Executive Summary. Iron Ore Beneficiation Plant / Pelletization plant

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1 OF Iron Ore Beneficiation Plant / Pelletization plant Hargarh Industrial Area Tehshil Sihora, Dist. Jabalpur (Madhya Pradesh) Proponent M/s Archana Hi-Tech Automation Systems Pvt. Ltd. C-12, Sukhasagar Valley, Gwarighat Road, Jabalpur (Madhya Pradesh) 1

2 1.0 Introduction M/s Archana HI-tech Automation System Pvt. Ltd. is the registered Private Limited Company having its head Office at 5-234/2 H.P. Road, Moosapet, Hyderabad, and Branch Office C-12, Sukhsagar Valley, Gwarighat Road, Jabalpur (M.P.). The company is engaged in various industrial activities in country and now entering in field of Mineral Beneficiation. The Jabalpur region is having very rich source of minerals like low grade Iron ore and Blue dust therefore company is planning to setup a Iron ore Beneficiation fallowed by Pelletization Plant at Notified Industrial area, Hargarh, Tehsil Sihora, District Jabalpur (M.P.). The proposed capacity of the plant is 0.72 Million ton per Annum of beneficiation plant & 0.64 MTPA Pelletization. The land measuring hectares (ha) is available for setting up of the Plant; the land has been allotted by Madhya Pradesh Audhyokik Vikas Nigam (MPAKVN), Jabalpur. The supply of Iron ore will be met from nearby mines. Substantial numbers of medium size deposits of low grade iron ore are available around Jabalpur. This iron ore is being mined, and most part of it is sold unprocessed by the mine owners. Considering the ever increasing demand for good quality iron ore by steel and metallurgical industries as well as conservation of mineral policy of the Government, we intend to exploit the process and produce iron ore meeting the specifications of user industries. Further to encouragement given by the Government of Madhya Pradesh for industrialization, it is proposed to set up a processing plant in various modules in stages at Plot B+C Industrial area Hargarh, Tahsil, Sihora, Jabalpur. Very low grade Iron ore can not be used in metallurgical plants and needs to be upgraded to increase the iron content and reduce gangue contents. A process adapt to up grade ore is called Beneficiation. Iron Ore is up graded to higher iron content through concentration. Iron ore is beneficiated to all around the world to meet the quality requirement of large steel industries. Several technologies are available such as washing, jigging, magnetic separation; advance gravity separation and floatation are being employed to enhance the quantity of the 2

3 Iron ore. Recent increase in demand for steel & increase in its costs has boosted up the production of iron & steel. The demand for iron ore also has sharply increased. The good quality iron ore is fast depleting thereby forcing the iron makers to use low grade iron ore after beneficiation. As per the EIA Notification issued from MoEF, New Delhi, dated , this project falls in category A, Project Activity 2 (a). 2.0 Project Details S. No. Particulars Details 1 Name of the project Iron Ore Beneficiation and Pelletization Plant 2 Location of the Project Area i Village Notified Industrial Area Hargarh ii Tehsil Sihora iii District Jabalapur iv State Madhya Pradesh 3 Area Specific Details i Proposed project area ha Ii Proposed Green Belt 8300 sq m (1100 sq m from Plot no. B+C and 7200sq m from AKVN, application for permission has already been given) iii Toposheet No. 64 A/3 iv Latitude North v Longitude East vi Plot No. Plot No. B+C 4 Requirements i Total Fresh Water requirement 910 cum ii Total Power requirement 300 KVA iii Total Manpower requirement 60 Nos iv Total cost of the project 26 Corers v Environmental Protection Cost 50 Lakhs 5 Details of Project Area i Nearest National Highway NH 7; 5.2 km ii Nearest Railway Station Sihora; 8 km iii Nearest Airport Jabalpur 60 km 3

4 iv National Parks, Sanctuaries, Biosphere Reserves, Wildlife Corridors, Tiger/Elephant reserves within 10 km radius No National Parks, Sanctuaries, Biosphere Reserves, Wildlife Corridors, Tiger/Elephant reserves within 10 km radius Bohra Reserved forest (2.0 Km) Dhanwahd RF 6.5 km v Nearest major city Jabalpur vi Nearest River Hirren river (1.5 km in S direction) 3.0 Raw Material Requirements S. No. Name Qty (MTPA) Source 1 Iron Ore 1.2 Nearby Mines 2 Bituminous Coal (Imported) Imported 3 Limestone Local Mining 4 Coke Breeze Local Mining 5 Bentonite Kutch, Gujarat 6 Furnace Oil As and when needed From Local market 3.1 Water Requirement Breakup of water requirement and usage: Activity Proposed requirement (m 3 /day) Total requirement (m 3 /day) No. of operationa l days in a year Annual requirement (m 3 /year) Industrial activity Residential/ domestic Greenbelt development/ Environment maintenance Other use Grand total Beneficiation Process: 1. Screening of raw ore through vibrating grizzely mm size will be crushed by JAW CRUSHER 3. This material is again screened through D. D. Vibratory screen 4

5 4. -1mm will go to sump and +1mm will be fed to ball mill 5. Discharge of ball mill will go through H. SP. Screen 6. -1mm will go to sump and +1mm will be re-fed to ball mill. 7. From sump the material will be pumped to Hydro cyclone 8. Under flow from Hydro cyclone will be collected in sump and Pumped to cluster of Cyclones 9. Under flow from cluster of cyclones will go to Primary spiral 10. From Primary Spiral concentrate will go to Secondary spiral and rejects will go to tailing Pond 11. From secondary spiral rejects will go to tailing pond, concentrate is finished product, will go to stock yard and spiral middle will be re-fed to primary spiral. 12. Over flow of Hydro cyclone and cluster of cyclones will be collected in a sump and Pumped to Desliming cyclone 13. Over flow will go to tailing pond and under flow will go to sump and pumped to WHIMS. 14. The concentrate from WHIMS will go to stock yard as finished product and tail will go to RCC bedded tailing pond. 15. Water from tailing pond will be taken in recovery tanks. There will be 3 recovery tanks with RCC sloping bed, after settlement of solids water is removed for re-use and solids will be scrapped out manually. The tanks will be used alternately while one is allowed to dry other two will be in use. Scrapped solids will be sold for brick making. 4.1 Pelletization Process: Grate Kiln technology is proposed for pelletization & the process is as below: 1. Additives (Limestone& Coke Breeze) grinding. 2. Coal Pulverization. 3. Proportioning & mixing of additives, binder & Iron Ore fines concentrate. 4. Green Balling & Screening. 5. Drying & Preheating in travel grate. 5

6 6. Roasting/ Induration in pulverized coal fired rotary kiln. 7. Cooling & Heat recovery in circular cooler. 8. Exhaust gas cleaning through ESP for emission control. Process Flow Chart 6

7 5.0 Baseline Environment Scenario: 5.1 Air Environment: Ambient Air Quality monitoring has been done during October 2011 to December 2011 at six monitoring stations for the parameters like SPM, PM10, SO 2, NOx and the concentration of parameters are found well below the prescribed limit. The concentration of SPM ranges µg/m 3, PM 10 ranges µg/m 3, SO 2 ranges µg/m 3, NOx ranges µg/m 3. The ambient air quality stations are as follows: S. No. Location Direction Distance A1. Project Site - - A2. Hargarh Village SW 1.8 km A3. Darauli Village E 2.4 km A4. Bichhiya Village S 3.1 km A5. Bhatadon Village W 3.8 km A6. AmgawanVillage SW 4.2 km 5.2 Water Environment Water samples are collected from six location analysis as per the IS and observed that the parameters are well within the limits. 5.3 Noise Pollution Noise levels have been measured in the neighborhood environment of the project site. Noise coming from Trucks, cars, birds, animals etc. is expected to add to the main noise generated by process operations of the Facility. Three Baseline noise level survey locations have been selected. One at project site, one at Village Hargarh 1.6 Kms. Ambient Noise Level S. No. Location Direction Distance Existing Noise Level (day time) N1. Project Site db(a) N2. Hargarh Village SW 1.8km 49 db(a) 7

8 N3. Darauli Village E 2.4 km 45 db(a) 5.4 Biological Environment: The biological environment mainly consists of flora and fauna and its relationship with surroundings. Biological environment includes species of native plants and animals and one may measures the degradation of environment by noting the decrease in the commonly species. Shrubs and bushes can be seen in the plant area. And there is no well known rare, endangered species in this region. Hence there will be no considerable impact on the biological environment. The massive afforestation planned for the plant site shall generate a forest having. 5.5 Fauna According to Survey of India, the study area does not host natural wild life. There are also no zoos or bird sanctuaries in the study area. Rodents, monkeys, jackals and large birds constitute the natural fauna in the study area. Peasants, pigeon, peacock can be sighted occasionally along with the birds of common occurrence in the study area. Even forestland has only sparse row of trees and is not able to sustain much natural fauna. The fauna encountered are listed in table below. Bengal Monkey (Macasus rhesus) Mongoose (Herpests mingo) Kalmuha monkey (Semnapthecus on lellccs) House sparrow (Passer domesticus) Common maina (Acrido tehras tristis) List of Fauna in Study Area Jungle cat (Felischaus) Sambhar (Crevus unicolor) Common haw cuckoo (Cuculus micropterces) House crow (carvus splendens) 8

9 5.6 Water Bodies Hiren River is flowing at a distance of 1.5 km towards the E direction from the proposed plant, this river will be the source of water for Hargarh Industrial area. Ground water is available both under confined and unconfined conditions. The ground water table in the study area is found 15m BGL. 5.7 Soil Quality The soil samples collected from 3 different stations and analyzed. The analysis report shows that the ph value ranges from 6.43 to 6.91, water holding capacity ranges from to 46.83% and Nitrogen contents are found 289 kg/ha to kg/ha 5.8 Socio Economic Status The population of the district Jabalpur as per census records 2001 is 21,51,203. Scheduled Caste & Scheduled Tribe fraction of the population of the study area is 12.73% and 15.01% respectively. Percentage of literacy is 75.69%. 6.0 Existing infrastructure facilities: Education Within the study area there are only seven primary schools. But at Sihora & Jabalpur have education facility with Collages & Higher Secondary Schools. Medical and Health The project proponents shall provide facilities for medical check-up of its workers and employees through a visiting Physician. They will also provide first-aid facilities at plant time office. Transport The National Highway no. 7 is connecting MP & Uttar Pradesh is 5.2 km away from site. All sorts of vehicles, viz. Trucks, Mini-trucks, Buses, Jeeps, Cars etc. play day and night over this highway and instant conveyance is available even upto Jabalpur. 9

10 Jabalpur is the nearest airport while Sihora is the nearest railhead about 8.0 kms Away from the site. 7.0 Green Belt Development The company will developed green over an area 1100 sqm in the factory premises while 7200 sqm land of MPAKVN. The permission for this is obtained by the company. So the total green cover shall be 8300 sqm. The whole area shall be covered by plantation within 3 years from start of the plant operation. 8.0 Anticipated Impact of the Project 8.1 Water Environment: The waste water generated from the washing of ore shall be taken to settling tanks of three Nos of size 1000 cum. The settling shall be done by adding poly electrolyte. The over flow clear water is re use in the process. Water requirement of the project shall be 6006 cum per day out of which 5100 cum water shall be recycled through specially designed equipments. Thus the fresh water requirement shall be 906 cum per day which will be supplied by MPAKVN. 8.2 Air Environment There is possibility of emissions during construction phase, which have negative impact on ambient air quality of surroundings, which will be temporary and reversible in nature and will be localized. The measure pollutant from the Iron Ore Beneficiation & Pelletisation plant are particulate matter, oxides of nitrogen (NOx) and Sulphur dioxide (SO 2 ). But proper mitigative measures like pollution control equipments to control the adverse impact the company will install suitable pollution control equipments like Electro Static Precipitator (ESP), Bag filters to maintain the dust concentration as per prescribed Norms. 10

11 8.3 Solid waste The main solid waste shall be generated during the beneficiation process is discards which is having % Iron contents. The quantity of discards shall be anticipated approx MTPA. It will be given to nearby bricks manufacturers, this will also used to backfill the abandoned mine pits of surroundings area. Storage of Iron Ore, Beneficiated ore shall be protected by garland drains leads to tailing pond. 8.4 Noise Level Noise level shall be generated from Crusher & Ball Mil. These units are equipped with acoustic enclosures to reduce noise level and bring them within Norms. 9.0 Post Project Environmental Monitoring Programme: Monitoring Schedule S. No. Description Frequency 1. Ambient Air Quality Quarterly 2 Water Quality Monitoring monthly 3 Noise level Monitoring Quarterly 4 Health Check up once in a year for employees 10.0 Conclusion M/s Archana HI-tech Automation System Pvt. Ltd. Will implement proper environment management plan, this project will encourage other developmental activities in the area, which will improve employment opportunity and lead to economic growth. The project will not cause any negative impact due to high standard of environment management system. 11