pre- feasibility report - welcome to...

PRE- FEASIBILITY REPORT

(In terms of provision of EIA Notification 2006)

For

Expansion of Maton Rock Phosphate mines from 0.18 MTPA to .5

MTPA

AT

MATON MINES, DISTRICT – UDAIPUR, RAJASTHAN

By

Hindustan Zinc Limited

Rajasthan

Submitted to

Ministry of Environment & Forest (MoEF)

New Delhi

May – 2012

Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA

1.0 EXECUTIVE SUMMARY

H

industan Zinc is India’s only integrated producer of Zinc and Lead and is

among the world’s leading zinc and lead producers with ore production

capacity of 9.75 million tonnes per annum. Its metal production capacity is

currently 1,064,000 tonnes per annum (879,000 tonnes per annum for Zinc

metal and 185,000 tonnes per annum for Lead metal) and associated by-

products i.e. Cadmium, Silver, Sulphuric acid etc. Hindustan Zinc Limited

(HZL) is Asia’s largest non-ferrous metal producer of Zinc and Lead and is

Head quartered at Udaipur, Rajasthan. HZL is world's second largest

integrated producer with a global share of approximately 6.0% in Zinc.

H

ZL has its operations in exploration, mining, ore processing, smelting and

refining of Zinc, Lead, Cadmium and Silver. It is also a major producer of

sulphuric acid as a by-product of Lead-Zinc metal processing. HZL also has

large investment in wind energy having capacity of 273 MW and thermal

power generation of 474 MW.

HZL also has Rockphosphate mining with an annual capacity of 0.18 million

tonnes.

T

he Maton mine is an operating mechanized opencast mine located at Village

Maton, Tehsil Girwa, District Udaipur, Rajasthan. It is located at about 12 km

southeast of Udaipur at a latitude 2432’34’’ and longitude 7347’30’’ and

falls in the Survey of India toposheet No. 45H/14. The Phosphate deposit of

Maton is located in a hill, which trends NE-SW. Site is well connected from

two sides by asphalt road from Udaipur. The nearest airport is at Dabok about

12 Km NW of the project site. The nearest railway station is Rana Pratapnagar

which is 8 km to the NW of Maton.


T

he instant proposal is for expansion from 0.18 million TPA to 0.5 million TPA

of ore production from its Maton mine of Rock Phosphate.

E

nvironment Clearance was granted by MoEF for 0.18 million TPA ore

production from Maton mechanized Opencast mine vide letter no.J-

11015/169/2009-IA.II (M) dated 17.03.2010. Consent to operate was granted

by Rajasthan SPCB for establishment of mine and associated structure vide

letter no. F(Mines)/Udaipur(Girwa)/13(1)/2009-2010/5608-5612 dated

26.11.2010 and F(Mines)/Udaipur(Girwa)/13(1)/2009-2010/1116-1120 dated

18.05.2011. The mining operations are being carried out as per the above

permissions.

2.0 INTRODUCTION OF PROJECT

2.1 Identification of Project and Project Proponent

2.1.1 Identification of Project

The deposit was discovered by the Geological Survey of India (GSI) in 1966/67.

There after an exploration program for the assessment of the deposit was under

taken. Based on the finding of GSI, HZL took over the lease on 17.03.1970 for a

period of 20 years with a view to develop the deposit as a captive mine for

meeting the in-house requirement of Rock Phosphate for the zinc smelter Debari

Udaipur.

Maton Rockphosphate mine have been engaged in the mining of Phosphorite ore

since inception. The initial lease area of 247.96 ha. was granted on 17.03.1970.

Subsequently the lease was renewed after the first approval period for ten years

w.e.f. 16.03.1990 and thereafter was granted an extension as second approval over

a reduced area of 143.13 ha (due to surrendering of Forest land) for a further

period of ten years w.e.f 16.03.2000. The application for further renewal has been

applied for and is under process of renewal with state Govt.


The mine was non-operational during 2001-2009. However, there has been an

upsurge in the demand of rockphosphate since 2007 which encouraged the

company to review the economics of reopening of the mine in 2009. The consent

to operate under Air and Water Act is granted by Rajasthan SPCB.

Clearance was granted by MoEF for 0.18 million TPA ore production from Maton

mechanized Opencast mine vide letter no.J-11015/169/2009-IA.II (M) dated

17.03.2010. Consent to operate was granted by Rajasthan SPCB for establishment

of mine and associated structure vide letter no.

F(Mines)/Udaipur(Girwa)/13(1)/2009-2010/1116-1120 dated 18.05.2011. Ever

since, the mine is in operation and operating to its rated capacity. The instant

proposal is for expansion from 0.18 million TPA to 0.5 million TPA of ore

production from Maton mine.

In India the economy being predominantly based on agriculture, the fertilizer

application to the cultivable lands plays a pivotal role in getting desired crop

production. To meet, the food requirements of ever increasing population, as per

the Planning Commission, the utilization of NPK fertilizers is expected to increase

at the rate of 4% till 2017.

India is net importer of its Phosphate requirements to the extent of 90%.

Indigenous sources are able to cater upto the extent of 10%. The imports inter alia

includes Rock Phosphate, Phosphoric acid which is an inter-mediatory for

production of DAP and NPK fertilizers, Mono Ammonium Phosphate and Triple

super phosphates. Out of the above, India is importing about 7.5 MT of Rock

Phosphate balance is met by indigenous resources to the extent of about 1.5 MT

(of the different grades). Of the 1.5 MT, HZL is contributing 0.18 MT from Maton

Mines. Considering the huge gap between Demand and Supply, HZL is proposing

to increase / expand its capacity from 0.18 to 0.5 MT.

2.1.2 Project Proponent

Hindustan Zinc Limited (HZL) is the only integrated Lead & Zinc manufacturer in

India and owns captive Lead and Zinc mines that supply complete requirement of

Lead and Zinc concentrate for its smelters. HZL operates mechanized open cast


mine at Rampura Agucha as well as underground Mines at Rajpura Dariba,

Sindesar Khurd, and Zawar Mines in the state of Rajasthan with state of the art

technology to meet the ore requirement of its smelting operation. The smelting

capacity stands 1.064 Mt of metal (0.879 Mt of Zinc and 0.185 Mt of Lead) and

associated by-products i.e. cadmium, silver, sulphuric acid etc. are located at its

smelters at Debari, Vizag, Chanderiya and Dariba in Rajasthan and a Melting and

Casting plant each at Pantanagar and Haridwar in Uttarakhand.

The fiscal and financial performance of the company for the past five year has

shown remarkable upsurge. The company has come a long way with technology

upgradation, research and development activities, up keeping of environment,

safety and ecological balance besides exploring new business opportunities. HZL

is also having a Rock Phosphate Mine viz. Maton Mines operating at 0.18 MtPA

capacity. HZL is also having Captive Power Plants and Wind Farms..

2.1.2.1 Growth

The growth of HZL is shown below.

TABLE-2.1

GROWTH PROFILE OF HINDUSTAN ZINC LIMITED

Sr. No Description Installed Capacity, MTPA

2002 2011

1 Zinc Lead Ore Mining and Beneficiation 3.2 10.05

2 Zinc Metal Production 0.169 0.879

3 Lead Metal Production 0.043 0.185

4 Sulphuric Acid Production 0.352 1.373

5. Captive Power Plant (MW) Nil 474

6. Wind Power (MW) Nil 273

7. Rock Phosphate NIL 0.18


TABLE-2.2

EXISTING MINING & SMELTING UNITS OF HZL

2002 2011

Zawar Group of Mines Rajasthan Lead Zinc Ore MtPA 1.2 1.5

Rajpura Dariba Mine Rajasthan Lead Zinc Ore MtPA 0.631 0.9

RampuraAgucha Mine Rajasthan Lead Zinc Ore MtPA 1.35 6.15

Sindesar Khurd Mines Rajasthan Lead zinc Ore MtPA 0 1.5

Maton Mines Rajasthan Rock

Phosphate

MtPA 0 0.18

Zinc MT 59,000 88,000

Sulphuric Acid MT 104,000 419,000

Cadmium MT 160 320

Zinc MT 40,000 56,000

Sulphuric Acid MT 72,000 72,000

Cadmium MT 115 115

Zinc MT 70000 525,000

Lead MT 35,000 85,000

Sulphuric Acid MT 1,76,000 752,000

Silver MT 74 168

Cadmium MT 375 375

Zinc MT Nil 210,000

Lead MT Nil 100,000

Sulphuric Acid MT Nil 400,000

Zinc MT NIL 400,000

Lead MT NIL 100,000

Silver MT NIL 350

Haridwar Zinc Plant Uttrakahand Zinc MT NIL 250,000

Unit

A. Mining Units

Annual Capacity

B. Smelting Units

Debari Zinc Smelter Rajasthan

VizagLead-Zinc Smelter Andhra

Pradesh

UttrakahandPantnagar Melting and

Casting Plant

Name of the Unit State Main

Products

Chanderiya Smelter

Complex

Dariba Smelter Complex

Rajasthan

Rajasthan


2.2 Brief Description of Nature of Project

2.2.1 Nature of the Project

The present proposal is for expansion of the existing mechanised open cast rock

phosphate mine at Maton, Udaipur District, Rajasthan from the present capacity of

0.18 MTPA to 0.5 MTPA of ore. The project is a mechanised opencast

rockphosphate mine and is classified as “Category-A” by Ministry of

Environment & Forests, New Delhi as per the EIA notification dated on 14th

September 2006 and further Amendments.

2.2.2 Size of the Project

The proposed rockphosphate deposit lies within the lease area of 143.13 ha with

an estimated ore reserves and resource of approx. 5.2 million tons. The grades

varying from 18 – 33.0% of P205. The target production capacity of mine

proposed is 0.5 million TPA. The ore produced will have an average grade of 23-

26% of P205.

2.2.3 Location of the Project

Maton Mine is located at about 12 km southeast of Udaipur, at a latitude

24032’34’’ and longitude 73

047’30’’ , and falls in the Survey of India toposheet

No. 45H/14. The nearest railway station is Rana Pratapnagar on Udaipur -

Chittorgarh broad gauge line of North - Western Railway at about 8 km away.

The area is connected by airways with the airport being at Dabok which is at

about 12 km. NW on Udaipur-Chittorgarh National Highway No. 76. The Mine is

well connected on two sides by metalled road from Udaipur.

2.2.3 Mining Method

The deposit is being mined by mechanised open cast mining method with benches

of 10 m width and 10 m height. The bench height and width parameters have been

optimized after studies on geo-technical slope stability were carried out by

CIMFR. Dhanbad. The study recommended a slope of 45˚ in footwall ortho-

quartzite upto a depth of 100 m from highest point. Beyond 100 m the overall pit

angle along footwall is suggested to be revised according to local conditions. The

mining of the deposit shall continue with the same method. The present working


is confined in E1-W1& E2 lens only. The heavy earth moving machineries

deployed for mining are diesel operated. A crusher is installed for crushing the ore

to a size of <12 mm prior to dispatch.

The mine will continue to be operated as mechanized open cast mines with

increase in the size of the machinery being used to cope up the proposed expanded

mining / excavation requirements. The capacity of the existing crusher will be

increased to match the production. A geotechnical study would also be carried out

for optimum and safe bench parameters with depth.

2.2.4 Importance to the Country & Region

Indian Fertilizer industry is one of the vital industries for Indian economy, since it

manufactures a very critical raw material for agriculture .The main objective of

the fertilizer industry is to ensure the supply of primary and secondary nutrients in

the required quantities.

The fertilizer industry in India has performed a vital role in enabling the necessary

increase in the use of plant nutrients for achieving the objectives of self

sufficiency in food grains production and accelerated and continuous agricultural

growth.

Rock phosphate constituets as a basic feed stock for manufacture of phosphatic

fertiliser.

2.3 Need for the Project and its Importance to the Country

The basis for success in the phosphate business is access to lower-cost phosphate

rock, a resource that is geographically concentrated. China, the US and Morocco

together account for approximately two-thirds of world rock production and

Morocco alone typically supplies more than one-third of global exports.

Approximately 30 percent of global phosphate producers are non-integrated,

relying on imports or domestic purchases for their rock supply.

India has limited indigenous supply of phosphate rock and is the world’s largest

importer, accounting for about 30 percent of global trade.


The following graph shows the Projection of fertilizer nutrients for 12th Five year

Plan.

0

5

10

15

20

25

30

35

2012-13 2013-14 2014-15 2015-16 2016-17

('0

00

to

nn

es)

Year

k

P

N

Source: FAI, New Delhi

2.4 Import Vs Indigenous Production

The present production of Rockphosphate in India is estimated at 1.5 MT whereas

the imports are estimated as 7.4 MT. If we consider the likely increase in

consumption @4.8% per year, the gap between Demand and supply is likely to

increase further. Whereas, on accounts of limited resources available with

RSMML (which is the main producer) and MP Mining Corp, the overall domestic

production is likely to remain stagnant.

The following graph clearly suggests the Demand of Rock Phosphate.


0

1

2

3

4

5

6

7

8

2004 2006 2008 2010 2012

In M

illio

n T

on

ne

s

Year

Demand

Import

Indegeneous

Source: 1. Mineral and Metal Trading Corporation of India Ltd.

2. International Fertilizer Industry Association, Paris

2.5 Export Possibility

As India is already having scarcity of rockphosphate for its domestic

consumption, the chances of export do not exists in near future.

2.6 Domestic and Export Market

India has very limited resources of Rock Phosphate as against the Demand. The

major use of Rock Phosphate in India is for manufacture of SSP, DAP, MAP,

TSP, Phosphoric acid, Di-calcium Phosphate and elemental phosphorus. The Rock

Phosphate from proposed expansion is proposed to be supplied as a feed stock to

SSP, Phosphoric Acid manufacturing either for standalone use or for blending

purpose.

There is no export market for rock Phosphate in India as per the reasons given

above.

2.7 Employment Generation.

The proposed expansion would provide direct employment opportunity for about

180 persons (30 Executives and supervisors and 150 skilled and unskilled

manpower) besides indirect employment.


3.0 PROJECT DESCRIPTION

3.1 Type of Project

The proposed project is a mechanized Open Cast mining project of Rock

phosphate

of Hindustan Zinc limited situated at Village – Maton; Tehsil – Girwa; Dist.

Udaipur.

3.2 Location


24032’34’’ and longitude 73

047’30’’ and falls in the Survey of India toposheet

No. 45H/14. The phosphate deposit of Maton is located in a hill, which trends NE-

SW, rising nearly 100 m above valley level. The climate is semi-arid with an

average annual rainfall of 600 mm. The temperature varies from 45C in summer

to as low as 1C in winter. The area is drained by a nallah, which is a tributary of

seasonal Ahar river draining to UdaiSagar Lake. Maton mine receives power at

33 KV from Aklingpura substation of AVVNL. The nearest railway station is

Rana Pratapnagar on Udaipur - Chittorgarh broad gauge line of North - Western

Railway at about 8 km away. Water requirement is met through rainwater stored

in old mine workings and purchase from 3rd

party sources.. The area is connected

by airways with the airport being at Dabok which is at a distance of 12km. The

Mine is well connected on two sides by metalled road from Udaipur. The revenue

map is attached for reference.

3.2.1 The general location map is as shown below.


Maton Mines


The details of environmental setting are given in Table-3.1.

TABLE-3.1

ENVIRONMENTAL SETTING OF THE SITE

Sr. No. Particulars Details

1 Latitude 24032’34’’

2 Longitude 73047’30’’

3 Elevation above MSL 568m

4 Climatic conditions

(Based on IMD Ajmer)

Annual Maximum Temp: 450 C

Annual Minimum Temp: 10C

Annual Average Rainfall: 600 mm

5 Present land use of mine site Agriculture, grazing , and barren land

6 Nearest Highway NH-76 (6 km, NW)

7 Nearest Railway Station Rana Pratapnagar (8 Km,NW.)

8 Nearest Airport Dabok (12 km)

9 Nearest Village Maton, Khardadia

10 Nearest Town/City Udaipur (12 km NW) City and District

11 Hills/Valleys Aravalli Hills

12 Reserved/Protected forest Bara Mandra RF, Kantla RF, Panwari RF,

Hinlashla RF, Segara RF, Hora RF,

Umara RF, Bagdara RF, Amarbir RF,

Sant RF.

13 List of Industries Major Industry RSMML at distance of 5

km and HZL’s Debari Zinc Smelter at 8

Kms

14 Socio-economic factors No fresh land acquisition.

15 Seismicity Seismic Zone-II.

3.3 Alternate Sites Considered

No alternate site is applicable since ore deposit is present at Maton.

3.4 Size of Operation


The project has been planned to produce 0.5 MTPA Rock phosphate Ore from the

mechanized opencast mine by expanding from the present 0.18 MTPA. The

salient features of the proposed project are given in Table 3.2

TABLE-3.2

SALIENT FEATURES OF THE PROJECT

Sr. No. Description Details

1 Name of Mine Maton Rockphosphate Mine

2 Mine lease area 143.13 ha

3 Mine Lease No ML-6/89

4 Ore mineral Rock Phosphate

5 Proved Reserves

Probable and Possible reserves

1.293 million Tonnes

Approx. 3.894 million Tonnes

6 Average Grade 24-26% P205

7 Ore body Width 3 m to 15 m.

8 Overall Strike length & Direction 3.2 kms , N40ºE- S40ºW

1.2 Kms with in Surface Rights

9 Ore body Dip 50º - 80º towards N50ºW

10 Mineable Reserves 2.5 million Tonnes

11 Established Depth Upto 520 mRL (190 mtrs)

12 Mode of Entry Haul Road

13 Method of Mining Open Cast Mechanized Mine

14 Rated Ore Production 0.5 Million Tpa.

15 Transportation of Ore By Truck/ Dumpers

16 Waste Rock Generation Approx. 11.5MT/Year (Avg)

17 Power requirement 1.0 MW

18 Water requirement 500 KLD

19 Manpower requirement About 180 (30 executives &

supervisors, 150 unskilled,

semiskilled & skilled personnel)

* The Reserves & Resources are estimated as detailed below in section 3.5.2


3.5 Project description with Process details

3.5.1 Geology

The rocks of Maton area belonging to Aravalli Super group of Proterozoic age,

strikes N 40E-S40W and dips at 50-80 degree’s towards N50 W and display a

synformal structure plunging moderately due NE. Dolomite and argillaceous

dolomite is the oldest formation. Next in the stratigraphic column is ortho-

quartzite and jaspery-quartzite, which hosts stromatolitic rock phosphate. The

rocks overlying rock phosphate are phyllite, which grid into mica-schist at places.

Rock Phosphate in general is unconsolidated, soft to medium hard in nature,

except in few patches where it is compact and cherty. The ore forming mineral is

mainly Fluor-apatite (Ca5 (P04)3F).

The phosphorite horizon in the Maton area extends over a strike length of 1.2 km.

Thickening and thinning of the horizon is quite common. The thickness of the

horizon varies from 3.0 m to as high as 15.0 m.

3.5.2 Ore Reserves

The reserve estimates are based on 1120 m strike length between S-14 to N-65

sections, width of the intersected ore zones and maximum depth up to 520mRL.

The reserve has been estimated by Datamine Software using geo-statistical

method and statistical analysis.

Depletion of reserves: During the plan period of 2009-10 to 2011-12, 0.362 MT

of ore reserves depleted up to the end of FY 2011-12.

Additional reserves estimates: During the plan period no exploration drilling has

been done due to access problem on hill slope. However Rock Phosphate has been

exposed, during mine development, along the strike of E2 lens towards north,

confirming its continuity along the strike up to B block. It can be thus assumed

that the ore body exists along the strike, both at surface and subsurface which may

add to the present reserves and resource.

Resource estimation

The resource estimation has been done by volume of each block * in situ density

and krigged grades. Total estimated reserves and resource upto -520mRL are


3.327 MT of rockphosphate. Additional ore if considered will increase the Qty to

5.2 MT. The categorisation of the ore reserves is as under.

The ore reserves at Maton Rockphosphate mine is as under -

CATEGORY Mt %P2O5

A) RESERVES

Proved 1.293 26.33

Probable 0.643 27.43

Total 1.936 26.69

B) RESOURCE

Measured (M) - -

Indicated (I) 3.251 28.10

Total M & I 3.251 28.10

Inferred -

The in-situ geological reserves/resource as on 01.04.12 is shown in the table

below


Qty Grade Qty Grade Qty Grade Qty Grade

0.082 27.47 0.082 27.47 0.000 0.082 27.47 690 610

0.210 27.03 0.013 24.27 0.223 26.86 0.000 0.223 26.83 610 570

0.168 31.38 0.172 31.38 0.340 31.38 0.018 31.38 0.358 31.38 570 520

S.Total 0.425 28.83 0.185 30.88 0.610 29.45 0.018 31.38 0.628 29.51

0.071 28.17 0 0.071 28.17 0.000 0.071 28.17 top 690

0.105 28.12 0 0.105 28.12 0.000 0.105 28.12 690 610

0.080 30.14 0.242 28.68 0.322 29.04 0.000 0.322 29.02 610 570

0 0 0.823 31.41 0.823 31.41 570 520

S.Total 0.359 31.41 0.257 28.68 0.616 30.27 0.823 31.41 1.439 30.21

0.148 23 0.148 23 0.000 0.148 23 top 690

0.429 23 0.121 23 0.550 23 0.000 0.550 23 690 610

0.095 23 0.095 23 0.170 23 0.265 23 610 570

0.376 23 0.376 23 570 520

S.Total 0.577 23 0.216 23 0.793 23 0.546 23 1.339 23

B- Block 0.800 0.800

0.219 25.73 0.219 25.73 0.219 25.73 732 690

0.616 24.47 0.121 23 0.737 24.23 0.737 24.57 690 610

0.290 27.88 0.350 26.97 0.640 27.38 0.170 23 0.810 26.48 610 570

0.168 31.38 0.172 31.38 0.340 31.38 1.217 28.81 1.557 29.37 570 520

S.Total 1.293 26.33 0.643 27.43 1.936 26.69 1.387 28.1 3.323 27.36

B- Block 0 0 0 1.864 1.864

TOTAL 1.293 26.33 0.643 27.43 1.936 26.69 3.251 28.1 5.187 27.36

Top to 520

E2

Top to 520

E1

Av.

Grade

Depth of

Estimation

W1

Lens

Proved Probable Reserve Possible Reserves

Total Res.

Top to 520

Top to 520

Top to 520

W1, E1,

E2

Top to 520

Top to 520

As per United Nation framework of Classification (U.N.F.C), Reserve and

Resources position as on 01.04.12 is as follows: (in million T)

BLOCK LENS Mineral

reserve

(111)

Mineral

reserve (121

& 122)

Mineral

resource

(211)

Mineral

resource

(221 & 222)

Mineral

resource

(331)

Mineral

resource

(332)

Mineral

resource

(333)

0.219 732 690

0.616 0.121 690 610

0.29 0.35 0.17 610 570

0.168 0.172 1.217 570 520

S.Total 1.293 0.643 1.387

B- BLOCK B- Block 0 0 1.864

1.293 0.643 3.251TOTAL Top to 520

Location

A- BLOCKW1, E1, E2

Top to 520

Top to 520


RESERVES AND ANTICIPATED LIFE OF MINE

A total of 5.187 million T of ore reserve and resources, 1.293MT Proved & 0.643

MT probable reserves) and 3.251 million T of resources have been estimated upto

520 mRL with average grade of 27.36 % in A & B Blocks. At a production rate of

0.18 million TPAin the first year and then @0.5 million tonnes in the subsequent

years, the present life of the mine upto 520 mRL will be about 8 years considering

limits of practical mining open pit of reserves and resources. As explained

previously, exploratory drilling done will further augment the reserves and

resources which would increase the life of the mine beyond 10 years.

3.5.5 Mining

3.5.5.1 Method of Mining:

The deposit is being worked by mechanised open cast mining method with

benches of 10 m minimum width and 10 m height. The bench height and width

parameters have been optimized after studies on geo-technical slope stability were

carried out by CIMFR. Dhanbad. They had recommended a slope of 45˚ in

footwall ortho-quartzite upto a depth of 100 m from highest point. Beyond 100 m

the overall pit angle along footwall has to be revised according to local

conditions. The mining of the deposit is intended to continue with the same

method. The present working is confined in E1-W1& E2 lens only. The entry to

the benches below 600 mRL is by a ramp driven from south side. Hangwall

overburden is removed first, then ore is mined out and then waste of Foot Wall is

removed on the bench to reduce the dilution to the maximum possible extent and

bench is formed. The heavy earth moving machineries deployed for mining are

diesel operated. With expansion, there would be increase in the size of the

machines viz. excavators and trucks to cope up the excavation requirements. The

crusher capacity would also be increased to meet out the crushing requirements of

expanded ore production.

Drilling and Blasting: At Maton Mine the bench height in waste (Over Burden)

and ore is 10 mtrs. The hole dia. for both ore and waste benches is 115/165 mm.

The drilling is carried out with the help of track mounted diesel engine powered

DTH (Down the Hole) drill machines of 115/165mm button bit. Drill machine


with dust extractor system is being used for controlling Air Borne Dust. ANFO

(Ammonium Nitrate Fuel Oil) is used as the column charge along with Primary

charge in the form of PETN cast booster or cartridge slurry explosive. The

initiation of the explosive is being done by down the hole delay Non Electric

shock tubes (NONEL). For interhole delay the trunk line delay detonators are used

on surface tie up for improved blast performance, reduced ground vibration and

noise level. The max. charge is kept within limit to minimize environmental

impact of blasting. The no. of blasts required in ore and waste clubbed together

are approx. 20-25 per month. However by increasing the size of the blast, number

of blasts would be reduced to 14 to 15 per month.

Depending upon the strata condition, bench height and rock type, spacing and

burden is being varied. Typical Drill & Blast design parameters are as under.

Spacing : 4 to 5 m

Burden : 3 to 4 m

Depth of holes : 10.5 to 11m

Sub grade drilling : 0.5 to 1.0 m

Primary charge/Booster charge : 250 gm PETN Booster / Cap sensitive

slurry cartridge of 83/125 mm dia (12.5

to 25 Kgs)

Column charge : Non cap sensitive (ANFO/Slurry

Cartridge)

Charge Length : 50-60% of hole depth

Powder factor : 4 to 5 T/Kg of explosive

Pattern of holes : Staggered or Square Pattern

Detonators : Millisecond delay detonators.

Av. No. of holes in a blast : 60 to 70 nos.

Av.Quantity of explosive/hole : 100 Kg. (Approx.)

Quantity of explosive/Blast. : 6-7 T (Approx)

Safe storage of explosive : Explosive is being sourced from licensed

magazines.


Secondary breaking: Oversize boulder’s (Boulder of size more than 1 mtr.) size

reduction is done by Hydraulic Rock Breaker. Secondary Blasting i.e. Pop

Shooting or Plaster shooting is avoided. With proposed expansion, additional rock

breaker would be put in to use to cope up the breaking of boulder. Efforts would

be made with improved blasting techniques as described above to keep generation

of boulders below 1% of total blasted volume.

Presplitting: To achieve stable slopes and control the blast damage to walls, pre-

splitting techniques would be adopted at final pit limits.. The technique would

involve, drilling small dia holes (100-115 mm) at a close spacing of 1.0 to 1.2

mtrs. along the final bench profile line at an angle of 70 to 80 degrees as per the

recommended slopes. These holes would be then charged lightly with 25-32 mm

cartridges which are suspended in to holes axially tied with a detonating fuse. A

charge factor of 0.40 to 0.60 Kg / sq meter would be maintained depending upon

the strata conditions. The holes are then fired instantaneously and are normally

fired prior to the production blast in front of limit line. The final production blast

is called “Trim Blast”. In Trim blast in front of Pre-Split, one or two small dia

production hole line is drilled at a standoff of 1.0 to 1.5 mtrs to reduce the charge

concentration near final wall. The trim blast is fired with inter hole delay of 42 ms

or 65 ms with inter row delays of 100 ms so as to have proper burden relief for

holes and reduced vibrations on wall. The excavation is then done maintaining the

slope. However exact parameters of pre-splitting can only be established after a

number of trial blasts with varying spacing and/or explosive charge and the most

appropriate pattern would be adopted.

The machinery to be deployed for expanded capacity would be as tabulated

below.

TABLE 3.6

DETAILS OF MACHINERIES


Equipment Capacity Existing (Nos.) Proposed (Nos.)

2.0 cum 4 2

6.7 cum - 2

Rock Breaker 1 1

20 MT 25 3

50 MT - 20

165 mm 1 2

115 mm 1 2

10 KL 2 -

20 KL - 2

D65 E 2 -

D275 A 2

Motor Grader - 1

Track Dozer

Excavator

Dumper

Drill

Water Sprinkler

The expanded production (ore and overburden) requirement is 40000 to 45000 T

of rock per day. The capacity of machinery has been arrived at after considering

the availability and utilization of the equipments. Four excavators (2 of 6.7 m3 &

2 of 2.0 m3 for ore) and twenty dumpers of 50 T are planned

3.5.5. 2 Conceptual Mine Plan

The present working is confined to E1-W1& E2 lens only. The present entry is

through a ramp along the hill on FW side. Hangwall overburden is being removed

first, then ore is mined and then FW is excavated thereby forming the bench and

reduced dilution. The ore body is proven up to 520 mRL and the pit will be

economical up to this depth of approx 190 meters from the top. It is proposed to keep

a pit slope of 45˚ in footwall ortho-quartzite upto a depth of 100 m from highest

point and beyond 100 m the overall pit angle along footwall has to be made flatter

according to local conditions. A detailed Geotechnical study would also be

conducted to arrive at optimal bench slopes and overall angles and depth of pit.

The mine operation is planned on three shifts per day of 8 hours duration basis. The

mine is scheduled to work for 300 days/ year after keeping margin for weekly day of

rest, public holidays and days lost due to weather conditions like rain, fog & storm.

Ore Production Schedule for Mining Plan period five years after grant of EC

would be as follows


Plan period Ore Production

2012-2013 1,80,000

2013-2014 5,00,000

2014-2015 5,00,000

2015-2016 5,00,000

2016-2017 5,00,000

Production in Year 1 has been considered as per existing plan considering the time

required for development of the ore for 0.5 MTPA capacity.

3.5.8 Selection of Dumping Site

The overburden generated from mines will be stacked at earmarked Dump

locations which are at north east of strike direction and East of the strike direction.

These sites have been selected as the area doesn’t bear any mineralisation and is

within the acquired land.

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.

Maton being a purely mining Project and there wouldn’t be any other process

involved like beneficiation. So no significant raw material requirement is there

except consumable like fuel for equipments and explosive / Ammonium Nitrate

for blasting purpose. The final product would be ROM and/or crushed

Rockphosphate. The mode of transport of material would be through trucks.

3.7 Resource optimization / recycling and reuse envisaged in the project, if any

Not envisaged

3.8 Water & Power Availability & Source

3.8.1 Water Availability


An additional 300 KLD of water will be required, as compared to the present 200

KLD for the present capacity of 0.18 MTPA. The additional requirement is

proposed to be extracted from ground from within or outside the mine lease

through bore wells after obtaining requisite approvals and also from the rain water

collection in the pit area, water collection pond is also proposed to be constructed.

3.8.2 Power Availability

Energy requirement will be 1.0 MW after expansion. Power will be wheeled from

captive power plant at Hindustan Zinc’s Zawar mines located 45 kms away

through AVVNL grid.

3.9 Waste Generation and its Management

3.9.1 Solid Waste

The waste rock generated from the mining will be systematically dumped at

earmarked overburden dumps with proper stabilization and plantation. The

physico-chemical analysis of the waste rock indicates that the waste is non-

hazardous in nature and not likely to cause any adverse impacts. Waste generated

by mining will be dumped at pre decided sites in ultimate dump configuration of

10 x 10 meters or 5 x 20 m lifts after obtaining necessary approval. Each lift

would have slope angle of 400 and overall final slope of 27

0. There is no sub grade

mineral available as such there would not be need for stacking of sub grade

mineral separately. The proposed excavation of overburden for five year is as

follows.

Year Qty(T)

2012-13 4680000

2013-14 13000000

2014-15 12500000

2015-16 11000000

2016-17 11000000

Total 52180000

3.9.1 Liquid Waste, effluents


No Liquid effluents / waste generation would be there as beneficiation plant is not

proposed.

4.0 Site Analysis

4.1 Connectivity


2432’34’’ and longitude 7347’30’’ and falls in the Survey of India toposheet

No. 45H/14. The nearest railway station is Rana Pratapnagar on Udaipur -

Chittorgarh Broad gauge line of North - Western Railway at about 8 km away.

The area is connected by airways with the airport being at Dabok which is at

about 12 km. (NW) on Udaipur – Chittorgarh NH 76. The Mine is well connected

from two sides by asphalt road from Udaipur. The revenue map is attached for

reference.

4.2 Land Form, Land use and land ownership

4.2.1 Land Form

The general topography of the Mining Lease area is flat to undulated. The

mineralization is within a hillock. HZL has the surface rights over the land where

mining and related activities are being carried out.

4.2.2 Land Use

Total Mine lease area is of 143.13 ha, out of which 114.44 ha is acquired within

mining lease area for carrying out mining and related support activities.

Additionally 81.02 Ha has been acquired outside the ML area for OB storage,

crusher, offices etc.

The pre operational land use pattern of mining lease is as follows:

The present land use detail of acquired land is as per following table.


Land Use Area(ha.)

Built up 4.42

Mine pit 19.84

Waste Dump 28.79

Green Belt 62.83

Others 79.58

Total 195.46

No additional acquisition of land is proposed for expansion from 0.18 million

TPA to 0.5 million TPA of ore production at Maton Rockphosphate Mine.

4.2.3 Land Ownership

Village wise details of total land acquired from within the mine lease and outside

the mine lease area for the mining project is as below.

Village Govt Land Private Land Total

Maton 133.1450 49.8378 182.9828

Umra 10.3750 1.2540 11.6290

Lakadwas 0.8216 NIL 0.8216

Karbadia NIL 0.0260 0.0260

Total 144.3416 51.1178 195.4594

4.3 Topography

Topography of the area is shown in attached map.

TOPOGRAPHICAL FEATURES OF THE AREA


4.4 Land Use Pattern of Mining Lease

Details of the land is as given in sec 4.2.2 and 4.2.3 above

4.5 Existing Infrastructure and Amenities

Existing Infrastructure viz. Office building, Crusher, and quarters for the security

personnel are available at site. As Udaipur, a major city is nearby from the project

site; all basic amenities like school, hospital, recreational facilities, electrical lines

are available.

4.6 Soil Classification

The texture of soil is mostly sand and silty sand in the study area.

The PH of the soil in the study area ranged from 7.0-7.7. The soil is neutral to

slightly alkaline.

Details of soil sampling locations:


Station

Code

Location Distance wrt.

Boundary of

ML Area (km)

Direction wrt

Centre of ML

Area

Present

Land Use

S1 Umra Village 2.2 S Agri. Land

S2 Lakadwas

Village

2.4 E Barren Land

S3 Nr UdaiSagar 3.0 NE Barren

S4 Maton Village 0.5 N Barren Land

S5 Kharbadia

Village

0.6 NW Barren Land

S6 ML area Core Zone - Industrial

area

The soil analysis parameters as per recent monitoring report Dec 2011 are as

shown below:

PARAMETER

S1 S2 S3 S4 S5 S6

pH - 7.66 7.39 7.03 7.22 7.4 7.35

Ca2+ % 4.4 4.3 2.3 2.2 2 3.5

Mg2+ % 1.44 1.14 1.32 0.84 0.36 0.42

SODIUM as Na % 2.12 2.59 2.34 2.39 2.76 2.22

POTASSIUM as K % 0.906 6.25 3.21 1.72 0.73 1.71

AVAILABLE “N” % 0.021 0.0224 0.024 0.0224 0.022 0.0238

CHLORIDE as Cl % 0.025 0.045 0.034 0.148 0.025 0.017

SULPHATE as So4 % 0.37 0.38 0.51 0.38 0.41 0.48

IRON as Fe % 4.42 5.12 6.6 1.3 1.74 2

MANGNESE as Mn % 0.163 0.74 0.837 0.079 0.022 0.027

ZINC as Zn % 0.009 0.0102 0.014 0.0084 0.01 0.0098

ALUMINUM as Al % 1.21 2.54 1.92 1.61 0.88 1.41

LEAD as Pb % 0.002 0.0013 0.003 0.0022 0.002 0.0018

PHASPHATE as Po4% 0.003 0.0045 0.005 0.0057 0.005 0.0064

PHOSPHOURS as P % 0.001 0.0014 0.002 0.0018 0.002 0.002

ORGANIC MATTER % 3.92 3.99 4.56 3.82 2.36 2.8

ORGANIC CARBON % 2.71 2.25 2.68 2.56 1.37 1.82

WATER SOLUBLE

CHLORIDE

% 0.025 0.045 0.034 0.148 0.025 0.017

UNIT RESULTS


4.7 Climatic data and secondary sources

The meteorological data recorded during the monitoring period is very useful for

proper interpretation of the baseline information as well as for input prediction

models for air quality dispersion. Historical data on meteorological parameters

will also play an important role in identifying the general meteorological regime

of the region.

The year may broadly be divided into four seasons:

Winter season : December to February

Pre-monsoon season : March to May

Monsoon season : June to September

Post-monsoon season : October to November

Onsite monitoring was undertaken for various meteorological variables in order to

generate the site – specific the data was collected at site every hour continuously

from 1st march 2009 to 31

st March 2009 covering pre-monsoon season. The

generated data then compared with the meteorological data generated by nearest

Indian meteorological Department (IMD) station located at Udaipur at a distance

of (12 km NW)

4.8 Social Infrastructure available

The location is very near to the city of Udaipur and all the basic social

infrastructure as listed below are available.

Hospitals

Banks

Post Office

Railway Station

Bus Station

Schools

Police Station

Shopping Complexes

Sports Infrastructure


Cinema Hall

5.0 PLANNING BRIEF

5.1 Planning Concept

The industry is mining. It is proposed for expansion of mine from 0.18 MTPA to

0.5 MTPA of ore production. The mining will be through open cast method by

conventional Shovel Dumper combination and Drilling and Blasting. The

operations will be fully mechanised. The ore excavated will be stacked at ore yard

from where will be loaded in dumpers and will be crushed to <12 mm size.

Separate stock yards of crushed ore will be maintained as per the grade. The ore

will be sold to the parties which shall be transported through trucks by road. All

required infrastructure is already available.

5.2 Population Projection

As per 2001 census, 25646 persons inhabited in 10 villages around Maton Mine.

The distribution of population in the study area is as per the table below.

TABLE 5.1 DISTRIBUTION OF POPULATION IN STUDY AREA

Sl. No. Village Total Family Population

1 Maton 229 807

2 Kharbadia 218 1195

3 Lakadwas 1171 5855

4 Kaladwas 601 3650

5 Eklingpura 338 1860

6 Umra 809 5779

7 DhuniMata 57 245

8 Boiki Pancholi 240 1200

9 Kanpur 897 4485

10 Kamlod 114 570

Grand Total 4674 25646


.

5.3 Land use planning

The land use pattern of the total acquired land is as given in Sec 4.2.2 above.

5.4 Amenities and Facilities

i) Education: There exists Primary, Secondary and Senior Secondary Schools

and colleges

ii) Social Infrastructure like Hospitals, Post Office, Bank, Police Station, Bus

Station, Facility Exists

iii) Telecommunication, LPG services, Marketing stalls, Sports infrastructure –

exists

iv) Recreation- Existing Recreation facilities such as cinema hall, Sports

infrastructure

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial Area

Infrastructure is already available for 0.18 MTPA capacity. The same

infrastructure will be shifted within the mine premises / acquired land on

expanding to 0.5 MTPA if needed.

Road Network – two way road along the mine.

Power transmission – 4 kms of 33 KV transmission line installed through

AVVNL.

Internal roads within mine boundary

Office buildings

The following would be developed as part of the proposed expansion

Truck parking facility

Residential Area: No residential Area shall be developed as HZL is already having

the residential colony at Udaipur.

6.2 Green Belt

HZL has planted 5500 plants saplings from 2009-10 to 2011-12 in an area of

2.225 ha. Thick vegetation will be developed along acquired land boundary to


attenuate the dust and noise. The plantation will be carried out along the roads

within the boundary to arrest dust. The plantation will also be carried out on the

waste dumps slopes as and when they mature i.e. reach to final limits after their

stabilization. Plantation will also be done on the top of waste dump benches.

Around 33% acquired area shall be developed with plantation.

6.3 Social Infrastructure

The Maton Mines is very near to the city of Udaipur and its suburbs and all the

social infrastructures as listed below are available.

Education: There exists Primary, Secondary and Senior Secondary Schools

and colleges

Social Infrastructure like Hospitals, Post Office, Bank, Police Station, Bus

Station facility exists

Telecommunication, LPG services, Marketing place exists

Recreation- Cinema hall, Sports infrastructure exists

Looking to above, company doesn’t propose for creation / construction of any

Social Infrastructure. However the company would continue its CSR activities in

surrounding villages of Maton.

6.4 Connectivity

The project site is located 12 Km South East of Udaipur city and is well connected

by Jhamarkotra road from Udaipur. The nearest Airport is Dabok about 12 Km

NW of the Maton Mine. The nearest railway station Rana Pratapnagar is 8 Km

NW of Maton Mine. NH 76 is at 6 km NW from the ML area.

As site is well connected, there is no requirement for any additional infrastructure

except strengthening of internal roads.

6.5 Drinking water management

15 cum/day of drinking water would be required during the operations. Same shall

be purchased from external sources in the same way as being done at present.


6.6 Sewerage System

As there will be no township facility developed within the boundary so no

sewerage waste would be there and need for Sewerage System would not be there.

6.7 Industrial Waste Water management

Since the Ore beneficiation Plant is not proposed, there would not be generation of

any industrial waste water and effluents. The rain water collected in mine pit area,

will be used in wet drilling and water sprinkling for dust suppression on haul

roads . Zero discharge of water shall be maintained from mining premises. Storm

water generated shall be allowed to flow naturally ensuring no contamination to it.

Garland drains and de-silt pit will be constructed around the OB dump to ensure

de- silting of rain water. The rainwater will be collected in suitable sump pits and

will also be used in mining operations and dust suppression.

6.8 Solid Waste Management

About 521,80,000 T waste rock (Over Burden) would be generated from the mine

proposed Mining Plan period of five year. Waste rock from the development

heading would consist of quartzite, phyllite, Jaspery quartzite, etc. Mine waste

from development areas shall be transported and dumped in a specifically

assigned area i.e. waste dump area. The waste is non-hazardous in nature and not

likely to cause any adverse impacts. The dumps will be stabilized by plantation of

trees.

The following mitigation measures for solid waste management shall be adopted:

Adequate slope will be maintained to give proper stability to the dump.

Waste will be stacked & leveled systematically in layers.

After reaching the benches to their ultimate height and location, plantation

shall be done on slopes and top.

Construction of garland drains around the Waste dump so that surface run

off from the dump is collected in a sump.

Regular maintenance of the garland drains constructed around the solid

waste dump to collect the surface run off.

6.9 Energy requirement


Presently Maton mine receives Power at 33 KV from Aklingpura substation of

AVVNL. Energy requirement will be approx 1.0 MW after expansion. Power will

be wheeled from captive power plant at Hindustan Zinc’s Zawar mines located 45

kms away through AVVNL grid.

7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN

There will not be any additional acquisition of land due to proposed expansion

from 0.18 million TPA to 0.5 million TPA. All the mining operation will continue

within the and acquired land within and outside ML.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

8.1 Project Schedule

The current production of rockphosphate ore of Maton mine is 0.18 MTPA .It is

proposed to increase its production of ore from 0.18 to 0.5 MTPA. The mine will

reach to the expanded capacity of 0.5 MT in Year 2 / year 3.

8.2 Capital Cost Estimates

As the project is going to be completely outsourced so there will be no capital cost

on machineries. The only cost comprise of crusher, office infrastructure, shifting

of power line, small warehouse etc. The total Capital cost has been estimated at

INR 120 million (12 crores)

The calculation below indicates that the project is robust and is economically

viable at a high stripping ratio of 24 considering average sale price of the product

at Rs 2500 per Tonne.

TABLE 8.1


ECONOMICAL

VIABILITY

Description 2012-13 2013-14 2014-15 2015-16 2016-17

Ore prod (Lac tons) Tentative 1.8 5 5 5 5

Total Excavation (in Lac Tons) 48.6 140 125 115 95

Capex (Crusher and Offices) 1200

Revenue @ 2500 (Av price) 4500 12500 12500 12500 12500

Operating Profit 975 2491 3508 4208 5608

Depreciation 420 117 99 85

Tax (30%) 293 621 1017 1233 1657

Net Cash Flow 683 249 2374 2876 3866

All Amounts are in Lacs.

9.0 ANALYSIS OF PROPOSAL (Final Recommendations)

9.1 Financial Benefit

The proposed project will reduce import of rockphosphate and phosphoric acid

thus saving of foreign exchange. It will boon for the fertilizer industry and

agriculture. This will also generate revenue to the state Government as well as

central government. The people around the region will get direct and indirect

employment thus improves the financial status. HZL will also get benefited.

9.2 Social Benefits

The proposed project shall proactively participate in the upliftment of socio

economic index of the communities around the project site by way of financial

and administrative support. The project will open up employment opportunities,

directly and indirectly. There shall be opportunities for entrepreneurs to engage in

many service sectors directly or indirectly associated with the project.

The CSR approach of the company continues to be towards sustainable livelihood

management of the community around. on the present focus areas shall be

continued in education, health, sanitation, drinking water, agriculture, water shed

management, culture identity preservation, tribal welfare, welfare of socially

weaker sections and marginalized people.

pre- feasibility report - welcome to...

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