chapter-1 introduction - …environmentclearance.nic.in/writereaddata/online/tor/06_jul_2016... ·...

Pre-feasibility Report for Beneficiation Plant of M/s. Thakur Industries, Koppal.

1 Prepared by: METAMORPHOSIS Project Consultants Pvt. Ltd., Bengaluru

1

CHAPTER-1

INTRODUCTION

1.1 The Company

M/s. Thakur Industries (TI) was incorporated as a Partnership Firm on 25th October 2007, Register Office address # 116, 1st Stage, Raghavendra Colony, Patel Nagar. The Company was engaged consultant to prepare Environmental Impact Assessment and Environmental Management Plan to obtain Environmental Clearance for throughput capacity of 0.6 million TPA. Accordingly, obtained Environmental Clearance from Ministry of Environment, Forests & Climate Change, New Delhi, vide letter ref no. J-11015/257/2010-IA.II (M), dated 19th April, 2012. Consent for Establishment (CFE) for setting up of Iron Ore Beneficiation Plant of 0.6 million TPA was obtained from Karnataka State Pollution Control Board (KSPCB), vide letter ref. no. 20/PCB/MIN/CFE/2012-13/238 dated 28th May 2012. Consent for Operation (CFO) was obtained for the same from KSPCB vide letter ref. no. 03/KSPCB/RO/KPL/SR/2014-15/201 dated 21st June 2014 (Copy is enclosed as Annexure I). Meanwhile, Deed of Partnership was reconstituted on 01st April 2015 with inclusion of two persons namely Mr. Shailesh Agarwal and Mr. M. Prakash Lalwani as Partners. Now the partners of the firm are as follows:

Mr. Naresh Kumar Cherania Smt. Anju Devi Chirania Sri. Shailesh Agarwal Mr. M. Prakash Lalwani

The copy of Reconstituted Deed of Partnership is enclosed for reference as Annexure II. Subsequently, again on 1st July 2015, Deed of Partnership has been reconstituted in view of retirement of partners namely Mr. Naresh Kumar Cherania & Smt. Anju Devi Chirania and continuation of other two partners namely Sri. Shailesh Agarwal & Mr. M. Prakash Lalwani. Mr. Shailesh Agarwal is authorized as Managing



2

Partner of the firm M/s. Thakur Industries with effect from 01/07/2015. The copy of the Reconstituted Deed of Partnership is enclosed as Annexure III. The register office address has changed to F-2, 1st Floor, R.R. Kuteera, Door No – 48, 29th Ward, BDCC Bank Colony, M.J. Nagar, Hosapete, Bellari District. Accordingly, change of management of M/s. Thakur Industries has been communicated to MoEF & CC vide letter ref. no. Nil dated 28th September 2015. Presently, the Management proposes to expand the Beneficiation Plant with throughput capacity from 0.6 mtpa to 1.5 mtpa within the exiting premises. Therefore, M/s. Thakur Industries, engaged the services of METAMORPHOSISSM Project Consultants Pvt. Ltd., for preparation of Environmental Impact Assessment to obtain Environmental Clearance from Ministry of Environment, Forests & Climate Change. Company’s unique selling points are:

Centralized location – huge advantage Quality Products Established network of marketing Advisory committee comprised of renowned steel technocrats /

bankers Professionals 1.2 About the Project Proponents 1.2.1 Shri. Shailesh Agarwal, Managing Partner - who holds Bachelor’s Degree in

Commerce and Charted Accountant (Intermediate) having over 14 years of total experience of which 5 years is in Beneficiation plant and he is the Authorized Signatory.

1.2.2 Shri. Prakash Lalwani, Partner - having over 18 years of total experience of

which 2 years is in Beneficiation plant and his having vast knowledge in Ore business and trading and He has been handling the entire production and project implementation activities of the Group.



3

1.3 Strength of Directors

A Team of Entrepreneurs, having ventured into Greenfield Projects and successfully establish and manage the Business Ventures.

Have come out Champions, sometimes in most difficult situations, having mastered the art of managing Technology & Innovations, Human Resources and Finance, the most critical factors in any successful Venture

Having in-depth knowledge of the ore beneficiation, well placed to ascertain requirements, benefits as well as pitfalls of the industry.

In-House financial strength, either through their own financial strength or internal borrowings from relatives or friends, enabling to take quick and unanimous decisions at critical junctions.

1.4 Proposed Expansion Project The company proposed expands Ore Beneficiation Plant at Hirebaganal Village, Koppal Taluk and District, Karnataka. The estimated cost of the project is Rs. 220 Lakhs.

Table 1: Proposed Manufacturing Facilities

Sr. No. Particulars Existing Capacity (throughput)

Proposed Capacity (throughput)

1 Beneficiation

Plant 6,00,000 Tons per Annum 15,00,000 Tons per Annum



4

Figure 1.1: Location Map of the Project



5

1.5 Objective of the Project

There is huge quantity of low grade ore at all the operating mines situated in the areas of Hospet-Bellary-Sandur sector in Karnataka State which are left behind of good quality of iron ore exports. The low grade ore are not in demand and hence ignored and a huge quantity generated in the past is accumulated and further accumulating day by day. Hence, vast quantity of low grade ore is available in Karnataka and adjoining state of Telangana and Andra Pradesh including Goa at the Existing Iron ore mines, which are lying unprocessed which is the basic raw material for the proposed plant.

Table 2: Objectives of the Project

Particulars Application

Ore Beneficiation Plant

Process to up-grade low grade iron ore and grind it to concentrate form for onward use in Pelletization process and steel plant.



6

CHAPTER – 2

MARKET PERSPECTIVE

2.1 Introduction

Mining of coal, non-metallic and metallic mineral deposits produces raw mineral which needs to be processed further by a specified method depending on the mineral and waste product (s) associated with it. The beneficiation methods and its associated processes chosen concentrate the mineral to the desired level. Mineral Beneficiation is of great economic importance to the mining industry and the country. The continual growth of infrastructure with rapid industrialization, exploitation of minerals is likely to increase. The increasing demand of minerals also promotes Mineral Beneficiation to upgrade the ore. With the growth of steel industries in India and also globally the need for high grade Iron ore is increasing day by day. There is large quantity of low grade Iron ore available at all the operating mines in Karnataka, Telangana, Andra Pradesh and Goa which are left behind after exporting/consuming good quality iron ore. The benchmark set for exporting Iron ore is considered as >60% Fe. Hence, upgrading low grade Iron ore by beneficiation process will generate good foreign exchange and also meet the domestic steel industry need. The minerals extracted from the mines invariably contain low quality ore looking at the vast availability of low quality ore in Karnataka, Telangana, Andra Pradesh and at the existing iron ore mines, there is a need to use advanced technology to convert these low grade ore to high grade ore which will not only generate foreign exchange, but also clean up the huge areas which are being occupied by these minerals. In this context particularly after the big boom in the steel industry we are in the race of earning more Forex and are giving away our natural resource like minerals specifically iron ore in the form of exports. As promoters of this project we feel that if value additions takes place to the iron ore and exported, will fetch us positive gains from various angles like more Forex, employment generation, Optimum utilization of our resource. This process should be encouraged in our country so as to enable us to retain high grade ore in our country and export the processed ore thereby having



7

a value added export. Technically speaking the process of improving of Fe content in the Iron ore by washing it with water is Beneficiation process. 2.2 Scenario for Thakur Industries

Thakur Industries has been setting new standards of excellence by way of manufacturing quality products. They are engaged in multi dimension business in Bellary, Koppal and other parts of Karnataka State. The promoter is having experience in the field of crushing, screening, trading, logistics. With all these experience, Thakur Industries proposes to expand the Ore Beneficiation Plant existing throughput capacity from 0.6 mtpa to 1.5 mtpa at Hirebaganal Village, Koppal Taluk and District, Karnataka State. The Plant which will run around 300 days in a year and will provide additional direct and indirect employment to around 55 people for expansion.

2.5 About Karnataka

The Karnataka is also the Knowledge Hub of the nation – it has the highest number of medical colleges and third highest number of engineering colleges in the country. The State is the pioneer in two cutting edge industries, aerospace and biotech, where it is the global face for India. The Bangalore has become to cost effective and quality solutions in numerous industries. While at the beginning, this represented off-shoring of low-end services in the BPO sector, the latent strengths of the State have now made it the first stop destination for high-technology cutting edge research and manufacturing centres of global majors. Bangalore is the world’s fourth largest technology cluster as it has the perfect ecosystem fostering growth and development of State-of-the-art technology.

The State economy has a sound base in its rich resources, manufacturing expertise and proactive government policies that have kept growth going in tough times. Agriculture sustains around 63 % of the population and the State accounts for 6% of all food grains production in India and 14% of India’s groundnut output. The State government is encouraging horticulture and Agro-processing to utilize the full potential of resources. Karnataka is one of the country’s largest producers of fruits and vegetables, it produces 12% of fruits and 8% of vegetables grown in India. The State ranks second in the production of flowers, it has in fact the largest area in the country under horticulture. Karnataka ranks second in area and third in production



8

of plantation crops. The state of Karnataka contributes 70% of India’s coffee production and is also the largest producer of spices, aromatic and medicinal crops. The State is the second largest producer of tobacco in the country and the third largest producer of sugar in the country, contributing 5.22% to India’s sugarcane output. It contributes 6% of the total cotton produced in the country, 65% of India’s raw silk and 12 % of India’s wool production, making the State a leading centre for the textile and garment industry. First State to bring the private sector into higher education, Karnataka has the highest number of medical colleges in the country. The State is one of the main centres for medical tourism in the country, as its super specialty hospitals draw in patients from abroad. Always on the forefront of innovation, the State is the biotechnology hub of the country, home to 187 out of India’s 340 biotech firms, and is leading in nanotechnology research. Currently ranking fourth in tourist destinations in India, the State is set to become the leading destination for tourists, in fact the State policy aims to make Karnataka the single largest sector in the economy by 2014. One of the top five industrialized States of India, Karnataka is emerging as an undisputed investment destination for investors. Available opportunities and subsequent benefits along with the investor-friendly policy of the Government make the state an ideal location for the business and residence.

Major Strengths

Good infrastructure development with readily available land, power and water.

Highly-skilled technical manpower base, with large number of engineering / technical institutions and centers of excellence.

A host of reputed multinational industrial & research organization. Technology – savvy work force with proficiency in English language. Conducive environment, salubrious climate, cultural diversity and

cosmopolitan lifestyle. Excellent healthcare facilities, connectivity, effective law and order and

cordial industrial relation. Fast growing markets and organized retail network with emphasis on new

economy sectors.



9

Investor-friendly governance combined with excellent logistics support and effective-governance.

Industrial investments - Driving growth

Robust infrastructure initiatives and efforts from the concerted authorities have ensured that Karnataka remains top on the priority list of the investors,

Consistently ahead in attracting Foreign Direct Investments (FDI). Ranked 3rd with a share of 10.11% of total FDI inflow to the country during 1997 to April 2008.

3,215 Industrial Entrepreneur Memorandums issued to establish large & medium industries in the state between 1991 and February 2009.

2.5.1 Karnataka Industrial Policy 2015 - 2020

Introduction

Karnataka is one amongst the industrially developed States in the Country. The State has potential to stand out on the fore front and has been focusing on development of industries, trade and service sectors. The State Government understands that the challenges posed due to global economic recession have to be addressed to promote economic growth of the State. A stimulus to boost economic activities needs to be given to sustain the current pace of overall development. Further, the state is endowed with rich natural resources across the State and such resources need to be optimally utilized for the benefit of local people. Value addition to resources is one of the efficient ways of optimizing the locally available wealth. This will also help to ensure uniform spread of industries and economic activities throughout the state and will accelerate the pace of development especially in the district of North Karnataka. Through these measures, the Government would be able to readdress the serious issue of regional imbalances in development. The state government realizes the limitation of agriculture sector to generate large scale employment to the local youths. About 56% of the state’s workforce is



10

estimated to contribute 19.13% of the GSDP. It is agreed that, the implementing sector has high potential to create maximum employment that too, to all sections and level of the aspirants. In order to provide suitable environment for investors, the state government has already enacted Karnataka Industries (Facilities) Act, 2002. Due to the progressive measure and pro-active mind set of the government, today, the Karnataka has been recognized as one of the preferred investment destination both for domestic and overseas investors. The state government has introduced Industrial Policy 2006-11 with an aim to increase the growth of GDP, strengthen manufacturing industries, increase share of exports from Karnataka, to generate additional employment of at least 10 lakh persons in the manufacturing and service sectors, reduce regional imbalance and ultimately aim at overall socio-economic development of the state. In the meantime, the Government of India enacted Micro, Small and Medium Enterprises Development Act, 2006 and requested all the States to provide required support and encouragement to make MSMEs more competitive. In order to make the state more attractive and investors friendly, there was a need to focus more on inclusive industrial development, comprehensive HRD programmes, special attention towards development of sector specific zones, classification of Taluk’s according to Mr. D M Nanjundappa Committee Report, attractive package of incentives and concessions, encouragement for existing industries to take up expansion, modernization and diversification etc.. The state also understands the need to provide stimulus measures for industries to combat the prevailing financial crisis. Keeping these points in view, the state intends to formulate a new Industrial Policy with a determination to provide required platform for all the investors. This policy is framed with the broad guiding principles of creation of employment development of backward regions and value addition to local resources.

Vision

To build prosperous Karnataka through development of human & natural resources in a systematic, scientific and sustainable manner.



11

Mission

To create enabling environment for the robust industrial growth.

To ensure inclusive industrial development in state.

To provide additional employment for about 1.5 lakh person by 2020.

To enhance the contribution of manufacturing sector to the state’s

GDP from the current level of 17% to 20% by the end of policy period.

Strategies

Thrust on provision of world-class infrastructural facilities for industries with active participation of private sector/industry.

Development of sector-wise industrial zones for optional utilization of local natural and human resources so as to minimize migration of people to urban centers.

Simplification of land acquisition procedures with emphasis on inclusive development.

Safeguarding the socio-economic interests of both farmers and investors while acquisition of land.

Preferential treatment for MSME sector enabling to meet the global Challenges.

Attractive employment and performance linked package of incentives and concessions to attract investments to backward regions and also to provide leverage to MSME sector.

Thrust on development of MSME sector through attractive package of incentives & concessions.

Tailor made package of incentives to larger projects having wider positive implication on the state’s economy to leverage a better edges over other competing states.

Additional incentives for entrepreneurs belonging to under privileged sections of the society to bring them to the main stream in order to achieve much needed inclusive growth.

Focus on skill development in order to enhance the employment ability of youth especially women and also to make ready-to-employ human resource to the industry.

Inculcate entrepreneurial qualities amongst local youth in general and women in particular and motivate them to take up self employment by extending



12

handholding support. Create level playing environment for all investors/private sector players by

enhancing the facilitation mechanism enabling to do their business with ease and less transaction cost.

Appropriate provision for the protection of environment and to encourage energy & water conservation measures in industry / project through go-green strategy.

2.4.2 Mining –vs- Beneficiation Plant in Bellary

Worldwide ore with Fe content above 62% is estimated to be only around 10% of total reserves. Even though the proportion in India is higher, it is fast getting depleted

Today sponge iron plants are forced to feed even 58% Fe ore into their kilns, compromising on life of key machinery and quality & price of finished products

There is an enormous price disparity between good grade ores and low grade ores. With huge profit margins in ores presently extracted by mine owners, they are least interested in investing in processing of low grade ores, in spite of pressure from Govt.

2.4.3 State Policy

With above considerations, the recent Govt. Policy stresses on the following areas

Utilization of Iron Ore Fines indigenously, specifically Beneficiation of Low Grade Ores.

Maximize Value Addition of Ores in the State, within the State, thus encouraging max. Investments/ Revenue Generation in Downstream Industries

Priority to establishments proposing Industries for Value Addition in the vicinity of mining areas

Last, but not the least, Utilize of Mine Wastes to minimize Environment Impact



13

CHAPTER – 3

SITE SELECTION

3.1 Introduction

M/s. Thakur Industries has already established and operating Beneficiation Plant with throughput capacity 0.6 mtpa at Hirebaganal Village, Koppal Taluk & District. The important consideration was with respect to location of the plant with respect to the accessibility.

The plant location has been so chosen and established that is close to the main Iron Ore mining area i.e. Hospet, Bellary, Sandur and Chitradurga. It is also close to the main road, broad gauge railway line and nearer to the ports like Goa, Mangalore and Chennai, so that transportation to various sites of finished products is easy and economical.

3.2 Criteria for Selection

The parameters that play a major role in site selection are as follows:

3.2.1 Land Availability

The nature of land for core plant must satisfy the following major criteria.

Flatness: Preferable flat or gentle natural slope of land to avoid excessive earthwork.

Stability: Geological and Geotechnical stability for economic foundation. Flooding Risk: Magnitude of runoff from surrounding areas to be minimized. Type of land: Preferably non-residential, non-irrigated with no forest land and

minimum of irrigated/cultivated land. Habitations: Area with large population should be away from plant location.

Displacement of habitants should be avoided or minimized.

3.2.2 Infrastructure Requirements

Proposed expansion of Beneficiation plant requires a number of basic infrastructures such as,

Availability of land Rail/road accessibility



14

Availability of raw materials and proximity to source Availability of water and proximity to source Environmental consideration

3.2.3 Transportation Logistics

The plant location has been so chosen that is close to the main road and broad gauge railway line so that transportation to various sites of finished products is easy and economical. 3.3 Salient Features of Koppal

There are many favorable factors, economical and environmental, for the site located at Hirebaganal Village and falls in the Toposheet no. 57 A/3 which is enclosed as Drawing – 1. 3.3.1 Land

M/s. Thakur Industries, has purchased sufficient land for the proposed expansion project. There shall be no resettlement and rehabilitation of population for this project. The land is suitably located against any flooding or inundation even during severe climatic conditions. The total land available at the present plant site is about 17.50 Acres.

3.3.2 Rail/Road Accessibility

The nearest railway station is Ginigera which is about 6 Km from the site. No problem is envisaged in accessibility and transportation of heavy equipment to site by road or rail. Road connectivity is through NH- 63 located at distance of 5 Km from the plant.



15

CHAPTER-4

DESCRIPTION OF PLANT FACILITIES

4.1 Infrastructural & Offsite Facilities

The proposed expansion of Beneficiation Plant will have the following Infrastructural & Offsite Facilities. The plant layout is enclosed as Drawing – 2. 4.1.1 Infrastructural Facilities

The major infrastructure facilities required for the proposed expansion Beneficiation Plant complex are as follows;

Water Supply Power Supply Transportation Facilities Other Facilities

4.1.2 Offsite Facilities

Main Ware House Maintenance Shop Administrative Building Control Room for all electrical equipments Canteen Water Facilities First Aid Road Weigh Bridge Car / Scooter Parking Fire Protection system Storm Water System Security Room

4.1.3 Water Supply

Beneficiation plant requires water to wash minerals with out water, plant can not work. In order to conserve fresh water, water economy has been an underlying criterion for selection of plant and equipment.



16

Water recirculation systems have been planned to cater extensive recycling and reuse of return water from plant processes. Requirement of water will be fulfilled by the 5 Bore wells which are located in the project site. 4.1.3.1 Emergency Water Supply During electrical power failure, all circulation pumps will stop functioning. Under such circumstances it becomes imperative to maintain water circulation through key equipment washing circuits. To combat against such eventualities overhead tanks of adequate capacity have been provided. This will ensure immediate supply of water with power failure at essential service terminal mentioned hereinbefore for sufficient period of time before starting the emergency diesel generator set. 4.1.3.2 Source of Make-up Water Supply Make-up water required for the system will be made available from Borewell which are located in the project site. 4.1.3.3 Water Conservation Measures

Extensive recycling has been adopted in the design of plant water systems. Quality of circulating water will be maintained through dosing of conditioning chemicals for controlling corrosion, scale deposit and microbial growth.

The process will be recycled and reused back in the process. 4.1.3.4 Rainwater Drainage Adequate rainwater drainage system consisting of open drains has been envisaged to keep the entire plant free from water logging. Depending upon the available contours at detailed engineering stage, the number of drainage out fall and extent of open drains etc. will be decided. The surface runoff will be collected in the rainwater harvesting pond. 4.1.3.5 Sanitary Sewage Wastewater generated from canteen and colony will be disposed off in the CPCB approved Soak Pit and Septic Tanks.



17

4.1.4 Power Supply

Power will be met through GESCOM and standby power from DG sets of capacity 62 KVA – 3 No’s, 155 KVA – 1 No. & 380 KVA – 1 No., will be availed.

4.1.5 Transportation

The plant location has been so chosen that is close to the main Iron Ore mining area i.e. Hospet, Bellary, Sandur and Chitradurga. It is also close to the main road, broad gauge railway line and nearer to the ports like Goa, Mangalore and Chennai, so that transportation to various sites of finished products is easy and economical.

4.1.5.1 Internal Transportation Transportation inside plant is conducted mainly through covered belt conveyer and truck running on roads. The raw material is conveyed from stockyard to process mainly by means of covered belt conveyer. Final product is sent through covered belt conveyer to product house. Trucks used to dispatch final products.

According to requirement on production, transportation and maintenance & repair, two kinds of road (circle type and road having end) are arranged that link traffic systems in surrounding area. Access roads shall be available to every main shop and every place for maintenance & repair.

Internal transportation of materials like scrap, spares, etc among various shops will be carried out by vehicles belonging to the plant. Internal transportation of in-process material and disposal of waste materials will also be done by road. Road vehicles of different types have been envisaged in adequate number to take care of the transport requirement.

4.1.6 Other Facilities

4.1.6.1 Fire Fighting Facilities

Many working premises in the beneficiation plant have hazardous and fire prone environment. To protect the working personnel, equipment and machineries, fire-fighting measures have been planned for the proposed plant.



18

In order to combat any occurrence of fire in plant premises the following fire protection facilities have been envisaged for the various unit of the plant.

4.1.6.2 Fire Protection Facilities

In order to combat any occurrence of fire in plant premises the following fire protection facilities have been envisaged for the various units of the plant. All plant units, office buildings, stores, etc., will be provided with adequate number of portable fire extinguishers to be used as first aid fire appliances. 4.1.6.3 Portable Fire Extinguishers

All plant units will be provided with adequate number of portable fire extinguishers to be used as first aid fire appliances. The distribution and selection of extinguishers will be done in accordance with the requirement of IS: 2190-92.

4.1.6.4 Hydrant System

A fire hydrant network system has been envisaged for the plant. Internal hydrants will be provided at suitable locations and at different levels inside the major plant units. Yard hydrants will be provided normally along the road and in the close vicinity of the units. Hydrant system shall have dedicated pump house, pumps, water storage and piping network etc. 4.1.6.5 Automatic Fire Detection System

Unattended and vulnerable electrical premises like electrical control rooms, cable tunnels, MCC, transformer rooms, switchgear rooms, oil cellars, etc will be provided with automatic fire detection and alarm systems. 4.1.6.6 Automatic Extinguishing System

Outdoor transformers of more than 10 MVA/ 2000 litre oil capacity will be provided with fire detection and emulsifier (high velocity water spray) system.



19

4.2. Ore Beneficiation Plant

4.2.1 Input: Ore Fines

In the present economy the Steel sector and iron ore business are the big factors of GDP growth for India. The Fe content in iron ore to make steel is 63%. Presently the Fe content in iron ore of Karnataka & Goa is 48-58%, though Orissa has much more Fe from 60-65%. Hence the need arises for Beneficiation plant to upgrade the content of Fe upto to 62-64%. The washing plant are already popular in India and many plants are already working successfully where iron of Fe content 58% is washed and upgraded by 2-3% but not suitable for up gradation above 2-3%. The Beneficiation Plant can upgrade Fe upto 6-9%, though the output would differ as per the Fe content in iron ore and % of Alumina & Silica. In India we have majorly Hematite iron ore mines and unlike magnetite iron it requires one special equipment known as high Gradient magnetic separator for beneficiation. The beneficiation plant is a very good business line in the field of steel. The dry beneficiation iron ore with 62-64% Fe content can be used in India by steel groups like Jindal, Central govt. companies & can be exported and can be further used to make pellets and more steel. Therefore, the immediate need is for Beneficiation plants. 4.2.2 Process of Beneficiation Plant

"Beneficiation," means the following as applied to iron ore: milling (crushing and grinding); washing; filtration; sorting; sizing; gravity concentration; magnetic separation; flotation; and agglomeration (pelletizing, sintering, briquetting, or nodulizing). Flotation is primarily used to upgrade concentrates from magnetic separation by reducing the silica content of the concentrate.

Most beneficiation operations will result in the production of three materials: a concentrate; a middling or very low-grade concentrate, which is either reprocessed (in modern plants) or stockpiled; and a tailing (waste), which is discarded.



20

In the present process the entire Material from the Dry circuit is received by Wet Drum Scrubber along with water, in which the material (-40mm) is allowed to be get conditioned and scrubbed properly in water medium with cascading action in a continuously rotating Drum. The output from the Wet Drum Scrubber is allowed to pass over a Triple Deck Vibro Screen, over which the water is sprayed with high pressure (Upper Deck as 22mm, Middle Deck as 8mm and Lower Deck as 4mm) by which the material is classified in accordance with size fraction as +22mm; the over size, is again crushed in a Cone Crusher (closed Circuit) to get complete –22mm sized Material is fed to Wet Drum Scrubber through the Feed Conveyor. The under sized material from middle decks (-22+8mm)is stocked out separately as the product, can be marketed as Sponge Iron Feed, Pig Iron Feed and sized Lumps, Calibrated ore (C-Ore). One more under sized material from the middle deck screen (-8+4mm) stocked out separately as Chips fine ore or Grained fine Ore. The below size material (-4mm) in slurry condition is fed to Screw Classifier in which the settled coarser iron particles will been dragged out from slurry and the over flow slurry water containing clay, silica, alumina, slimes with fine iron particles is fed Tangentially to First stage (contains one Primary and one Secondary) Hydro Cyclone. The Primary Hydro Cyclone, in which the lighter particles such as slimes, clay, alumina, Silica with water are recovered at top opening as Over flow and the Heavier particles collected from the bottom opening is treated as Under flow which is once again conditioned with water (PD maintained) and is fed to Secondary Hydro Cyclone.

The under flow from this is the Super Grade material and the Over Flow from Secondary Hydro Cyclone along with Over Flow from primary Hydro Cyclone in First stage is fed to Second Stage Hydro cyclone (one No.), the under flow is fed to a High intensity magnetic separator (wet), the magnetic values are collected as Super grade concentrates.

The over flow from the magnetic separator and the overflow from II stage Hydro Cyclone is fed to the High Rate Thickener. In Thickener, more than 80% of used water is recovered as clear water (Thickener Over flow) and can be collected in Fresh water pond and recycled, the Under flow- thickened slurry is passed through a filter to separate the water. The water is circulated to the thickener and the dry tailings are collected. The Process Flow chart is given in Figure 1.



21

Feeder

Crusher

Wet drum Scrubber

Triple Deck Vibro Screen

Water

Classifier

Primary Hydro Cyclone

Secondary Hydro Cyclone

Magnetic Separator

Thickner

Filter Press

- 22 mm

Sponge & Iron Feed & sized lumps

- 22mm +8mm

- 8 mm + 4mm Chips fine ore or grained Fine Ore

Screen

- 4 mm

+ 22 mm

Dry Tailing Yard

Water

Super Grade concentrates

Overflow

Figure 1: Flow Chart of Beneficiation Plant



22

4.2.3 Raw Material Characteristics The following band width of raw material characteristics have been considered while designing the Plant Chemical Composition Fe 52% - 58% FeO < 0.5% Al2O3 < 04% L.O.I. Preferably < 06% Mineralogy Hematite Not less than 45% Geothite Not exceeding 30% Clay Preferably < 8% Characteristics Fe Liberation Preferably -65 mesh Bond work Index 8.5 KW/Ton max. 4.2.4 Concentrate Properties Desired properties of concentrate produced in the process has been considered as Chemical Composition Fe 63% - 64% FeO < 0.5% Gangue (SiO2+Al2O3) < 06% L.O.I. Preferably < 06% Particle Size 200 mesh, 90% passing Moisture Content Preferably < 09%, Maximum 10% 4.2.5 Major Equipments

List of machinery required for the planned production is given in Table no. 2.

Table 2: List of machinery

Sr. No. Equipment Quantity

1 Main Hopper 1 2 Grizzly Feeder 1 3 Scrubber 1 4 Screen 2



23

5 Classifier 1 6 Cyclones 2 7 Jig 1 8 Ball Mill 1 9 Magnetic Separator 1

10 Filter 1 11 Jaw Crusher 2 12 Thickener 1 13 Conveyors 14 14 Pan Feeder 2 15 Bin 2

Pre-feasibility Report for Ore Beneficiation Plant of M/s. Thakur Industries, Koppal.


24

CHAPTER – 5

RAW MATERIAL AND CONSUMABLES 5.1 Primary Raw Material – Iron Ore

Keeping in mind abundant availability of Low Grade Iron Ore and Waste Dumps, plant has been designed to accept these low grade ores as primary input.

When High grade Iron Ore is being mined, while extracting the good ore, a proportional amount of Low Grade Ore commonly referred to as Waste Dumps are also extracted and remains unutilized.

Over the decades of mining that has been carried out in this sector, Millions of Tons of Low Grade Iron Ore, commonly known as Waste Dumps have been extracted proportionate to the quantum of High Grade Ores shipped. Most of these remain unutilized.

Detailed analysis has been carried out on Low Grade Ores generated in the Sandur Sector and it is observed that these ores can be easily and economically upgraded through Conventional Methods only.

Proposed expansion plant is designed to utilize this Low Grade Ore, upgrade it to higher quality, the same which can be direct inputs to Sponge Iron Plants or Blast Furnaces.

5.2 Advantages of Low Grade Ore

Even though Sponge Iron Plants are designed for high grade, high tumbler index iron ore, expecting input grade of 63% - 65% Fe, in reality the reserve for good grade ore is limited.

Worldwide ore with Fe content above 62% is estimated to be only around 10% of total reserves. Even though the proportion in India is higher, it is fast getting depleted.

Today sponge iron plants are forced to feed even 58% Fe ore into their kilns, compromising on life of key machinery and quality & price of finished products.

There is an enormous price disparity between good grade ores and low grade ores. With huge profit margins in ores presently extracted by mine owners, they are least interested in investing in processing of low grade ores, in spite of pressure from Govt.



25

Table 5.1: Raw Materials for Production

Division Requirement and Sources

Beneficiation Plant Low Grade Ore from Karnataka, Telangana, Andra Pradesh and Goa at existing mines.

5.3 Raw Material Required for Beneficiation plant

Table 5.2: Raw Material Required for Beneficiation Plant

Raw Materials

Raw Material Required per

Day (T)

Raw Material Required per

Month (T)

Raw Material Required per Annum (T)

Ore 5,000 1,25,000 15,00,000

5.4 Water Requirement

The total water requirement only for the proposed expansion activities in the plant is 3150 KLD. The details are shown in the Table 5.3.

Table 5.3: Water Requirement

Usage Water Consumption (KLD) Source of Water

Dust Suppression 75

Bore well

Drinking 40 Afforestation 35 Process 3000

Total 3150 But the consumptive water consumption for the plant will be only 300 KLD.



26

CHAPTER-6

ORGANISATION AND MANPOWER 6.1 Manpower

Efficient management of the unit requires judicious manpower planning, selection of qualified and experienced personnel and appropriate organizational structure, clearly defining the functions and responsibility of the managerial and supervisory staff.

The manpower requirement in accordance with the targeted production of plant operation has been estimated on the following consideration:- The estimated production and productivity level which is achievable in

various sections of the plant with the proposed expansion plant and machineries.

The total number of personnel required to perform various duties associated with the different processing steps.

A preliminary estimate of the manpower requirement allowing for leave, absenteeism, sickness and holidays for smooth and efficient operation of various sectors of the plant has been prepared purely on technical and managerial grounds primarily to indicate the order of manpower requirement. It would be emphasized that the manpower requirement will have to be reviewed at the time of commissioning of the plant. Further, the implementation of industrial laws and regulations and locational factors of labour employment will also have to be considered. In order to operate and maintain the plant facilities, including its technical general administration needs, the estimated manpower requirement at the full development stage of the integrated complex has been estimated to be 50 persons.

Company has already appointed key personnel for the project. The Company has also appointed many middle and junior level staff who will work to complete the project within the schedule time frame. It may be mentioned that the company shall be appointing skilled, experienced and semiskilled manpower requirement in connection with this industry by recruiting people from all parts of the Country.



27

6.2 Training

The selected executives and key operating, technical and maintenance staff will undergo specific training in the process licensor’s & turnkey equipment supplier’s associated plants. The other operating and maintenance staff will be trained at site, which will include:

Company orientation for all employees Safety training for all employee Specific job training for all the employees Trade and basic educational training for selected employees.



28

CHAPTER-7

ENVIRONMENTAL CONSIDERATIONS 7.1 Introduction

There is no sanctuary, national park or archeological monuments within study area of 10 km radius of the project site. There is also no Reserved/Protected Forests within the 10 kms radius of the plant. The proposed expansion of Beneficiation plant would be equipped with modern, efficient pollution control devices to bring down the emission/discharge of pollutants within the acceptable norms stipulated by the environmental legislations. 7.2 Environmental Issues

This section covers the followings;

The genesis of pollution, Principal sources of pollution, The nature of pollution Proposed measures required for meeting the prevailing statutory

requirements of gaseous emissions, waste water discharge characteristics, noise level etc.

For environmental management purpose in connection with the expansion of Beneficiation Plant.

Pollution prevention and control measures for each of the section are enumerated below: 7.2.1 Pollution from Ore Beneficiation Plant

Feed to the plant will be of dry in nature. The entire stretch of belt conveyor will be covered to avoid escape of air borne dust particles into open atmosphere. The entire beneficiation process is of wet in nature, thereby air pollution from the process is negligible. The dust generated during movement of vehicles will be the main source of pollution.

Water used for the process will be recycled and reused. Only domestic wastewater will be disposed off to the CPCB approved septic tank and soak pit. Noise generated from the beneficiation plant will be having impact to some extent. Necessary control



29

measures will be adopted to ensure that the noise generated will be well within the limits. 7.3 Pollution Control Measures

7.3.1 Air Pollution Control

The measures to control the air pollution will ensure the ambient air quality standards as laid down by Central Pollution Control Board for industrial and mixed-use areas. In addition, the emission from the chimneys will be kept below the permissible limits of statutory norms for dust. Gaseous emissions will be released through stacks of required height so as not to exceed ambient air quality due to the entire plant. The roads inside the plant premises will be asphalted to reduce the dust emissions. 7.3.2 Water Pollution Control

The pollutants present in the waste water will be reduced to acceptable levels by adoption of the following schemes:

The processed water will be recycled & reused to maximum extent. Disposed off the domestic sewage in CPCB approved Soak Pit and Septic

Tank. Storm Water Drainage –

Storm water drainage system shall consists of well-designed open surface drains network so that all the storm water is efficiently drained off without any water logging.

Based on the rainfall intensity of the proposed area drainage system shall be designed on the basis of the storm water flow and the depth available at the out fall point so as to ensure no back flow.

Storm water drains shall be provided on both sides of roads. Rectangular drains shall be provided based on the quantity of storm water to be conveyed and depth limitations.

7.3.3 Noise Pollution Control

Various measures taken to reduce noise pollution include reduction of noise at source, provision of acoustic lagging for the equipment and suction side silencers, selection of low noise equipment, isolation of noisy equipment from working



30

personnel. In some areas where due to technological process, it is not feasible to bring down the noise level within acceptable limits, personnel working in these areas will be provided with noise reduction aid such as ear muffler and also the duration of exposure of the personnel will be limited as per the norms.

7.3.4 Waste Material Management

The waste generated from the process will be silt obtained in the Tailing pond. This silt will be sold to brick /cement manufacturing industries. The domestic organic waste generated will be composted and used as manure for gardening. Inorganic waste and Hazardous waste generated from the plant will be sold to authorized recyclers /reprocessors. 7.3.5 Green Belt

Adequate green belt will be provided all around the plant and inside the plant premises in addition to already existing green belt 33% of the plant area will be brought under green belt as per industrial norms. Locally available types of trees, which are resistant to pollutants will be planted.

7.4 Quality Control

A chemical laboratory and quality control department will be planned to meet the routine necessities of the operative units of the plant for maintaining product quality and the targeted productivity. The activities of this department will comprise:

Collection and preparation of samples. Testing of raw materials and other process inputs. Inspection, testing and quality certification of finished products (pigs). Feed-back assistance to main production units to ensure control of process. Parameters and to take timely corrective measures. Assessment of process irregularities and in-plant failures standardization of

process norms.



31

7.4.1 Chemical Laboratory Keeping in view the above perspective, it has been envisaged that the plant

will have one laboratory that will cater the requirement of raw material, slag and pig iron analysis.

7.4.2 Sampling

All samplings will be done by manual method. For raw material testing sample will be collected from stockyard and belt conveyor carrying raw materials. Sampled materials will be transported to the laboratory for preparation and tests.

7.4.3 Sample Transportation

Transportation of samples from sampling sites to the laboratory for preparation and testing will be done manually.



32

CHAPTER - 8

PROJECT IMPLEMENTATION AND SCHEDULE

8.1 Strategy The installation of several production units along with utilities and services require co-operation for procurement of equipment, equipment foundations, award of all contracts and supervision of all construction jobs at plant site. The project implementation schedule has been drawn up to maintain a strict time schedule. The factors which are responsible for timely implementation of the project are:- Arrangement of proper finance for the project. Finalization of layout of the proposed plant. Design of utilities and services. Placement of orders for plant and machinery. Arrangements for Govt. sanctions and supply of power. Recruitment of personnel.

8.2 Construction Materials It is envisaged that cement, reinforcing steel and structural steel materials, sheets will be procured by the company and issued to the contractors free of cost or at agreed recovery rates. For this, advance action has to be initiated by the company so that these materials are sufficiently stored in adequate quantity before commencement of the work at site. All other construction materials will be procured by the contractors. 8.3 Construction Facilities Construction facilities will mainly include providing construction water construction power, construction road and drainage, construction storages, Construction and fabrication yard, construction lighting etc. It is envisaged that these work shall be done/arranged by the company.



33



34

chapter-1 introduction - …environmentclearance.nic.in/writereaddata/online/tor/06_jul_2016... ·...

Documents