESS) is selected for the proposed coal beneficiation. The air dense medium separation uses a dense fluidized medium of air and fine magnetite particles for beneficiation of any material. By means of a two phase gas-solid pseudo-fluid separating medium, the light and heavy particles stratify in the fluidized bed according to their individual densities. The bed density is more or less same throughout fluidizing region. As the bed density of medium is presumed to be equal to the separating density and the distribution of pressure in fluidized bed is the same as in the static fluid, the motion of particles in the bed has been considered to explain the mechanism of the beneficiation process.

PRINCIPLE OF AIR DENSE MEDIUM FLUIDIZED BED SEPARATOR It is known that the general beds of particles fluidized by liquids behave very differently from those fluidized by gases. In case of fluidized by liquid, it almost behaves homogeneous manner with increasing liquid flow rate, whereas gas beds are characterized by existence of bubbles. When fine powder is fluidized by gases, the bed expands homogeneously up to a certain point over a range of gas velocity extending well beyond minimum fluidization at which bubbles start to appear. The void fraction of the dense phase is greater than at incipient fluidization where the velocity of the gas increases, then the homogeneous or particulate system transfers to heterogeneous or aggregate fluidization.

SEPARATION MECHANISM WITH AIR DENSE MEDIUM FLUIDIZED BED In dry air dense medium fluidized bed separator, a medium is created by suspending solid particles in an upward direction of air flow. This acts in the same way as hydraulic dense medium separator, allowing clean coal to float to the surface of the medium and rejects to sink. By means of a two phase gas-solid pseudo-fluid separating medium, the light and heavy particles stratify in the fluidized bed according to their individual densities. The bed density is more or less same throughout fluidizing region. As the bed density of medium is presumed to be equal to the separating density and the distribution of pressure in fluidized bed is the same as in the static fluid, the motion of particles in the bed has been considered to explain the mechanism of the beneficiation process. The forces affecting a coal particle immersed in a fluidized bed are gravity, pressure, frictional drag forces between air and coal particle, air and medium particle and medium and coal particle. It is the fluid like characteristics of the air dense medium fluidized bed that separates the heavy and light particles.



The position of coal particles in the bed depends on the relative velocity between the coal particle and medium solids. Separation efficiency is generally decided by the motion of the coal particles (i.e., misplacing effect of viscosity) and the velocity of medium solids (misplacing effect of motion). At too low gas velocity the activity of medium solids is weak, which results in a higher misplacing effect of viscosity. Moreover, when the medium of solids are not well dispersed and gas cannot be uniformly distributed in the bed, the misplacing effect of motion is also larger in some areas of bed. At too high gas velocity, back mixing of the medium solids caused by gas bubbles is enhanced and the misplacing effect of motion will also be intensified. With decrease of coal size, the specific surface increases and the terminal velocity of coal particle decreases, resulting in the increase of ratio of drag to gravity exerted on the coal particle and the increase of the misplacing effect of both viscosity and motion. Therefore, the gas velocity of fluidization should be chosen according to the optimal velocity for the separation of feed stock with minimum size.

3.6 Raw material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and finished product.

The raw material required for the project is Low grade Iron Ore, Manganese Ore and Raw Coal. The quantity is 7.5 Lakh TPA Iron Ore, I.0 Lakh TPA Manganese Ore and 6.5 Lakh TPA Coal. Iron Ore and Manganese will be sourced from mines located in Keonjhar and Sundergarh district. And the coal for the project will be sourced from the Coal Mines of Mahanadi Coalfields Limited (MCL) located in Sambalpur/Sundargarh district.

3.7 Resource Optimization / Recycling and Reuse Envisaged in the Project, if any, should be briefly outlined.

Operation will be carried out strictly as per the detailed Project Report with a view to optimize all resources available.

3.8 Availability of Water, Its Source, Energy / Power Requirement and its Source

Power: The total power requirement of will be 1.1 MVA. Power will be provided by the Orissa State Electricity Board (OSEB) subsidiary known as WESCO. The power will be taken from Biramitrapur Substation which is at 8 km distance from the project site. Voltage level of the power provided by the State Grid is 33 KV. This 33 KV power is stepped down at plant premises by



installing a 33/0.415 KV substation. Then the desired 415 V power will be fed to the MCC room which distributes it to the various equipments. Power back up is being provided by one 500 KVA silent type Diesel Generator sets. Water: Water requirement for the industry is broadly divided in the following categories depending on the use and type of industry etc.

A. Industrial requirement:

i) Make -up for the water system loss in

ii) Horticulture use for maintaining green belt

iii) Environmental maintenance

B. Domestic use for Drinking, personal hygiene

a) Plant manpower.

A. Industrial requirement:

Water system for the proposed Iron Ore Beneficiation Plant shall comprise the following:

- Makeup water

- Re-circulating water system

- Drinking water system

- Dust suppression system. Besides the above, provisions are also made for evaporation loss, transmission loss, process loss etc. The estimated makeup water requirement to replenish the process and treatment losses for the unit are given below.

Iron Ore Beneficiation:

Make-up water system: For the proposed plant, the estimated make–up water requirement for the plant is 9.50 cum / hr. Raw river water will be collected through infiltration gallery and intake well located on the river bank and pumped by means of two (2) (one-standby) vertical turbine pumps of suitable capacity. The river water is used to the raw water treatment plant located at the plant site, comprising two (2) flash mixtures, two (2) clari-flocculators etc. for treatment of raw river water. The clarified water is stored and pumped by means of two (2) (one-standby) pumps of suitable capacity to a ground storage reservoir, which provides storage of make-up water for three months. Make up water to the plant re-circulating system, once through system, dust suppression etc. are supplied from on-



ground reservoir by means of three (3) nos. pumps (one standby) of suitable capacities.

The losses in the cooling tower, system and other once through uses shall be replenished from the ground reservoir by providing suitable tapping and feeding the cold wells of the re-circulating system.

The estimated Make-up water requirement to replenish the process and other losses for the facilities including drinking and sanitary are given below:

Table-5 Break-up of Make-up Water Requirement in Iron Ore Beneficiation plant

Sl. No Type of unit Water Quantity(m3/hr)

Remark

1 Process 7.8125 -

2 Dust suppression 0.250 Recycled water can be used(-)

3 Drinking/Washing 0.600 -

4 Greenbelt development 0.25 Recycled water can be used(-)

Total 8.4125 -

5 Loss 5% 0.421 -

Grand Total 8.833 Say 9.00

9.0cum/hr = 144 cum/day

Dry Coal Beneficiation Process

As it is dry process no water is required in beneficiation process directly. However, because of huge generation of tiny coal particles & dust enormous water is required for sprinkling in haul road, internal road & processing area. Besides the above, water is also required to be sprinkled on coal in stockyard to protect it from fire due to sun & exposed to air. Capacity of the proposed plant is 1.0 LT/A coal which is the principal raw material for the plant contains about 20% as dust, fines etc. During process this quantity is washed away resulting only 80% as the actual annual capacity.

The water demand of the plant is about 41Cum/day for 16hours running time as calculated below. Requirement of makeup water for different units such as



sprinkler and dust suppression, , green development, office and domestic use etc. has been carefully calculated considering the most economical and effective use. Besides the above, provisions are also made for evaporation and transmission loss, etc. The estimated makeup water requirement to replenish the process and treatment losses for the unit is given in table below.

i. Greenbelt: Plantation & greenbelt development is a primary criterion in every process/ manufacturing unit where minerals, mines product are raw material. Two basic reasons for plantation/ greenbelt are:

i. To keep the surroundings & environment eco friendly.

ii. To check soil erosion & raise water table in the area. The plant species suitable for green belt development need to be selected based on the following criteria.

Fast growing

Thick canopy cover

Perennial and evergreen

Large leaf area index

High sink potential

As per guide lines of MoEF, greenbelt area should be at least 1/3rd of net area in premises.

Water requirement for Greenbelt Assuming area of iron ore beneficiation plant = 1.50acres (out of total 7.81acres) = 6070 Sqm. Assuming area of Coal beneficiation plant =1.50acres (out of total 7.81acres) = 6070 Sqm Area of Manganese ore beneficiation plant =1.20acres (out of total 7.81acres) = 4856 Sqm Total for Beneficiation Plants = 16996 Sqm



Roads, pavements & Built up area= (654.86+214.54) Sq m =869.40Sqm Raw material stock yard =2000Sqm Product stockyard =2000Sqm Net area= (31606.00-16996.00-869.40-4000) Sq m =9740.60Sq m Area left for future expansion out of above net area = 4000.00Sqm Thus, greenbelt area =5740.6Sqm=1.42 No of saplings required (medium growth) =1000/Acre Total no of sapling =1.42x1000=1420. Assuming mortality rate as 15%

No of saplings required=1420x1.15 =2130.

No of irrigating days = 245/year (Non monsoon period)

No of watering/day = 03

Rate of watering = 1.litre/once /sapling

Water required = 2130x1.0litre x3 = 6.39 Cum/day Dust suppression:

As per CPCB guidelines sufficient watering is required on haulage road and

raw material yard in the plant premises so that dust and fugitive particles

should be within ambient level so that there would be no respiratory health

problem to the workers. Therefore, frequent sprinkling is required for this

purpose. Besides that, sprinkling is also required for the approach road to

plant.

Presently there is about 31606 Sq.m of plant premises out of which road, paved area is about (4000+654.86+4000) =8654.86Sqm,

As per MoEF norms, minimum daily three times watering @1litre/once/sq.m is

required. Thus, water requirement is 8654.86x3x1lit/day = 25.964 cum/day

ii. Office, drinking Consumption No of staff including workers = 50 Consumption = 50x135litres/day= 6.075Cum/day



Total consumption = (6.39+25.964+6.075) = 38.428Cum/day Add 5% for seepage loss, evaporation loss, theft =1.921Cum/day Total = 40.349Cum/day, Say 41.00 Cum/day

Manganese Ore Beneficiation

The quantity of water required for manganese beneficiation is computed as 48

cum/day as proposed by consultant.

Thus, gross water requirement for all the three beneficiation process and

other requirement = (144+41+48) cum/day=233 cum/day

Availability of Water:

Sundar Nallah is a small tributary of river Sankha, which ultimately forms river Brahmani at Vedavyas. The total catchment of the nallah is about 27sq.km at proposed drawl point. As there is no direct gauge discharge measuring arrangement/device across Sundar nallah the discharge of Sundar nallah is computed by area proportion method by considering the discharge data of G.D station at Mandira dam site for Sankha river. The calculation is enclosed in excel sheet. This data has been utilized considering its proximity to the point of drawl and similar catchment characteristics. Hence, the water requirement for the plant can be fulfilled by surface water either from “Sundar nalla” or from ground water through bore well.

3.9 Quantity of Wastes to be generated (Liquid and Solid) and Scheme for Their Management / Disposal

During construction, waste generated is limited to levelling of any low lying areas within the plant premises. Plant would operate on zero discharge concepts. Thus no waste water discharge is envisaged in the said project

3.10 Schematic Representations of the Feasibility drawing which give information of EIA Purpose.

Purpose of preparation of EIA is for prior environmental clearance required a s per EIA notification dated 14 th September, 2006 and amended thereafter as the project proponent proposed for establishment of Iron Ore Beneficiation Plant (Wet Process) 7.5 Lakh TPA capacity, Manganese Ore Beneficiation Plant (Wet



Process) 1.0 Lakh TPA capacity and Coal Beneficiation Plant (Air Dense Medium Fluidized Bed Separation – Dry Process) 6.5 Lakh TPA capacity.

The proposed schematic representation provides information for preparation of EIA is as per the following drawing in Fig - 3.

Fig- 3

(EIA Process for Env Clearance of A Category Mineral Beneficiation Project)



Chapter – 4

Site Analysis

4.1 Connectivity The said Project is a new proposal of establishment of Iron Ore Beneficiation Plant (Wet Process), Manganese Ore Beneficiation Plant (Wet Process) and Coal Beneficiation Plant (Dry Process) at village Raichhapal, PO : Khumjharia, Dist. : Sundergarh in Odisha State. Kuarmunda Tehsil in Sundargarh district of Odisha state on the left side of NH-143 running from Banarpal to Ranchi and about 14kms from Vedavyas Chhak on way to Biramitrapur. (Survey of India Toposheet No 73B/11). The nearby villages are Kharlabud, Kumjharia, Ratakhand etc. Nearest railway station Biramitrapur under S.E railway is about 10km from plant site. The site is ideally located from transportation & communication point of view as it enables both inward transportation of raw materials and outward supply of plant produce.

The proposed site is accessible from road and rail transport.

4.2 Land Form, Land Use and Land Ownership The total land requirement is of 9.81 Ac. The total land has already been acquired and is owned by the project proponent.

The land available for the project is sufficient for the expansion. The breakup of the land use for the project area has been described in the Table No. 6

Table No. 6 Break up of Land use

Land use Area (Acre)

Plant area 4.20

Raw coal stock yard 2000 Sqr Mtr

0.50

Clean coal stock yard 0.50

Water Reservoir

1.37 Administrative building

Parking and Rest room area

Green belt area 3.24

Total 9.81



4.3 Topography

The topography or the physical features of the study area are shown in the topographical map. The topographical map of the study area reveals that the area is a combination of plain, hilly undulating terrain. The contour of the study area varies from 180 meter aMSL to 428 meter aMSL.

The Reserve forests, open jungle, Dense jungle, fairly dense sal forests, open sal forest, manmade plantation, fairly dense mixed jungles mainly sal, open mixed jungles, open ponds, wells, perennial rivers and its tributaries, etc., are the main physical or the topographical features in the area. Upper half of the study area, predominant by forest and hilly area.

The central part comparatively plain land. Adjacent to core area is mostly industrial. Some agricultural land is there towards the east and west of the study area. There is no such Ecologically Sensitive area as per Hon’ble Supreme Court Civil writ petition No.460 of 2004. Chadri Reserve Forest is in the east of Project site. Jugsai Reserve Forest is in the south east of Project site.

Important physical features in the study area are Brahmani River and its tributary Sankh and Koel. River Brahmani is flowing in South east direction . River Shank & River Koel are the main tributary of River Brahmani and both are flowing from west to east towards south of Project site. Mandiara Dam is at 06 Kms distance towards west South west of the Project site.

There is no national park/wild life sanctuary/biosphere reserve/ tiger reserve/ elephant reserve in the core (applied project area) and buffer zone (10 km radius of the project area). There is no endangered fauna like elephant, sloth bear, python etc in & around the project area. Nearest CRZ area is at Paradeep, which is more than 400 kms from the project area.

However, detail study and survey will be conducted during preparation of EIA/EMP report for the proposed project.

There is small nalla flowing adjoining to the proposed plant site named “Sundar nalla” a tributary of river Sankh flows at a distance of about 6 Km in southern side of the plant site serves as a major drainage system and is a perennial source having catchment area in Rajgangpur, Lathikata and Kuarnmunda block. It meets river Koel from Jharkhand to form river Brahmani at Vedvyas.



4.4 Existing Land Use Pattern (Agriculture, Non- Agriculture, Forest, Water Bodies (including area under CRZ)), shortest distances from the periphery of the Project to the periphery of the Forest, National Park, Wild Life Sanctuary, eco-sensitive areas, water bodies (distance from the HFL of the River), CRZ.

Existing land use is Industrial.

Distance of Various Physical Features from the Boundary of the Project Area

There is no national park/wild life sanctuary/biosphere reserve/ tiger reserve/ elephant reserve in the core (project area) and buffer zone (10 km radius of the project area).

Jogisar RF is in south of project site at a distance 7.104 Kms.

Mudra RF is in south east of project site at a distance 8.28 Kms

Chadri RF is in south east of project site at a distance 4 Kms

Lassey RF is in north east of project site at a distance 1.5 Kms

Kudabera Surface Water Body is in north east direction at 4.4 Kms distance.

Jhungara RF is in north east of project site at a distance 2.66 Kms.

Jalingbera RF is in north of project site at a distance 4.4 Kms.

Ghagri RF is in North West of project site at a distance 2.1 Kms.

Ratakhandi RF is in West - Southwest of project site at a distance 5.0 Kms.

Jharbeda RF is in West - Southwest of project site at a distance 6.21 Kms.

Mandira Reservoir South west of project site at a distance 8.5 Kms.

Sankh River in South of project site at a distance 9.17 Kms.

Koel River in South East of project site at a distance 9.0 Kms 4.5 Existing Infrastructure. For establishment and successful operation of a coal washery it is imperative to ensure availability of the following infrastructure:

i) Availability of principal raw materials, viz., Iron Ore, Manganese Ore and Raw Coal, and its proximity to the plant to reduce cost of transportation.



ii) Road / Rail head connection so that raw materials and products can be easily and economically transported.

iii) Availability of water.

iv) Permanent and reliable source of power.

v) Land for Plant installation, storing of products and disposal of rejects.

Since the raw material shall be required in bulk quantities, the location of the plant shall be nearer to the mines to save in transportation cost and to ensure consistent supply of raw coal.

Necessary road connection is already available between the plant site and nearby coal mines.

Power supply can be easily met from the existing grid / DG Set. Sufficient land required for expansion of coal washery is available at the plant site.

4.6 Soil Classification These soils include Red sandy soil, Red earths and Red black soil. These soils are deficient in nitrogen and P2O3. Both total and available K2O are fairly adequate and pH varies from 6.5 to 7.3. The reddish color is due to oxidation of original ferruginous. The regional area represents conspicuous geomorphic variations comprising of denudational hills (both large and Small), buried pediments (shallow and medium), valley fill, residual valley hills, inselbergs, pediment, lateritic upland etc. The area belongs to Brahmani river basin and drained by river Brahmani and its tributaries like Sankha and Koel.

4.7 Climate data from Secondary Sources Meteorological conditions prevailing at any geographical area play an important role in analyzing its existing air quality and the environmental conditions. Climate, weather and other meteorological parameters generally influence and also alter site-specific activities. Meteorological data, which is averaged over thirty years of data from 1961 to 1990 by Indian Meteorological Department will be considered while preparing EIA/ EMP report as a secondary data. And on-site meteorological data of standard parameters such as wind speed, wind direction, temperature, relative humidity and rain fall for the study period will be collected.

The climate of this region is mainly tropical and is influenced to some extent by the conditions in Bay of Bengal.

Southwest monsoon season starts from June and extends upto September . The total annual rainfall of the project site is about 936 MM out of which maximum rainfall is observed in the monsoon season only. The summer is



peak during April –May with temperature as high as 46.00C in May. Winter prevails from December to January. The minimum average temperature recorded during January is 6.9 0C. The relative humidity varies from 31 % in April to 90 % in July.

4.8 Social Infrastructure available

Criteria are suitably met at this location.

Nearest Populated village Kuarmunda is at 6.5 kms from the project site.

Nearest railway station Biramitrapur under S.E railway is about 10km from plant site.

Nearest town Rourkela is at a distance of 15 kms from the project site.

Necessary infrastructure such as transportation, communication, roads, water etc. are also available.

The proposed location is having proximity of raw material.


Nearest Road is NH-143 at a distance of 1.5 running from Banarpal to Ranchi and about 14kms from Vedavyas Chhak on way to Biramitrapur.

Hospitals, Schools, Colleges, Police Station, Fire Station, Temples, Forests, Fishery, banking, Revenue, Judiciary Local bodies are also available in the area.



Chapter – 5

Planning Brief

5.1 Planning Concept (type of industries, facilities, transportation etc.) Town and Country Planning / Development Authority Classification

The said proposal is a new proposal. The project does not have any plan for construction of its own town ship for its employees. Mostly local villagers are and will be employed. They are and will be commuting from local areas. Public and self transport facilities are used for commuting from their residence to the project site.

5.2 Population Projection

Present population in the district as a whole is 2080664 as per 2011 Census report (Provisional). Present Population in the study area will be given in detail EIA report along with other demographic information. Growth rate (2001 – 2011) in the district (Sundargarh) is around 13.64 % as per 2011 Census report.

5.3 Land Use planning (breakup along with green belt etc.). The total land requirement is of 9.81 ha. The whole of land already acquired and is owned by the Project proponent.

The land available for the project is sufficient for the said proposed project.

The plant lay out is shown in Map No.1 in previous section.

5.4 Assessment of Infrastructure Demand (Physical & Social)

There will be requirement of water, electricity and raw material.

Public road will be used for transportation.

Permission of water is required.

Local Grid will be used.

Local market will be used for office stationary and daily requirement.

Public School & Colleges will be used for employees’ children’s education.

Govt. hospitals will be used in some extent.



5.5 Amenities / Facilities

Criteria are suitably met at this location. Nearest Populated village Kuarmunda is at 6.5 kms from the project

site. Nearest railway station Biramitrapur under S.E railway is about

10km from plant site. Nearest town Rourkela is at a distance of 15 kms from the project

site. Necessary infrastructure such as transportation, communication,

roads, water etc. are also available. The proposed location is having proximity of raw material.


Nearest Road is NH-143 at a distance of 1.5 running from Banarpal to Ranchi and about 14kms from Vedavyas Chhak on way to Biramitrapur.




Chapter – 6

Proposed Infrastructure

6.1 Industrial Area (Processing Area)

The said Project is a new proposal of establishment of Iron Ore Beneficiation Plant (Wet Process), Manganese Ore Beneficiation Plant (Wet Process) and Coal Beneficiation Plant (Dry Process) and will be established in the own land of the proponent where the proponent had established earlier a Iron Ore Crusher Plant at village Raichapal, Panchayat : Khumjharia, Dist. : sundergarh in Odisha State. Kuarmunda Tehsil in Sundargarh district of Odisha state.

No extra land is required for expansion. The land land is industrial land.

6.2 Residential Area (Non – Processing Area) No residential facilities envisaged in the project.

6.3 Green Belt 33% of the total area will be covered under plantation. The local species are and will be selected for plantation.

The green belt is planned to be completed in two years. Plantation will be carried out from the outer zone followed by the middle zone and finally the inner zone will be planted.

Maintenance of green belt

The green belt will be protected by barbered wire or natural fence.

Any dead plants will be regularly removed and replaced.

Proper watch and ward arrangement will be done.

Regular watering at appropriate intervals will be done and wastewater from the industry shall be utilized

6.4 Social Infrastructure Criteria are suitably met at this location. Nearest Populated village Kuarmunda is at 6.5 kms from the

project site. Nearest railway station Biramitrapur under S.E railway is about

10km from plant site. Nearest town Rourkela is at a distance of 15 kms from the project

site.



Necessary infrastructure such as transportation, communication, roads, water etc. are also available.

The proposed location is having proximity of raw material. Skilled and unskilled manpower is easily available. Nearest Road is NH-143 at a distance of 1.5 running from Banarpal

to Ranchi and about 14kms from Vedavyas Chhak on way to Biramitrapur.


6.5 Connectivity (Traffic and Transportation Road / Rail / Metro / Waterways etc.)

The said Project is a new proposal of establishment of Iron Ore Beneficiation Plant (Wet Process), Manganese Ore Beneficiation Plant (Wet Process) and Coal Beneficiation Plant (Dry Process) and will be established in the own land of the proponent where the proponent had established earlier a Iron Ore Crusher Plant at village Raichapal, Panchayat : Khumjharia, Dist. : sundergarh in Odisha State. Kuarmunda Tehsil in Sundargarh district of Odisha state.

The proposed site is accessible from road and rail transport.

6.6 Drinking Water management (Source & Supply of Water). The total requirement of water including drinking water would be 233 m3/day.

Sundar Nallah is a small tributary of river Sankha, which ultimately forms river Brahmani at Vedavyas. The total catchment of the nallah is about 27sq.km at proposed drawl point. As there is no direct gauge discharge measuring arrangement/device across Sundar nallah the discharge of Sundar nallah is computed by area proportion method by considering the discharge data of G.D station at Mandira dam site for Sankha river. The calculation is enclosed in excel sheet. This data has been utilized considering its proximity to the point of drawl and similar catchment characteristics. Hence, the water requirement for the plant can be fulfilled by surface water either from “Sundar nalla” or from ground water through bore well.

Sewerage System No residential facilities envisaged in the project. However, septic tank with soak pit will be provided for the employees of the project which will be designed as per BIS specification.



6.7 Industrial Waste Management (Liquid Effluent) Liquid effluent generation of the plant would be from Iron Ore and Manganese Ore Beneficiation Plant. But there will not be any discharge as it will be a closed re-circulation system.

6.8 Solid Waste Management

1. Solid waste will be mainly, Tailings from Iron Ore beneficiation Plant. Which will be sold 100% after processing along with fines.

2. Solid waste like waste cottons, empty bags, rejected gaskets, empty bottles, discarded jerry canes, steel structures and rejected spares of process equipments etc, generated may have scarp vale and shall be disposed off with price realization.

3. Used oil will be disposed to authorized reprocessing units having valid authorization from Orissa State Pollution Control Board.

6.9 Power Requirement & Supply / Source The total power requirement of will be 1.1 MVA. Power will be provided by the Orissa State Electricity Board (OSEB) subsidiary known as WESCO. The power will be taken from Biramitrapur Substation which is at 8 km distance from the project site. Voltage level of the power provided by the State Grid is 33 KV. This 33 KV power is stepped down at plant premises by installing a 33/0.415 KV substation. Then the desired 415 V power will be fed to the MCC room which distributes it to the various equipments. Power back up is being provided by one 500 KVA silent type Diesel Generator sets.



Chapter – 7

Rehabilitation and Resettlement (R & R Plan)

7.1 Policy to be adopted (Central / State) in respect of the project affected person including Home Oustees, Land Oustees and Land Less Labourers

No settlements exist within the project area. However, R & R Policy of Govt. of Odisha will be adopted wherever applicable and CSR activities will be adopted by the Project proponent as per the need.



Chapter – 8

Project Schedule & Cost Estimate

8.1 Likely date of Start of Construction and Likely Date of Completion (Time Schedule for the Project to be given).

It is expected to commission the Washery expansion within 18 months from the receipt of the all regulatory approvals.

8.2 Estimated Project Cost along with Analysis in terms of Economic Viability of the Project.

The project cost is budgeted at Rs. 1.10 Crores (Rupees Eleven Crores) and will be funded by financial institutes with promoters contribution.

Table No. 10 Environmental Cost for Environmental Protection

Sl. No. Particulars Cost

(Rs. In Lakhs)

1 Pollution control 75.00

2 Pollution monitoring 20.00

3 Occupational health 10.00

4 Green belt 5.00

Total 110.00



Chapter – 9

Analysis of Proposal (Final Recommendations)

9.1 Financial and Social Benefits with Special Emphasis on the Benefit to the Local People including Tribal Population, if any, in the area.

Most of the work force required for construction and operation of the proposed project will be employed from the surrounding areas. No rehabilitation and resettlement issues are involved in the proposed project.

The economic growth of the area in terms of employment generation and market-growth are the expected outcomes of the project. The project has an employment generation impact on skilled/ semiskilled/ unskilled category of manpower. The direct employment potential of the project is estimated as 30 persons for the proposed project. However, indirect employment potential will have major share in the regional economy, which is expected to be of high order. It is assumed that the generation of indirect employment would be multiple of direct employment.

The direct beneficiaries in this process would be the local producers and local people providing services. Therefore, the significant positive impact on employment and occupation is envisaged on account of

Better economic status of the community due to better earnings

Higher inputs towards infrastructural facilities due to establishment of plant

Enhancement of literacy due to improved educational facilities made available to the nearby backward village as a part of Corporate Social Responsibility of the company.

The general social development of the area, at least in restricted sense of the term, is expected due to the improvements in infrastructure and communication system. New facilities will be created to meet growing demand of the population. Due to proposed project, there will be development of communication facilities in the area. The plant site area will be equipped with sufficient infrastructural facilities including drinking water, toilets, sanitation facilities, dispensary facilities, etc.

Improvement in Socio-Economic Conditions

Employment: During operation, plant will generate direct employment. The preference will be given for local population for employment in the semi-



skilled and unskilled category. Indirect employment is created by the plant for supply of daily domestic goods.

Health and Safety Measures: The workers engaged in pollution generation area will be equipped with appropriate protective equipment.

Following measures will be adopted in the plant to keep check on the safety measures and health:

A periodic health check-up camp will be arranged for the workers in the plant for occupational diseases. All the employees will have to undergo medical check- ups at regular time interval to determine any impact on the health of employees due to the plant atmosphere.

Inspection and maintenance of pollution control systems regularly

All safety measures such as provision of safety appliances, imparting training, giving-of safety awards, display of posters with slogans related to safety will be taken

The workers exposed to noisy sources will be provided with ear muffs/plugs

Adequate facilities for drinking water and sufficient toilets will be provided for the employees

Social Welfare Measures: The Company shall earmark funds of 5 % of the total project Cost towards social development and welfare measures in the surrounding villages. These measures shall include funding for:

Repair and improvement of existing schools

Repair and improvement of health centres

Repair and improvement of community centres, building such as panchayat halls, baratghars, etc.

Conducting Awareness pro grams

Women and child development programs

Medical camps

Competitions and prizes

Drinking water availability efforts

Rain water harvesting measures

cisi -...

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