JODA WEST MANGANESE MINE Lessee : TATA STEEL LIMITED

Transcription

1 JODA WEST MANGANESE MINE Lessee : TATA STEEL LIMITED 2 ND REVIEW OF MINING PLAN & SCHEME OF MINING ( TO ) Submitted under Rule No. 12, MCDR 1988 & PROGRESSIVE MINE CLOSURE PLAN ( TO ) Submitted under Rule No. 23B, MCDR 1988 Lease Area Hect. Date of Lease Execution Executed Lease Period 20 Years (2 nd Renewal from to Date of Lease Expiry Date of Renewal Application (For 3rd Renewal) Forest Area Hect. Non-Forest Area Hetc. Category of Mine A-OTFM PREPARED BY:- HARIDRUMAT BEHERA REGD. NO. RQP/BBS/093/2010-A TATA STEEL LIMITED FERRO ALLOYS & MINERALS DIVISION JODA WEST MANGANESE MINE, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ODISHA)

2 This is to certify that : A) The provisions of Mines Act, 1952 Rules and Regulations made there under have been observed in the preparation of the Scheme of Mining of Joda West Manganese Mine of M/s Tata Steel Limited over the lease area of ha. in Keonjhar district of Orissa and wherever specific permissions are required, the applicant will approach the DGMS. B) The information furnished in this Scheme of Mining of Joda West Manganese Mine is true to the best of my knowledge. C) Further standards prescribed by DGMS in respect of miner s health will be implemented. Name : Designation : Head (Underground Mining Project) TATA STEEL LTD. Ferro Alloys and Minerals Division RQP : Regd. No. RQP/BBS/093/2010-A Place : Sukinda Date :

3 C E R T I F I C A T E This is to certify that the provisions of MCDR 1988 have been observed in the preparation of the Scheme of Mining of Joda West Manganese Mine of M/s Tata Steel Limited in Keonjhar district of Orissa and wherever specific permissions are required, the applicant will approach the Indian Bureau of Mines. Name : Designation : Head (Underground Mining Project) TATA STEEL LTD. Ferro Alloys and Minerals Division RQP : Regd. No. RQP/BBS/093/2010-A Place : Sukinda Date :

4 CONTENTS (SCHEME OF MINING) Sl.No. Description Page No Introduction 7-8 Part I 1.0 Review of Approved Mining Plan 9-21 Part II 2.0 Proposal under Scheme of Mining For the next five years 3.0 Reserves Conceptual Mining Plan Mining Handling of Waste / Sub-grade Material Use of Mineral Mineral beneficiation Environment Management Plan

5 CONTENTS (PROGRESSIVE MINE CLOSURE PLAN) Sl.No. Description Page No Part III 1.0 Introduction Reason of Closure Statutory Obligation Closure Plan preparation Mine Description 2.1 Geology Reserves Method of Mining Mineral Beneficiation Review of Implementation Closure Plan 4.1 Mined Out land Water Quality management Air Quality Management Waste Management Top soil management Tailing Dam Management Infrastructure Disposal of Mining Machinery Safety & Security Disaster Management & Risk Assessment Care & Maintenance during Temporary Discontinuance 5.0 Economic repercussions of closure & 121 Manpower retrenchment 6.0 Time Scheduling for abandonment Abandonment Cost Financial Assurance Certificate Plans, Sections etc 128 4

6 LIST OF DRAWINGS Sl.No. Title Drawing No. Scale 1. Key Plan MP/JWMM/01/12 1 : 50, Copy of Lease Plan MP/JWMM/01A/12 1 : Digitized Lease Plan MP/JWMM/01B/12 1 : Copy of Diverted Broken up Forest Land MP/JWMM/01C/12 1 : Copy of Diverted Virgin Forest Land MP/JWMM/01D/12 1 : Copy of Satellite image showing the lease boundary MP/JWMM/01E/12 1 : Surface Plan MP/JWMM/02A/12 1 : Part Surface Plan H Quarry MP/JWMM/02B/12 1 : Part Surface Plan I Quarry MP/JWMM/02C/12 1 : Part Surface Plan D Quarry MP/JWMM/02D/12 1 : Part Surface Plan Gangaigora & Sankhaiburu Qry. MP/JWMM/02E/12 1 : Part Surface Plan Old H Quarry MP/JWMM/02F/12 1 : Geological Plan MP/JWMM/03/12 1 : Part Geological Plan (5 Sheets) MP/JWMM/04/12 1 : Geological Section (6 Sheets) MP/JWMM/05/12 1 : Excavation Plan D Quarry (5 Sheets) MP/JWMM/06 A/12 1 : Composite Development Plan D Quarry MP/JWMM/06 A-1/12 1 : Excavation Plan H Quarry (5 Sheets) MP/JWMM/06 B/12 1 : Composite Development Plan H Quarry MP/JWMM/06 B-1/12 1 : Excavation Plan Old H Quarry (5 Sheets) MP/JWMM/06 C/12 1 : Composite Development Plan Old H Quarry MP/JWMM/06 C-1/12 1 : Excavation Plan Gangaigora (2 Sheets) MP/JWMM/06 D/12 1 : Composite Development Plan Gangaigora Quarry MP/JWMM/06 D-1/12 1 : Excavation Plan I Quarry (3 Sheets) MP/JWMM.06 E/12 1 : Composite Development Plan I Quarry MP/JWMM/06 E-1/12 1 : Composite Excavation Section (2 Sheets) MP/JWMM/07/12 1 : Waste Dump Plans & Sections (5 Sheets) MP/JWMM/08/12 1 : Sub-grade ore Stack Plans & Sections MP/JWMM/08-A/12 1 : Environment Management Plan MP/JWMM/09/12 1 : Environment Plan MP/JWMM/09A/12 1 : Present Land Use Plan MP/JWMM/10/12 1 : Financial Assurance Plan MP/JWMM/11/12 1 : Conceptual Plan MP/JWMM/12/12 1 : Progressive Mine Closure Plan MP/JWMM/13/12 1 :

7 ANNEXURES Annexure No. Description Page No. I Consent Letter from Applicant Initial I - A Certificate on change of company s name I - B Certificate from Applicant Initial I - C Copy of the Resolution of Board nominating the Owner I - D Copy of Photo ID & Address Proof of Applicant I - E Metalliferrours Leases held by the company 09 I - F Undertaking by Applicant to carry out exploration in a time bound manner 10 I - G Undertaking by Applicant for submission of geo-referenced cadastral plan 11 I - H Copy of Letter addressed to Controller of Mines under 42(1)(b)(i) of MCDR, I I Copy of the letter for seeking the specific permission for for disposal of overburden from Khandbond Iron & Mn.Mine within the Joda West lease I J Undertaking by Applicant to submit the specific approval before commencement of disposal of overburden generated from Khandbond at 16 Joda West I K Copy of Abstract of Surface Right granted 17 I L Copy of renewal application (Form J) I M The certified copy showing details of position held by the Board of Directors in other company/ firm/ organization II Copy of RQP Certificate 34 III Copy of Lease Deed IIIA Form D for Renewal of Mining Lease 141 IV Ambient Air Quality Report V Water Quality Report VI Copy of Environmental Clearance VII Copy of Forest Clearance VIII Copy of Consent Order obtained from State Pollution Control Board IX Copy of Chemical Laboratory Recognition Letter 168 X Copy of Scale Exemption Letter 169 XI Typical Bore hole logs XII Details of expenditure incurred towards exploration during XIII Copy of Report from CIMFR on experimental blasting XIV Pre - Feasibility Report XV Photographs P-1 Some Photographs of ML Pillars P-2 Some Photographs of Mining & Allied activities P-3 Some Photographs of Environmental Protection measures already in place P-4 Some Photographs of measures taken for rain water management P-5 Some Photographs of reclaimed and rehabilitated area considered as Green Belt XVI Copy of Bank Guarantee BG 0006BG dated and validity till

8 INTRODUCTION Location of Lease: The Joda West lease area falls in villages of Joda, Bichakundi, Kamarjoda, Banspani, Bhuayan Roida & Baitarani Reserve Forest in the Keonjhar district of Odisha. The lease area is located in Survey of India Topo sheet No. 73 G/5 & 73 F/8 within the longitude: 85 o E & 85 o E & latitude: 21 o N & 22 o N. Lease grant & Renewals: Mining lease was granted in favour of the Applicant by the Provincial Government for 30 years from to over Sq Miles including other 2 Tata Steel leases of Khondbond & Katamati. The Mining lease was renewed (1 st Renewal) for 20 years from to over the same area. The Mining lease was further renewed (2 nd Renewal) for 20 years from to over Ha separately. Subsequently, 3 rd lease renewal application was filed in Form-J in due time on for 20 years from to over Ha. Form D for acceptance of our application in Form J was issued on the same day on rd Renewal of Mining Lease has been approved in principle by State Govt vide letter no. IV(A)SM-17/ /SM, dated & by Central Govt, vide letter no. 5/100/2010- M-IV, dated and formal intimation for execution of deed is awaited Mining Plan & Scheme of Mining: Mining Plan and subsequent scheme of mining was approved as per the details given below. Mining Plan / Scheme of Mining Approval Letter No. & Date Period Mining Plan BBS/KJ.Mn/MP-107. Dt to Modification of Mining Plan BBS/KJ/Mn/MP-107, Dt to st Review & MS/OTFM.MECH/39-ORI/BHU/ , Scheme of Mining Dt to Forest Clearance: Forest Diversion proposal (FDP) was filed on and after several rounds of scrutiny & clarifications, Stage-II was granted by MoEF vide Letter No.F.No.8-89/2004- FC over an area of ha on Further, FDP over entire balance forest area of ha excluding safety zone [ ha for conveyor corridor (State Sl.No. 381, Dt ) & ha (State Sl.No.432/10, Dt )] is in active consideration of the Forest Department. 7

9 The Company also paid for an amount of Rs Cr. to Forest Department as Net Present Value (NPV) over the entire forest area within the lease. Environment Clearance: The mine has already obtained the Environmental Clearance from the MoEF vide letter no.j /86/2004-IA.II(M), Dt for TPA of Manganese Ore. The mine has also obtained the Consent to operate for production level at TPA of Manganese Ore under Air (Prevention and Control of Pollution) Act, 1981 & Water (Prevention and Control of Pollution) Act, 1974 from State Pollution Control Board, Orissa. (Consent Order No.67, valid up to

10 PART I REVIEW OF APPROVED 1 ST SCHEME OF MINING 9

11 1.1 NAME OF MINE: JODA WEST MANGANESE MINE AT / PO : BICHHAKUNDI VIA : JODA DIST : KEONJHAR STATE : ORISSA PIN : PARTICULARS OF APPROVAL OF MINING PLAN / SCHEME OF MINING: The Mining Plan of Joda West Manganese Mine over an area of ha. was submitted under Rule 24A of MCR, 1960 and was approved by the Regional Controller of Mines, Bhubaneswar vide letter no. BBS/KJ/Mn/MP-107, dated In order to take care the violations raised vide letter no.ori/mn/kjr/mcdr-8/bbs, dated , a modification of approved mining plan for the period from to was submitted under Rule No.10, MCDR, 1988 and the same get approved vide letter no. BBS/KJ/Mn/MP-107, dated The Progressive Mine Closure Plan was submitted under MCDR, 1988 and MCR, 1960 and the same get approved vide letter no. BBS/KJ/Mn/MP-107, dated The 1 st Review of Mining Plan and Scheme of Mining for the period to was approved vide letter no. MS/OTF.MECH/39-ORI/BHU/08-09, dated DATE OF COMMENCEMENT OF MINING OPERATIONS: Joda West Manganese Mine is a semi-mechanized mine of the Tata Iron & Steel Company Limited and it is in operation since 17 th Jan, The mining lease was originally granted for a period of 30 years w.e.f over an area of sq.miles ( ha.) including Katamati and Khonbond blocks. The first lease renewal was done for a period of 20 years w.e.f over an area of sq.miles ( ha.). During the second lease renewal for a period of 20 years w.e.f , Joda West formed an independent lease over an area of ha. The application for third renewal over an area of ha. was made on The covering letter in the form of Form D for the above renewal application enclosed as Annexure- IIIA. 1.4 REVIEW OF SALIENT FEATURES OF THE APPROVED MINING PLAN:- a) Deficiency if any in the Approved Scheme of Mining: None b) Review of important chapters of the Approved Mining Plan: 10

12 Salient features of the Approved Mining Plan were reviewed and the deviations / changes are enumerated. CHAPTER 3.4: RESERVES Section 3.4.1: Exploration Proposed Table below gives the exploration figures as proposed in the approved scheme of mining and the actual exploration done. Table 1.4.1a (Core Drilling as on ) Year Proposed Core Bore Holes Actual Core Bore Holes Drilled Nos. Meterage Nos. Meterage Total Table 1.4.1b(DTH/RC Drilling as on ) Year Proposed DTH / RC Bore Holes Actual DTH / RC Bore Holes Drilled Nos. Meterage Nos. Meterage Total Table 1.4.1c [Total exploration (Core +RC) as on ] Total Proposed Bore Year Holes Actual Bore Holes Drilled Nos. Meterage Nos. Meterage Total

13 Cumulative exploration carried out in the lease area since inception is 655 Nos. of core boreholes with total meterage of and 156 Nos. of DTH/RC boreholes with total meterage of The location of all the boreholes drilled at Joda West Manganese Mine has been duly indicated in the updated Geological Plan in drawing no. MP/JWMM/03/12. The actual number of core boreholes drilled during to (till Oct 12) was more than the proposed number of core boreholes. This was mainly due to the fact that most of the proposed boreholes were in forest areas where necessary clearances could not be obtained and as such modification of exploration plan was submitted to IBM for the period to in compliance with the violations pointed out during task force inspection. In the modified exploration plan borehole proposal was increased in the stage-ii approved forest areas. CHAPTER 4.0: MINING Part II: Proposed Development & Production Programme - Table below gives the details of production of manganese ore with respect to the proposal in the approved mining plan. 12

14 Year (Till Oct) Total ( ) Pit / Quarry Overburden (CuM) Table:1.4.2 As proposed in Approved Scheme of Mining ( to ) Mineral Saleable Sub-grade Stripping ROM Ore Fines/ Ore Ore Ratio (Tonne) Rejects (Tonne) (Tonne) (CuM/T) (Tonne) Total Excavation (CuM) Overburden (CuM) ROM Ore (Tonne) Saleable Ore (Tonne) Sub-grade Ore (Tonne) Mineral Fines/ Rejects (Tonne) Stripping Ratio (CuM/T) Total Excavation (CuM) D'Quarry H'Quarry G.Gora S.Buru I'Quarry Total D'Quarry H'Quarry G.Gora S.Buru I'Quarry Total D'Quarry H'Quarry G.Gora S.Buru I'Quarry Total D'Quarry H'Quarry G.Gora S.Buru I'Quarry Total D'Quarry H'Quarry G.Gora S.Buru I'Quarry Total D'Quarry H'Quarry G.Gora S.Buru I'Quarry Total Actual 13

15 Reasons for deviation are as follows: 1. The excavation and production during the last planned period was 53% and 59% respectively. Though certain sections were well within the diverted forest area, we were constrained to confine the workings within broken up area only due to delay in obtaining the subsequent tree felling permission after Stage II Forest Clearance. 2. The excavation was confined within the major quarries which are contributing about 83% of the total planned production. The other small quarries were not operated after first year of scheme period due to curtailment in low grade production because of low market demand and considering the rising inventory at pit head. (Inventory of low grade : as on MT & as on MT) 3. The overburden excavation was 54% of the planned quantity. The OB excavation was low as the workings had to be confined to the broken area for reasons as stated above. Moreover, the need for OB removal was reduced due to non-operation of the quarries and sections thereof having higher stripping ratio for reasons as stated above. However, the overall stripping ratio was 6.61 against the plan of CHAPTER: 9 Environment Management Plan Table below gives the afforestation and construction of toe wall with garland drain as proposed in the approved scheme of mining and the actual carried out so far. Table Plan Actual Year Plantation Garldn Retaining Plantation Garldn Retaining Area No. of Drain Wall Area No. of Drain Wall (ha) saplings (m) (m) (ha) saplings (m) (m) Total Reasons for deviation: The area covered under afforestation was 73%. This was due to less land degradation caused by dumping of overburden (excavation of overburden was only 54% of the planned quantity). Similarly the construction of retaining wall and garland drain was 83% due to the same reasons as stated above. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 14

16 c) Review of compliance position of conditions imposed in the approval letter of the Mining Plan: All conditions that were imposed in the approval letter have been complied. d) Review of compliance position of violations pointed out by IBM: (A) There were two violations pointed out during task force inspection vide Show Cause cum Violation Notice No. ORI/MN/KJR/MCDR-8/BBS, dated: which was duly explained in our reply vide letter no. Head/1168/2010, dated Issue 1 Item Financial Year Proposed Exploration 29 nos. bore hole of core drilling and 61 nos of DTH holes at D Quarry Achieved 7 nos. of Bore Holes and no DTH drilling were carried out Comments: In view of the nation-wide spurt in exploratory drilling due to the boom in the iron ore and coal sectors, good drilling contractors were already overbooked with lot of jobs. They showed little or no interest to drill for minerals like Manganese since the volume of business was much lower than that for Coal & iron. The drilling parties were able to get quicker returns in the above sectors, particularly from new lessee who were also not having stringent technical requirements. As such, the drilling contractors had to be selected amongst those that were available. We had to continue with them although their performance was poor. Moreover, the Manganese mineralization is associated with Chert. The progress was lower than predicted since problems were encountered while drilling through such cherty formation. We are alive to the above problem and have recently been able to get a more competent drilling contractor who has already deployed a modern, imported and more powerful hydraulic core drilling machine. We are hopeful that we shall be able to clear the back log of 22 bore holes of before the end of Mar The proposal for the DTH drilling was made for barren proving in the old workings of the D & H quarries. Essentially, the barren proving by these DTH holes is for facilitating the possibility of reclamation by back filling of the overburden in such old workings during the next scheme period from 2013 onwards. The backlog DTH drilling work will be taken up in the current financial year. Issue 2 Development/ Overburden D Quarry 5,94,488 Cu. M H Quarry 6,24,638 Cu. M Gongaigora Cu. M Sankhaiburu Cu. M I Quarry Cu. M D Quarry 1,54,066 Cu. M H Quarry 2,84,761 Cu. M Gongaigora Nil Sankhaiburu Nil I Quarry 21,953 Cu. M JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 15

17 Production of Mn Quarry D Quarry 96,713 tonnes H Quarry tonnes Gongaigora 21,268 tnnes Sankhaiburu 1532 tonnes I Quarry 6593 tonnes D Quarry 29,730 tonnes H Quarry tonnes Gongaigora Nil Sankhaiburu Nil I Quarry 2955 tonnes Development and production was lagging from proposed target and two quarries are not worked at all. Comments: The plan for the development work was based on the stripping ratio for the proved ore occurrences in the respective quarries. The plan Vs actuals for overburden, ROM production and stripping ratio is given in the table below. Proposal as per Mining Plan ( ) Actuals ( ) Finished Stripping Finished Ore ROM Ratio; OB (in Ore ROM Producti (in MT) OB (Cum)/ Cum) Productio (in MT) on (MT) ROM (MT) n (MT) OB (in Cum) JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 16 Stripping Ratio; OB (Cum)/ ROM (MT) D- Quarry 5,94,488 96,713 1,13, ,54,066 29,730 30, H- Quarry 6,24,638 53,894 63, ,84,761 34,420 35, Gongaigora 74,991 21,268 25, Sankhaiburu 64,279 1,532 1, I-Quarry 56,898 6,593 7, ,953 2,955 3, Grand total ,80,000 2,11, ,60,780 67,105 69, From the above table, it may be observed that the planned stripping ratio has been followed and achieved. Moreover, since the height and the width of the benches in all the above working quarries have been maintained, no lag in development of the working quarries is perceived. The production level from Joda West Mn Mines was enhanced to 1,79,500 Mt per annum in after due modification of the mining plan. The achieved production of manganese ore from onwards is given below: Year Proposed Production Actual Production (MT) (MT) Thus the above production plan of 1,80,000 Mt per annum has been a realistic proposal. The manganese ore required for the downstream process of ferro alloy production has to meet very stringent specifications with respect to not only Mn percentage,

18 but also Mn / Fe ratio, Al2O3 / SiO2 ratio, granulometry, decripitability etc. The ore quality with respect to the above parameters as well as recovery varies widely in different quarries. Accordingly, the company operates different quarries to have a suitable blend in order to satisfy all the above quality parameters. At the time of modification of the Mining Plan in the Forest and Environmental clearances for all the manganese mines being operated by the company were pending since long. The forest clearance for some of the leases was still pending even at the time of the current plan period of to Moreover, all the manganese mines were working under deemed extension as per Rule 24A(6) of the Mineral Concession Rules, 1960 and the third renewal of the leases is still awaited. In order to take care of our growth plans, wide variability in the ore quality at different quarries and uncertainties related with statutory clearances, we had accordingly planned for the above higher production levels. Accordingly, based on the Mining Plan, Environmental clearances were also obtained for the above higher production levels. The production from the Gangaigora and Sankhaiburu quarries were planned as a contingency measure. While the need for operating these quarries and higher production levels did not actually arise in , the perceived threats related to statutory clearances continued to remain. As the planned stripping ratio was achieved by close monitoring of the development of the quarries and since the overall interest of safe and scientific mining was being fulfilled, no further modification of the Mining Plan was sought as per provisions of Rule 10 of MCDR, The production plan for D & H-quarry and its development was made for extention of the quarry in areas for which Stage-II clearance from the Government of India in the Ministry of Forest and Environment had already been received. However, the production could not be enhanced since tree felling permission required for extention of the quarry has still not been granted. (B) There were five violations pointed out during inspection vide Letter No. G /1/2011-BBS, Dt which was duly explained in our reply vide letter no. MGM/P&E/ 1071 / 2011, dated i) Violation under Rule 13 (1) as It was proposed to excavate up to the end of scheme period ( ) in Quarry H (Old) 3600E E and 1100N N, whereas during inspection, it was observed that excavation has been carried out up to 4000E & 1100N N in the year Hence deviation in excavation of H Quarry (Old) beyond the area of approved Scheme of Mining was noticed. Compliance Status: We would like to appraise you regarding the year-wise extent of working at H Quarry (old) as per the approved Scheme of Mining. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 17

19 Year Extent of Working N N 3720E E N N 3700E E N N 3700E E N N 3680E E N N 3680E E As depicted, the ultimate extent of working is 1100N N & 3680E E during planned period. The extent of working for 10m beyond the approved extents towards northing and 20m towards the easting during the period 1 st Apr 2008 to 30 th Jun 2011 was primarily to provide a wider road for safe movement of our HEMMs. No further extension of this road shall be done during this Scheme period. This extended road is being proposed to be within next five year Mining Scheme period. ii) Violation under Rule 13 (1) as It was proposed to drill 42 nos. of boreholes of core drilling in the year (20 nos nos. of backlogs of ). However only 24 boreholes were carried out. Compliance Status: Core drilling could not be completed during the year due to non-performance of our core drilling partners. However, the said exploration is in progress and a total of 22 boreholes have already been drilled with a cumulative meterage of during April 2011 to August We are expecting to complete the said exploration program by March iii) Violation under Rule 13 (1) as Existing check dam near Pump House was not desilted to avoid pollution due to wash offs from adjacent dumps in to Kundra Nalla. Compliance Status: The check dam and sedimentation basin has been properly de-silted to avoid water pollution due to wash offs from adjacent dumps in to Kundra Nallah. In future, the proper de-silting of our existing check dams shall be ensured at a periodic interval. Photographs of the area are also enclosed as Annexure - I for your kind reference. iv) Violation under Rule 33 (2) as Ore stocks were not secured by retaining wall to prevent wash offs. Waste dump in Quarry Q was not secured by garland drain and retaining wall to prevent formation of gullies and escape of the material there from. Compliance Status: The construction of retaining wall and garland drain along the ore stack yard and waste dump of D Quarry to prevent wash offs has already been started and will be completed within two months of time. v) Violation under Rule 21 (1) as Log books in respect of heavy earth moving machinery used in the mine are not being maintained as required. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 18

20 Compliance Status: The log book for heavy earth moving machineries is being maintained. Photocopies of sample sheet were submitted for reference. (C) There were three violations pointed out during inspection vide Letter No. ORI/MN/KJR/MCDR-8/BBS, Dt which was duly explained in our reply vide letter no. MGM/P&E/ 59 / 2013, dated i) Violation under Rule 13 (1) as In Quarry-H, excavation has been approved between 2070N-2380N & 3580E-3980E, up to depth of 541 mrl at the end of year in this scheme period. Whereas during inspection, it was observed that excavation has been carried out between 1890N-2250N & 3470E-3850E and depth of this quarry has gone up to 533 mrl. Compliance Status: We would like to appraise you that, the approved excavation plan is confined within the extent of 2070N-2425N & 3580E-3850E as per the approved Scheme of Mining for the period to Out of this excavation plan, the extent within 2290N-2425N & 3580E-3850E falls within diverted forest area for which tree felling permission was applied to Forest Department of State Government on and approval is still awaited. Hence, the excavation could not take place within the said area. To overcome this constraint, the work was extended towards the extent of 2000N-2250N & 3455E-3580E to enable proper bench dimensions for safe movement of heavy earth moving machineries during Jan 12 to Mar 12.Further, one sump (within the extent of 2030N-2075N & 3530E-3630E) has been developed at the bottom of the pit to accumulate rain water during last monsoon to facilitate safe working in bottom benches. No further lateral extension of this pit is possible unless and until the tree felling permission is obtained. We also assure you to restrict the excavation within the approved extent till the approval of next Scheme of Mining which has been submitted on 30th Nov ii) Violation under Rule 13 (1) as Dump D-1 near Quarry D has not been properly terraced and secured by retaining wall & garland drain as approved to prevent environmental degradation. Compliance Status: The terracing of Dump D-1 is has been completed. The retaining wall and garland drain along the toe of the dump has been provided. The photographs are being enclosed in Annexure I & II respectively for your kind perusal. iii) Violation under Rule 45(5)(b) as on scrutiny of annual return for the year , It is observed that, information furnished was not as per prescribed format (Form-H2). Such as in Part-VI (Production, Despatch and Stocks), Audit Adjust/Anly. Adj has been shown under heading of Grade-wise Production, Despatch, Stocks and Ex-Mines prices of processed ore. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 19

21 Compliance Status: We would like to appraise you that, the manganese ore production booked as per the volumetric measurement of stack multiplied by the conversion factor for each grades (i.e Low, Medium, High & Di-Oxide) based on the analytical results of our laboratory. Further the ore is being again analyzed during removal permission process at Govt. Laboratory at Office of Dy. Director Chemical Analysis, Joda. In some cases stacks having Mn content close to next grade get upgraded and quantity increased. Such changes in quantity is considered as Analytical Adjustment and require necessary adjustment during the month. Similarly, the physical stock verification is being carried out annually. The excess / shortage as ascertained to the ground balance are considered as Audit Adjustment and get adjusted in opening balance. However, after implementation of online filing of monthly returns, the information is being furnished strictly as per the online format. e) Any other points requiring attention: i) The memorandum of association and articles of association of company dated 27th Jul 05 and Dy. Registrar of Companies letter no , dated 12th Aug 05, the name of company was changed from Tata Iron & Steel Co. Ltd to TATA STEEL LIMITED. Copy of the same is enclosed as Annexure- IA. ii) Method of Mining :- As per the approved Mining Plan, while the OB was removed by mechanized means, the ore raising operations within the quarry was totally manual. The ore was blasted by 32 mm Jack Hammer drill holes and a bench height of 1.5m was being maintained in the ore benches. The ore used to be excavated manually, dressed and sorted within the quarry and then loaded manually into placer dumper buckets. As mentioned in the 1 st Review of Mining Plan and Scheme of Mining, mining machineries like wagon drill (100 mm dia.), excavators (bucket capacity 2.45 CuM) etc. are being deployed for deep hole drilling, excavation, loading and transportation of both the overburden and ROM within the quarry. Bench height of 8m is being maintained for both OB and ore benches. The processing of the ore involving dressing and sorting is being done manually at sorting yard located at the pit top. iii) Joda West Manganese Mine takes active participation every year in Mines Environment & Mineral Conservation Week organized under the aegis of Indian Bureau of Mine, Bhubaneswar Region. The activities were recognized by prizes as; JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 20

22 Year: Sedimentation & Water Management 1 st Reclamation & Rehabilitation 2 nd Year: Sedimentation & Water Management Top Soil Management Afforestation Overall Performance 1 st 1 st 1 st 1 st Year: Sedimentation & Water Management Waste Dump Management Afforestation Year: Top Soil Management Waste Dump Management Afforestation 1 st 1 st 2 nd 1 st 1 st 2 nd 2 nd Overall Performance Installation & Use of Mech. Beneficiation Facility 2 nd iv) M/s ORSAC, Bhubaneswar has been declared as the authorized agency by the State Govt. for carrying out the DGPS survey to comply with the CCOM Circular No. 02/2010. Such DGPS survey by ORSAC has been done for this lease during Mar The copy of the drawing showing the lease boundary over the satellite image received from ORSAC is being enclosed as Drawing No. MP/JWMM/01E/12. However, the superimposed maps have still not been provided by ORSAC although we have been following up on the matter regularly since long. The information in this regard shall be furnished to the IBM as soon as the same is finalized and received from ORSAC. The Minutes of the Meeting as circulated in the website of the Dept. of Steel & Mines, Govt. of Odisha vide letter no. 6202/SM, Bhubaneswar, dated in this regard, may please be referred to. v) The excavation is by mechanized mean and the ROM ore is subsequently processed (dressing, sorting and screening) by manual means in the sorting yard which is away from the pit/quarry. Considering a productivity of 1 tonne / man day and 300 working days/annum (as mentioned in the Scheme of Mining), the total average employment of manual labour in the mine will be around 600. Although the average employment of manual labour exceeds of manual labour exceeds 150 as stipulated under Rule 42(1)(b)(i) of MCDR,1988, there is a doubt whether this mine is to be treated as fully mechanized category A mines. Further clarification has been sought from Chief Controller of Mines, IBM, Nagpur vide our letter no. SCM/GM(O)/122/2010, dated and clarification has not been received till date in this regard. Copy of the letter is enclosed as Annexure I-H for kind reference. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 21

23 PART II PROPOSAL UNDER 2 ND SCHEME OF MINING FOR THE NEXT FIVE YEARS ( TO ) JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 22

24 2.1 NAME AND ADDRESS OF THE APPLICANT: The applicant and the present nominated owner of the mine is as follows: Mr. H.M. Nerurkar Managing Director & Nominated Owner TATA STEEL Ltd., Jamshedpur, East Singhbhum, Jharkhand Phone: / Fax: mdoffice@tatasteel.com The copy of the resolution passed by Board of Directors showing the status of applicant as Nominated Owner is enclosed as Annexure IC. 2.2 NAME, ADDRESS AND REGISTRATION NUMBER OF THE RECOGNIZED PERSON: Name : Mr. Head (Underground Mining Project) Tata Steel Ltd., Sukinda Address : At/P.O. : Kalarangiatta Dist : Jajpur State : Orissa Pin Code : Phone : Fax : Regd. No. : RQP/BBS/044/2003/A (Copy of the certificate enclosed as Annexure - II) The RQP, Sri has been duly authorized by the applicant. The letter of consent is enclosed as Annexure-I. 2.3 MINERALS TO BE MINED: Manganese shall continue to be the principal mineral to be mined. Incidental production of some quantity of iron ore is also expected in the course of mining for manganese and lateral extension of the quarries. This is evident from the geological plans where the presence of some small and stray occurrences of iron ore is noticed. 2.4 AREA AND DATE OF EXPIRY OF LEASE: The mining lease was originally granted for a period of 30 years w.e.f over an area of sq.miles ( ha.) including Katamati and Khonbond blocks. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 23

25 The first lease renewal was done for a period of 20 years w.e.f over an area of sq.miles ( ha.). During the second lease renewal for a period of 20 years w.e.f , Joda West formed an independent lease over an area of ha. The application for third renewal over an area of ha. was made on The covering letter in the form of Form D for the above renewal application enclosed as Annexure-IIIA. The legal status of the applied area of ha. is as follows: Reserve Forest : ha Khesra Forest : ha Non forest Govt. land treated as forest Land as per DLC report : ha Total Forest land : ha Non-forest Govt. land : ha Non-forest Private land : ha Grand Total : ha DLC Revenue Non-forest land, which is now treated as forest as per the report of the District Level Committee, which was formed following the Supreme Court Order. Land Use pattern: The present status of diverted forest area, broken up area, surface right area (acquired area) as on , area in process for surface right area (acquired area) & diversion has been mentioned below in the Table Joda West Mining Lease RML Area Diverted Forest Area Broken up Area as on Reserve Forest (ha.) Khesra Forest (ha.) DLC Forest (ha.) Table Total Forest (ha.) Non Forest (ha.) Total (ha) Remarks JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 24

26 Surface Right Area Applied Forest Area for diversion Area applied for Surface Right Applied for Conveyor Corridor from Khandbond to Joda through Joda West Lease Applied for Mining & Allied activities 2.5 DATE OF EXPIRY OF THE APPROVED SCHEME OF MINING: The 1 st Review of Mining Plan and Scheme of Mining for the period to was approved vide letter no. MS/OTF.MECH/39-ORI/BHU/08-09, dated and valid up to This 2 nd Review of Mining Plan and Scheme of Mining for the period to is being submitted for approval under Rule 12 of MCDR, 1988 and will valid till JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 25

27 3.0 RESERVES: 3.1 CATEGORY-WISE RESERVES INDICATED IN THE APPROVED SCHEME OF MINING: The reserves of Manganese and Iron ore indicated in the approved scheme of mining for the Joda West lease as on are given in Table and Table below. Table CATEGORY-WISE GEOLOGICAL RESERVES AND RESOURCES OF MANGANESE ORE AS ON (All figures in million tonnes) Proved (111) Probable Indicated Inferred Quarry Ch + Total Med Gr Low Gr Total (122) (332) (333) H Gr D Quarry H Quarry Gangaigora Sankhaiburu I Quarry Total Table CATEGORY-WISE GEOLOGICAL RESERVES AND RESOURCES OF IRON ORE AS ON (All figures in million tonnes) Proved Reserve Probable Reserve Inferred Resource Total (111) (122) (333) ( ) DEPLETION OF RESERVES: The year wise ROM production of manganese ore for the period to is given in Table 3.2.1below. Table Quarry-wise Production of ROM of Manganese Ore in MT Year Quarry Ch+H Gr Med Gr Low Gr Total D Quarry H Quarry Gangaigora Sankhaiburu I Quarry Sub Total JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 26

28 (Till Oct 12) Total D Quarry H Quarry Gangaigora Sankhaiburu I Quarry Sub Total D Quarry H Quarry Gangaigora Sankhaiburu I Quarry Sub Total D Quarry H Quarry Gangaigora Sankhaiburu I Quarry Sub Total D Quarry H Quarry Gangaigora Sankhaiburu I Quarry Sub Total D Quarry H Quarry Gangaigora Sankhaiburu I Quarry Total There was no ROM depletion of Iron ore reserves for the period to ADDITIONAL RESERVES ESTABLISHED: As mentioned in section 1.4.1, 306 boreholes were drilled during The locations of these boreholes have been shown in the updated geological plan MP/JWMM/03/12. The updated reserves for the quarries of Joda West Manganese Mine were estimated as per the details given under the Para 3.4. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 27

29 Working back from the updated reserves the additional reserves were established based on the earlier reserves given under the Para 3.1.7, the depletion of reserves given under the Para 3.2. The category wise additional reserves established in the various quarries are as given in Table below. Quarry Table Addition of Reserve Proved (111) Ch + H Gr. Med Gr Low Gr Total Probable (122) Indicated (332) Inferred (333) Total D Quarry H Quarry Gangaigora Sankhaiburu I Quarry Total Basis of resource estimation:- The deposit evaluation and resource estimation procedure is given below: Deposit evaluation has been done by using mine planning software Gemcom Surpac Version 6.1. Data collection from graphical borehole logs, recording and codification. Data recording in excel file and validation of data is being carried out. Creation of database in application software Gemcom Surpac Version 6.1. Creation of digital database of topography, geological features (litho contact) and surface features by digitization. Preparation of Digital Terrain Model (DTM) of topography using survey data and extraction of surface profiles along cross section lines. Preparation of transverse geological cross sections from geology and assay database of boreholes. Correlation of ore bodies in transverse cross sections. 3D Solid ore body modeling by triangulation method. Block Modeling and estimation of grade by Inverse Square Distance (ISD) method. o In this method, down-hole compositing of assays was carried out for manganese ore zones. Compositing of depths are taken as 1m with condition of inclusion of any sample with length up to 75% of the designated composite length. o For block grade estimation, block size chosen is 5m X 5m X 2m, considering the pockety nature of manganese ore bodies. o Minimum and maximum number of samples considered for estimation is 1 and 15 respectively. An ellipsoidal search with a maximum search distance of 50m in the horizontal plane and 3m in the vertical plane has been considered for estimation. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 28

30 Insitu bulk density is considered to be 2.5 t/cu m for calculating tonnage. The cut-off grade for manganese ore is considered to be 25% Mn for production of saleable ore and the threshold limit is considered as 10% Mn for calculation of reserves / resources. The cut-off grade for iron ore is considered to be 58% Mn for production of saleable ore and the threshold limit is considered as 45% for calculation of reserves / resources. The chemical analysis of bore hole logs are being done in company s own laboratory which has been recognized by Directorate of Geology, Govt. of Odisha. The copy of recognition is enclosed as Annexure IX. Resource classification has been done as per UNFC norms. Measured mineral resources (UNFC 331) has been established for the areas where there is proving information with higher confidence level provided by less than 50 m x 50 m grid space drilling. Indicated mineral resource (UNFC 332 category), is categorized for the resource estimated for the areas where there is proving information with lower confidence level provided by more than 50 m x 50 m and less than 100 m x 100 m grid space drilling. Inferred mineral resource (UNFC 333 category), is categorized for resource estimated for the areas where there is proving information with lowest confidence level provided by more than 100 m x 100 m grid space drilling and also for exposed outcrops mapped in 1:5000 scale. Following the UNFC norms for codifying reserve under Proved (111) and Probable (122) category, mine feasibility as well as economic aspects are implied on the geologically Measured (331) and Indicated (332) mineral resources. The lateral extent of the proved (111) ore category has been considered 25m from the existing boreholes. Similarly, for inferred category the extent of the ore boundary has been considered 50m from the existing borehole. However, no depth extension of the ore category has been indicated as the mineralization has been proved at depth with the help of boreholes. All the outcrops of manganese ore mapped (on 1:5000 scale) in the lease area (including the forest areas) which indicate occurrence of potential ore zones, however, feasibility of mining, economics and the exact geological details in terms of actual depth and grade distribution cannot be qualified for such outcrops at this stage are brought under inferred (333) category. Possible depth for such outcrops is assumed to be 3 meters for resource estimation. Resource evaluation for iron ore has not been completed as the proposed exploration is in progress and the estimation will be done after completion of the said exploration program. Therefore, there is no revision/addition in iron ore resources and reserves. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 29

31 3.4 CATEGORY WISE UPDATED RESOURCES & RESERVES: The category wise updated geological resources and reserves of Joda West lease for manganese and iron ore as on (follows from sections 3.1 to 3.3 above) is given in Table no & below: Quarry Table No : CATEGORY WISE GEOLOGICAL RESOURCE & RESERVE OF MANGANESE ORE AS ON (All figures in million tonnes) Proved (111) Ch + H Gr. Med Gr Low Gr Total Probable (122) Indicated (332) Inferred (333) Total D Quarry H Quarry Gangaigora Sankhaiburu I Quarry Total Iron Ore Reserve: Table CATEGORY-WISE GEOLOGICAL RESERVE OF IRON ORE AS ON (All figures in million tonnes) Proved Reserve Probable Reserve Inferred Reserve Total (111) (122) (333) ( ) JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 30

32 The details of calculation of Reserve / Resources: The section-wise calculation of reserve / resource of Manganese Ore are furnished in Table 3.4.2(a), 3.4.2(b) & 3.4.2(c). Section No Table (a) Proved Reserve (UNFC Code 111) Manganese Ore Influence Sectional Area Bulk (both side) Tonnage (in sq. m) Density (in m) Tonnage (Mill. Tonne) JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 31

33 Total JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 32

34 Probable Reserve Area (sq m) Table (b) Probable Reserve (UNFC Code 122) Manganese Ore Geological Thickness Bulk Confidence Tonnes (m) Density factor in % Tonnage (Mill. Tonne) Total Remarks Outcrop area Inferred Resource 333 Table (c) Inferred Resource (UNFC Code 333) Manganese Ore Geological Tonnage Area Thickness Bulk Confidence Tonnes (Mill. (sq m) (m) Density factor in % Tonne) Remarks Outcrop area Surrounding area Total The section-wise calculation of reserve / resource of Iron Ore are furnished in Table 3.4.2(d) & 3.4.2(e). Table 3.4.2(d) Section No Sectional Area (in sq. m) Proved Reserve (UNFC Code 111) Iron Ore Influence (Both side) (in m) Bulk Density Tonnage Tonnage (Mill. Tonne) Breakup of Prov. Reserve (Mt) H quarry JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 33

35 Stackyard/ Bending yard Total Inferred Resource 333 Area (sq m) Table 3.4.2(d) Inferred Reserve (UNFC Code 333) Iron Ore Thickness (m) Geological Confidence factor in % Bulk Density Tonnes Tonnage (Mill. Tonne) Total Remarks Outcrop area Outside Outcrop area Justification of Manganese Ore Resources Proved Mineral Reserve (111): G1(Detailed Exploration) GEOLOGICAL AXIS 1.Geological survey: (i)mapping-for coal, mapping 1:5000;for other minerals 1:1000 (ii)preparation of detailed topographical-cumgeological map including all surface geological features, extent of deposit, structure, location of boreholes, assay plan & sections of exploratory mine development &borehole data; (iii)topogrid/triangulation stations linked in the maps. 2.Geochemical survey: Detailed grid pattern sampling and analysis. 3.Geophysical survey: Detailed and specific borehole geophysical survey. 4.Technological: (i)pitting - 2 to 5 per sq. km. for simple deposits; Work carried out 1) i) Geological mapping done at 1: 5000 and 1:1000 scale. ii) Detail topographic contouring has been with contour spacing of 5m and other relevant features are furnished in surface geological plan. iii) Done. 2) Detailed analyses of the borehole are available. 3) Not done. 4) i) Mine already exists. ii) Mine already exists. iii) Drilling done at 25m & 50m grid JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 34

36 (ii)trenching - At spacing of m; (iii)drilling- closer spaced (with definite grid pattern) than that for G2 category; For opencast project grid spacing may be 100m x 50m (iv)exploratory mining and check drilling results if possible (v)sampling- systematic pit and trench sampling, core and sludge sampling for laboratory scale and bulk sample for the pilot plant scale beneficiation studies. 5.Petrographic and mineragraphic study: Refining of data on the petrographic character of rocks of the deposit and its surroundings, alterations (if any), including study of grain size texture gangue and its liberation characteristics for further refining of data 6.Geostatistical analysis of borehole data thickness of ore: waste encountered in holes, assay values of samples if considered necessary. interval. iv) Mine already exists. v) Detailed analyses of the borehole and blastholes, face samples are available. 5) Mineralogical study has been done for manganese ore and its associated rocks. 6) Geostatistical analyses have been done. FEASIBILITY AXIS F1 (Feasibility Study) 1. Geology: Geology of area and project, detailed exploration, closed spaced drilling, ore body modelling, bulk samples for beneficiation, geotechnical and ground water &surface waters studies. 2. Mining: Mining plan, mine recoveries and efficiencies, equipment selection, manpower requirement. 3.Environment: EIA studies & EMP including socioeconomic impact, rehabilitation of project affected persons, waste disposal/reclamation, detailed land use data. 4. Processing: Pilot scale/industrial scale investigation data, list of equipment, manpower and environmental considerations like waste disposal of tailing, etc. 5. Infrastructure and services, construction activities: Full details 6. Costing: Detailed break-up of capital cost, operating cost, details of working capital. 7.Marketing: Overview, specific market aspects. 8. Economic viability: Cash flow forecast, inflation effects, sensitivity studies. 9. Other factors: Statutory provisions relating to labour, land, mining, taxation etc. Work carried out 1) Detailed geological study, exploration, ore body modeling mineralogical studies has been done. There is no problem for geotechnical and ground water problem for ore excavation. 2) Enclosed in Mining Plan. 3) EIA studies and EMP has been done. 4) The manganese ore is being dressed, sorted, sized and graded manually at sorting yard. 5) Enclosed in Mining Plan. 6) Costs details have provided in annual returns 7) Marketing of Manganese Ore is being done by Company s central team. 8) This is being constantly monitored by Company s accounts department 9) Statutory provisions pertaining to mines are being strictly adhered JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 35

37 ECONOMIC AXIS E1(Economic) 1. Detailed exploration. 2. Mining report /mining plan / working mines. 3. Specific end-use grades of reserves (above economic cut-off grade). 4. Specific knowledge of forest/non-forest and other land use data. Probable Mineral Reserve (122): G2(General Exploration) GEOLOGICAL AXIS 1.Geological survey: (i)mapping on 1:5,000 to 1:1,000 or larger scale with triangulation stations, benchmarks, if any; (ii)linking of maps so prepared with topo- grids, (iii)assessment of lithology, structure, surface mineralisation, analysis of old history of mining. 2. Geochemical survey: (i)detailed litho-geo-chemical channel sampling from fresh rock exposures, trenches, pits for further refinement of data; (ii) Recording of deleterious elements and likely by-product elements. 3.Geophysical survey: (i) Borehole geophysical survey ; (ii)special geophysical traverses for problem solving if required. 4. Technological (i) Pitting/trenching for helping surface and subsurface, correlation of mineralised zones; (ii)drilling-close spaced drilling to decipher the ore - shoot behaviour atleast upto two levels; in general, spacing of probe points along strike may be 100m but in specific cases, depending on the necessity, it may be brought down to 50 m. especially for precious metals; a few probe points for deeper intersections; (iii)detailed core sampling, bulk sampling for testing of processing technology; (iv)collection of abiotic geo-environmental parameters. (10% check sampling). 5. Petrographic; Detailed study of data on the petrographic character of rocks including study of grain size, texture, liberation characteristics. Work carried out 1) Has been carried out as per mine plan 2) Mine plan submitted. 3) Consumed for making of Ferro Alloys. 4) Non forest area and details of land use data mentioned in Mine Plan. Work carried out 1) i) Geological mapping done at 1: 5000 and 1:1000 scale. ii) Detail topographic contouring has been with contour spacing of 5m and other relevant features are furnished in surface geological plan. iii) Done. 2) Detailed analyses of the borehole are available. 3) Not done. 4) i) Mine already exists. ii) Drilling done at m grid interval. iii) Done. iv) Not done. 5) Petrographic study has been done for manganese ore and its associated rocks. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 36

38 F2 (Pre-feasibility Study) FEASIBILITY AXIS 1. Geology: Geology of area, detailed exploration/general exploration guided by geochemical and geo-physical surveys, moderate to close - spaced drilling, different mineralised zones at viable cut off grades, core and sludge sampling for exploratory stage beneficiation studies/laboratory scale investigations. 2.Mining : Methods, pre-production plan, development plan, manpower requirements. 3.Environment : EIA/EMP with details of waste disposal and likely unavoidable effects of projects. 4.Processing: Proven laboratory scale/pilot plant scale ore dressing investigations on bulk samples and likely establishment, cost estimates for processing plant. Work carried out 1) Detailed geological study, exploration, ore body modeling mineralogical studies has been done. There is no problem for geotechnical and ground water problem for ore excavation. 2) Enclosed in Mining Plan. 3) EIA studies and EMP has been done. 4) The manganese ore is being dressed, sorted, sized and graded manually at sorting yard. 5) Enclosed in Mining Plan. 5.Infrastructure and services and construction activities: Brief details. 6. Costing :Capital and operating costs-rough estimates based on comparable mining operations. 7. Marketing: An overview, demand supply relations, industry structure. 8. Economic viability: Preliminary study of cash flow forecasts. 6) Costs details have provided in annual returns 7) Marketing of Manganese Ore is being done by Company s central team. 8) This is being constantly monitored by Company s accounts department 9) Statutory provisions pertaining to mines are being strictly adhered 9. Other factors: Statutory provisions relating to land, labour, mining, taxation, etc. ECONOMIC AXIS E1(Economic) 1.Detailed exploration. 2.Mining report /mining plan / working mines. 3.Specific end-use grades of reserves (above economic cut-off grade). 4. Specific knowledge of forest/non-forest and other land use data. Work carried out 1) Has been carried out as per mine plan 2) Mine plan submitted. 3) Consumed for making of Ferro Alloys. 4) Non forest area and details of land use data mentioned in Mine Plan. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 37

39 Inferred Mineral Resource (333): GEOLOGICAL AXIS G3 (Prospecting) 1.Geological survey: (i) Mapping on 1:50,000 to 1:25,000 scale (for coal, lignite exploration- mapping on 1:10,000); (ii)linking of maps so prepared with topo-grids; (iii)assessment of lithology, structure, surface mineralisation, analysis of old history of mining. 2.Geochemical survey: Geochemical sampling, rock type-wise and if necessary, rock type-cumskeletal soil-domain-wise (for all metallic mineral exploration). 3.Geophysical survey: Detailed ground geophysical work; bore-hole geophysical logging, if possible. 4)Technological: (a)pitting/trenching to explore bed rock/mineralised zone; (b)drilling: Preliminary drilling (dry drilling for bauxite and in formation vulnerable to wash). Bore-hole spacing - (ii) Iron and manganese ore to 400 m; (c) Sampling: Sampling at well-defined locations at surface and also from pits/trenches, boreholes and existing mine openings. 5.Petrographic/mineragraphic studies: (i)petrographic study of rocks of the deposit and its surroundings, alterations if any connected with mineralisation; (ii)determination of phase in which mineral of interest occur; (iii)mineralogical studies including paragenesis, identification of zones of oxidation and primary zones, grain size distribution, overall characteristics of useful minerals. Work carried out 1) i) Geological mapping done at 1: 5000 ii) Done iii) Done 2) Surface samples analyses has been done. 3) Not done. 4) (a)pitting and trenching done for all manganese outcrops. (b)boreholes drilled at more than 100m spacing. Analyses of the borehole samples are available. 5) Preliminary mineralogical study has been done. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 38

40 F3 (Feasibility Study) FEASIBILITY AXIS 1.Geological and related study: (i) Geological, mineralogical and chemical analysis data; (ii) Topographical setting and nature of land; (iii) Infrastructure; (iv) Meteorological and preliminary ecology data if possible. 2. The activities as above or less than that required for F2 i) Mining: Methods, pre-production plan, development plan, manpower (rough estimate). ii) Environment: Base line data on environment. iii) Processing: Proven laboratory scale/pilot scale beneficiation, investigation data,likely establishment, iv) Infrastructure and services, construction activities: Brief details v) Costing: Capital and operating cost - rough estimates based on comparable mining operations. vi) Marketing: Overview like industrial structure, demand supply relation, pricing, etc. vii) Economic viability: Preliminary study of cash flow forecasts. viii) Other factors: Statutory provisions relating to labour, land, mining, taxation, etc. E3 ( Economic) 1.Reconnaissance to detailed geological study, rough estimates of grades (may be below economic cut-off), general idea about forest /non forest and land use status. 2. The activities as above or less than that required for E2 i.specific end-use grades of reserves (above /marginally below economic cut-off grade). ii. General knowledge of forest/non-forest, other land use data. Work carried out 1) Geological study, exploration and mineralogical study has been done. Topography survey has been conducted. Meteorological and preliminary ecology data available. 2 i) Not done ii) EIA studies and EMP has been done iii) Not done. iv) Enclosed in Mining Plan. v) Costs details have provided in annual returns vi) Marketing of Manganese Ore is being done by Company s central team. vii) This is being constantly monitored by Company s accounts department. viii) Statutory provisions pertaining to mines are being strictly adhered. ECONOMIC AXIS Work carried out 1) Has been carried out, however, the data is not sufficient enough to carry economic study. 2) i)not established. ii) locked up in forest areas and hence it is not possible to mine out right now. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 39

41 Justification of Iron Ore Resources & Reserves above cut-off grade (Fe> 58%): Proved Mineral Reserve (111): GEOLOGICAL AXIS G1(Detailed Exploration) 1.Geological survey: (i)mapping-for coal, mapping 1:5000;for other minerals 1:1000 (ii)preparation of detailed topographical-cumgeological map including all surface geological features, extent of deposit, structure, location of boreholes, assay plan and sections of exploratory mine development and borehole data; (iii)topogrid/triangu-lation stations linked in the maps. 2.Geochemical survey: Detailed grid pattern sampling and analysis. 3.Geophysical survey: Detailed and specific borehole geophysical survey. 4.Technological: (i)pitting - 2 to 5 per sq. km. for simple deposits; (ii)trenching - At spacing of m; (iii)drilling- closer spaced (with definite grid pattern) than that for G2 category; ii) For opencast project grid spacing may be 100m x 50m depending on the geology, weather mantle cover, burning nature of coal seams. (iv)exploratory mining and check drilling results if possible ; (v)sampling- systematic pit and trench sampling, core and sludge sampling for laboratory scale and bulk sample for the pilot plant scale beneficiation studies. Work carried out 1) i) Geological mapping done at 1: 5000 and 1:1000 scale. ii) Furnished in the surface geological plan iii) Done 2) Detailed analyses of the borehole and blastholes are available. 3) Not done. 4) i) Mine already exists ii) Mine already exists iii) Drilling done at 100m and 50 m interval iv) Mine already exists v) Detailed analyses of the borehole and blastholes, face samples are available. 5.Petrographic and mineralographic study: Refining of data on the petrographic character of rocks of the deposit and its surroundings, alterations (if any), including study of grain size texture gangue and its liberation characteristics for further refining 5) Has been already done during commissioning of the beneficiation plant. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 40

42 of data 6) Geostatistical analysis of borehole data thickness of ore : waste encountered in holes, assay values of samples if considered necessary. 6) Geostatistical analyses have been done. F1 (Feasibility Study) FEASIBILITY AXIS 1. Geology: Geology of area and project, detailed exploration, closed spaced drilling, ore body modelling, bulk samples for beneficiation, geotechnical and ground water &surface waters studies. Work carried out 1) Detailed geological study, exploration, ore body modeling beneficiation studies has been done. There is no problem for geotechnical and ground water problem. 2. Mining: Mining plan, mine recoveries and efficiencies, equipment selection, manpower requirement. 3.Environment: EIA studies and EMP including socio-economic impact, rehabilitation of project affected persons, waste disposal/reclamation., detailed land use data. 4. Processing: Pilot scale/industrial scale investigation data, list of equipment, manpower and environmental considerations like waste disposal of tailing, etc. 5. Infrastructure and services, construction activities: Full details 6. Costing: Detailed break-up of capital cost, operating cost, details of working capital. 7.Marketing: Overview, specific market aspects. 8. Economic viability: Cash flow forecast, inflation effects, sensitivity studies. 2) Enclosed in Mining Plan. 3) EIA studies and EMP has been done 4) Processing details enclosed in Mine Plan 5) Enclosed in Mining Plan.. 6) Costs details have provided in annual returns 7) Captive Mine. 8) Economic viability is being calculated on the basis of our captive requirement. 9) Complied. 9. Other factors: Statutory provisions relating to labour, land, mining, taxation etc. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 41

43 E1(Economic) ECONOMIC AXIS 1.Detailed exploration. 2.Mining report /mining plan / working mines. 3.Specific end-use grades of reserves (above economic cut-off grade). 4. Specific knowledge of forest/non-forest and other land use data. Inferred Mineral Resource (333): GEOLOGICAL AXIS G3 (Prospecting) 1.Geological survey: (i) Mapping on 1:50,000 to 1:25,000 scale (for coal, lignite exploration- mapping on 1:10,000); (ii)linking of maps so prepared with topo-grids; (iii)assessment of lithology, structure, surface mineralisation, analysis of old history of mining. 2.Geochemical survey: Geochemical sampling, rock type-wise and if necessary, rock type-cum-skeletal soil-domain-wise (for all metallic mineral exploration). 3.Geophysical survey: Detailed ground geophysical work; bore-hole geophysical logging, if possible. 4)Technological: (a)pitting/trenching to explore bed rock/mineralised zone; (b)drilling: Preliminary drilling (dry drilling for bauxite and in formation vulnerable to wash). Bore-hole spacing - (ii) Iron and manganese ore to 400 m; (c) Sampling: Sampling at well-defined locations at surface and also from pits/trenches, boreholes and existing mine openings. 5.Petrographic/mineralogaphic studies: (i)petrographic study of rocks of the deposit and its surroundings, alterations (if any) connected with mineralisation; (ii)determination of phase in which mineral of interest occur; (iii)mineralogical studies including paragenesis, identification of zones of oxidation and primary zones, grain size distribution, overall characteristics of useful minerals. Work carried out 1) Has been carried out 2) Mine plan submitted. 3) Mentioned in Mine Plan 4) Non forest area Work carried out 1) i) Geological mapping done at 1: 5000 ii) Furnished in the surface geological plan iii) Done 2) Surface samples analyses has been done. 3) Not done. 4) Boreholes drilled > 400m spacing. Analyses of the borehole samples are available. 5) Preliminary study of the petrography has been done JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 42

44 FEASIBILITY AXIS F3 (Geological Study) 1.Geological and related study: (i) Geological, mineralogical and chemical analysis data; (ii) Topographical setting and nature of land; (iii) Infrastructure; (iv) Meteorological and preliminary ecology data if possible. Work carried out 1) Geological study, exploration and mineralogical study has been done. Topography survey has been conducted. Meteorological and preliminary ecology data available. 2. The activities as above or less than that required for F2 i). Mining: Methods, pre-production plan, development plan, manpower (rough estimate). ii). Environment: Base line data on environment. iii). Processing: Proven laboratory scale/pilot scale beneficiation, investigation data,likely establishment, iv).infrastructure and services, construction activities: Brief details v). Costing: Capital and operating cost - rough estimates based on comparable mining operations. vi).marketing: Overview like industrial structure, demand supply relation, pricing, etc. vii) Economic viability: Preliminary study of cash flow forecasts. viii). Other factors: Statutory provisions relating to labour, land, mining, taxation, etc. i) Not done ii) EIA studies and EMP has been done iii) Not done. iv) Enclosed in Mining Plan.. v) Costs details have provided in annual returns vi) Captive Mine. vii) Economic viability is being calculated on the basis of our captive requirement. viii) Complied. E3(Intrinsically Economic) ECONOMIC AXIS 1.Reconnaissance to detailed geological study, rough estimates of grades (may be below economic cut-off), general idea about forest /non forest and land use status. 2. The activities as above or less than that required for Work carried out 1) Has been carried out 2) i)not established. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 43

45 E i.specific end-use grades of reserves (above /marginally below economic cut-off grade). ii. General knowledge of forest/non-forest & other land use data. ii) Mostly in forest areas EXPLORATION PROPOSED DURING NEXT FIVE YEARS: Exploration has been proposed in order to bring more and more of inferred category of resources to the measured category and also to prove additional resources in virgin land throughout the lease area. The total meterage of drilling during the period to is proposed to be 7750 m. The proposed boreholes have been indicated in the geological plan enclosed as drawing no. MP/JWMM/03/12. The year-wise exploration programme for next 5 years is given in Table no & below: Table Year Proposed Bore-holes Nos. Meterage Grid Pattern Depth (m) Remarks X50, X 100, Avg. 50m each 200X200 & till end of Subject to & mineralization forest X400 Clearance TOTAL In order to cover the total lease area, exploration has been proposed (at 200m and 400m grid pattern) in forest land and also in areas where necessary clearances are not available at present. The said exploration will be done only after getting necessary clearances. There is also proposal for drilling of RC drill holes in the current pits to increase the confidence level during excavation. A total of 100 RC boreholes with a cumulative meterage of 5000 m are proposed to be carried out during the period to Table Proposed RC Bore-holes Grid Year Depth (m) Remarks Nos. Meterage Pattern TOTAL X50 Avg.50m each & till end of mineralization JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 44

46 4. CONCEPTUAL MINING PLAN: The conceptual mining plan as far as the area of excavation of the pits is concerned remains the same as was envisaged in the approved mining plan for Joda West. However, considering the higher rate of high grade production desired from the mine in order to meet the needs of our Ferro Alloy Plant, Joda it is now necessary to develop the mines further in order to exploit the reserves from the deeper levels. As mentioned in Section 5.3 of this scheme the production demand of high grade and medium grade ore will continue to be higher and will demand opening up of more number of production faces in order to meet the production, particularly for high-grade manganese ore. Once a patch or small pocket of ore is completely exploited, the production from that quarry drops drastically till another pocket of ore is exposed for exploitation. Since such pockets within a quarry are usually quite far apart both laterally as well as depth, exposure of new pocket of ore takes substantial time. It is therefore necessary to develop another location in advance and keep the ore exposed to take care of such exigencies in order to maintain the production level at a steady state. With the depleting reserve base and increased production demand it shall no longer be possible to meet the entire production from the present major working pits (D & H Quarry) at Joda West for the next five years. It shall therefore be necessary to exploit the other small occurrences at Gangaigora, Sankhaiburu and I quarry. In view of the mineral conservation and proper utilization of low grade manganese ore produced from the mine which amounts to around 35% of total production, Research and development initiatives have been taken up by R & D wing of Tata Steel to come up with a breakthrough beneficiation technique for enriching the low grade manganese ore. The progress in this direction is quite satisfactory and the results are very much promising. We hope to commission a beneficiation plant during FY 16 which will be a first of its kind in India for beneficiation of low grade unusable ore being produced from our mines The deposits of manganese ore in the entire lease follows no regular pattern and the mine operation staff relies heavily on the experienced mining personnel who are able to often provide worthwhile additional clues to the patchy and tricky occurrences. Thus exploration activities are planned and carried out based on these field observations, yet it is extremely difficult to predict the evolving shape of the pits and to estimate the ore reserves for an accurate prediction of the life of the pits. An effort has been made to conceptualize the mining operation under such conditions for exploitation of the ore bodies. Mining of such small patchy occurrences have therefore been indicated to be taken up through exploratory mining. Land Use Pattern: There is also a proposal for construction of conveyor belt transport system from Khandbond Iron Mine to Joda East Iron Mine railway siding of the company. A part of the conveyor system will pass across the Joda West Mining lease and will serve as a utility corridor for our both the adjoining leases. We also propose to backfill our old exhausted JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 45

47 quarry of Joda West Mn. Mines with the Overburden removed from Khondbond Mn. Quarries of Khondbond Iron & Mn. Lease. The detailed land use pattern of the entire Joda West lease over an area of ha. At present, at the end of the 5 years planned period and at the conceptual end of life is furnished below. The break up of the land use pattern within the said lease area has been furnished in the same table. (Table No.4.0.1) Sl.No. Type of Use Table As on As at end of plan period ( ) At end of life 1 Area to be excavated Storage of Top Soil Waste dump Mineral Storage Infrastructure (Utility Corridor, Workshop, office, rest shelter etc) Roads Railways Greenbelt Tailing Pond Effluent Treatment Plant Mineral Separation Plant Township Area Others Area untouched (including private land and safety zone) Total The mineral storage area includes the finished ore stacking area, sorting yard and mineral fines stacks. The ultimate pit limit has been conceptualized after considering all the borehole sections assuming an ultimate pit slope of 45 degrees as shown on schematic excavation / ultimate pit plan in Plate 4 & 5. The stripping ratio has accordingly been estimated based on total overburden and spoils that has to be removed to mine out the entire proved and probable mineral reserve of manganese and iron ore, as mentioned below in section 6.1. The conceptual plan (end of life) is given in drawing no MP/JWMM/12/08. It is now evident from the updated geological sections that there is a significant jump in the stripping ratios as mentioned under Section 6.1. Thus, accommodating the overburden to be generated within the lease area is of major concern and a challenge for effective exploitation of the deposit. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 46

48 After a detailed study of the updated geological sections the mining sequence has accordingly been modified in order to fully extract the ore from the areas having proved reserves at relatively lower depths so that the same can be backfilled at the earliest. However, all the existing quarries/ part thereof are not expected to be exhausted during the present plan period. During last scheme period, some old pits were proved non-mineralised at a greater depth and being proposed for reclamation in this scheme period. The up-dated boreholes along the above section line shown in drawing no.mp/jwmm/05/12. At present, the development of the pit and excavation of ROM ore are being done with 8 m high benches and worked by shovel-dumper combination. Due to the irregular nature and patchy occurrence of manganese, it is not feasible to calculate the pit limit for the individual deposits. However, an attempt has been made to design the ultimate pit limits for the ore bodies that have been already explored. In order to exploit the entire proved and probable manganese ore reserves of all the working pits, the ultimate pit limit has been conceptualized as shown in drawing no. MP/JWMM/12/12. However, the extents of the quarries viewing present proved and probable reserves shall be as follows: D Quarry: Ultimate pit slope : 45 degrees Ultimate depth of pit : 90 m Length : 600 m Breadth : 500 m D Quarry (Extension): Ultimate pit slope : 45 degrees Ultimate depth of pit : 60 m Length : 400 m Breadth : 225 m H Quarry: Ultimate pit slope : 45 degrees Ultimate depth of pit : 110 m Length : 500 m Breadth : 400 m Old H Quarry: Ultimate pit slope : 45 degrees Ultimate depth of pit : 70 m Length : 500 m Breadth : 400 m JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 47

49 Gangaigora Quarry: Ultimate pit slope : 45 degrees Ultimate depth of pit : 45 m Length : 500 m Breadth : 400 m Sankhaiburu Quarry: Ultimate pit slope : 45 degrees Ultimate depth of pit : 60 m Length : 300 m Breadth : 200 m I Quarry Ultimate pit slope : 45 degrees Ultimate depth of pit : 100 m Length : 425 m Breadth : 260 m The above pit limits are subject to change with future exploration and proving of additional reserves. As a part towards mechanization, crushing, screening and mechanical sorting (based on Radiometric X-Ray technology) unit is proposed to be commissioned during the scheme period for mechanizing the subsequent processing of the ROM. The plant shall have a capacity up to 100 TPH to crush the ROM to -75mm size. The screening shall be done at 10 mm size. The products of mm shall be shifted to stack yard for preparation of stacks in geometrical shape. The fines (-10mm) shall be shifted to the mineral reject stacking area by using loader and dumpers. The waste generated if any shall be shifted to waste dumps. The above unit shall be of dry process and the following environment protection measures shall be taken to control the air pollution: Enclosures shall be provided to trap the dust while crushing, screening and conveying. Water spray shall be provided at all transfer points. To make use of low grade manganese ore for the production of Mn. alloys, it is envisaged to evaluate various available technologies and its techno-economic viability for beneficiation. It is proposed to take up pilot plant studies for assessing the feasibility of beneficiation of the low grade manganese ores. Conceptual exploration Exploration in the Joda West leasehold area will be carried out in different phases. The main objective of the exploration program is to increase the resource base of manganese and iron ore and also to cover the total lease area by exploration at least up to inferred category stage of UNFC in the next five years. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 48

50 For this, the exploration program has been categorized based on the status of land available for carrying out exploration. The broken forest and non-forest areas and the diverted (stage II approved) areas has been considered first for carrying out exploration. Subsequently, the forest areas will be taken up after getting necessary clearances. The number of ore bodies to be explored in the mining lease is divided into Phase I, II, III etc. and Phase I will be the priority ore bodies for which exploration work will be planned. The ore bodies of Phase II will not be taken up without completing ore bodies of Phase I. The Phase II is again divided in to Stages I, II, III etc, where Stage I will include random bore holes to locate ore bodies. In Stage II, a drilling pattern may be followed with wide spacing and the detailed exploration of the deposit / lenses / pockets as per existing practice may be taken up in a subsequent stage. Stage II or III can be done away with if stage I proves negative. Similarly, stage III can be dispensed with if Stage I is promising but Stage II is discouraging. In spite of such detailed geological investigation. Most of the ore bodies show typically erratic behavior in the working quarries and no generalized rules can be framed. The ultimate pit limit has been conceptualized after considering all the borehole sections assuming an ultimate pit slope of 45 degrees as shown on schematic excavation / ultimate pit plan in Plate 4 & 5. The stripping ratio has accordingly been estimated based on total overburden and spoils that has to be removed to mine out the entire proved and probable mineral reserve of manganese and iron ore, as mentioned below in section 6.1. The conceptual plan (end of life) is given in drawing no MP/JWMM/12/08. It is now evident from the updated geological sections that there is a significant jump in the stripping ratios as mentioned under Section 6.1. Thus, accommodating the overburden to be generated within the lease area is of major concern and a challenge for effective exploitation of the deposit. After a detailed study of the updated geological sections the mining sequence has accordingly been modified in order to fully extract the ore from the areas having proved reserves at relatively lower depths so that the same can be backfilled at the earliest. However, all the existing quarries/ part thereof are not expected to be exhausted during the present plan period. During last scheme period, some old pits were proved non-mineralised at a greater depth and being proposed for reclamation in this scheme period. The up-dated boreholes along the above section line shown in drawing no.mp/jwmm/05/12. At present, the development of the pit and excavation of ROM ore are being done with 8 m high benches and worked by shovel-dumper combination. Due to the irregular nature and patchy occurrence of manganese, it is not feasible to calculate the pit limit for the individual deposits. However, an attempt has been made to design the ultimate pit limits for the ore bodies that have been already explored. In order to exploit the entire proved and probable manganese ore reserves of all the working pits, the ultimate pit limit has been conceptualized as shown in drawing no. MP/JWMM/12/12. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 49

51 Conceptual reclamation The Steel company propose to reclaim the mining pits and dumps by backfilling and afforestation when they are permanently abandoned. The afforestation of the dumps and mining benches will be done by following methods. a) Method of pitting and planting. (i) The worked out mining benches will be reclaimed by making pits 0.3 m X0.3 m X0.3 m size 2m apart. The pits will then be filled with sweet earth, sand and cow-dung. (ii) Neem cake powder will be applied in the pit to protect the plants from white ants. (iii) Such ground preparation will be done before monsoon after which appropriate varieties of saplings will be planted during monsoon. The method of pitting and planting ahs been explained in Figure - 6 b) Method of planting by contour trenching This method is proposed for slopes wherein contour trenches are dug at 3m interval along the contour. The excavated earth is stacked on the edge of the trench on the lower slope side to arrest the water flow that comes due to rains and accumulates on the trenches and gradually seeps through the strata enabling the planted saplings to get water and nutrients regularly for healthy growth. The method has been shown in Figure - 7. Manganese Ore Beneficiation: At present, the manganese ore is being dressed, sorted, sized and graded manually at sorting yard. The process of mineral beneficiation of the low grade manganese ore is known since long. A beneficiation process flow sheet is in process to explore to upgrade these ores using high intensity magnetic separators and reduction roasting followed by low intensity magnetic separation. Beneficiation and agglomeration test is being carried out to demonstrate the beneficiation process flow sheet at R & D, Tata Steel, IIMT- Bhubaneswar and Mintek Laboratory of South Africa. High Intensity magnetic separation can upgrade the Mn ore up to usable for Silico manganese Production and detail test work on reduction roasting process is in progress to upgrade this resource, which can be used for Ferro manganese making. The progress in this direction is quite satisfactory and the results are very much promising. We hope to commission a beneficiation plant during FY 16 which will be a first of its kind in India for beneficiation of low grade unusable ore being produced from our mines However, the economic viability of the process is under study in view of the high energy cost. Our company s R&D proposed to take up pilot plant studies for assessing the feasibility of beneficiation of the low grade manganese ores and fines. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 50

52 FIGURE 1 JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 51

53 FIGURE 2 JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 52

54 FIGURE 3 JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 53

55 FIGURE 4 JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 54

56 FIGURE 5 JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 55

57 FIGURE 6 JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 56

58 FIGURE 7 JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 57

59 5.0 MINING: 5.1 SALIENT DESCRIPTION OF PRESENT MINING METHOD: Manganese mine operations are spread in four areas namely D Quarry, H Quarry, I Quarry and Gangaigora & Sankhaiburu Quarry within Joda West Manganese Mine lease. Overburden and ROM are being removed by using shovel-dumper combination. The benches are 8m high. Blast holes for both overburden and ore are drilled by 100mm diameter crawler drills with 365cfm compressors. For blasting, conventional slurry / emulsion explosives are used. Bottom initiation pattern with controlled blasting technique is being followed by using down the hole (DTH) and trunk line delay (TLD) to minimize ground vibration, fly rock etc. Hydraulic excavator / front end loader and rear dump truck combination is used to bring the blasted overburden to dump yard. Similarly, the blasted run-off mine ore is being hauled to sorting places located at the top of the quarry. The ROM is then dressed, sorted, sized and graded manually at sorting place. The un-skilled manpower are deployed at different sorting places considering the average output per man shift of 1 ton viewing the finished ore production required from the particular quarry. For annual production of 1,80,000 MT max. of manganese ore in 300 working days, about 600 piece-rated workers will be deployed for production of 600 t/day. The different quality of ores are then loaded manually to the dumpers and transported to stacking ground for stacking the ore in regular geometrical shapes and samples are collected and analyzed at our laboratory. Then removal permission is obtained from Mining & Geology Department of State Government after stack verification. Thereafter, the stacks are dispatched to our FAP Plant Joda and railway siding. The ore from railway siding is transported through rail to different parties. The fines generated in the process are kept separately for screening to recover residual lump. After recovery of the lumps, the fines are stacked separately and sold whenever a market for such ore is available. Miscellaneous operations in the mine includes leveling of dumping yard, preparation and maintenance of haul roads, dozing of boulders from face, loading of trucks at stack yard etc. Present Dimensions major quarries : D Quarry: Pit slope : 36 degrees Depth of pit : 59 m Length : 535m Breadth : 415 m D Quarry (Extension): Pit slope : 30 degrees Depth of pit : 30 m Length : 233 m Breadth : 155 m JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 58

60 H Quarry: Pit slope : 38 degrees Depth of pit : 64 m Length : 364 m Breadth : 297 m Old H Quarry: Pit slope : 39 degrees Depth of pit : 63 m Length : 326 m Breadth : 218 m Gangaigora Quarry: Pit slope : 29 degrees Depth of pit : 28 m Length : 182 m Breadth : 170 m Sankhaiburu Quarry: Pit slope : 42 degrees Depth of pit : 39 m Length : 230 m Breadth : 142m I Quarry Pit slope : 43 degrees Depth of pit : 58 m Length : 409 m Breadth : 230 m The manganese ore deposits occur as small tabular lenses and irregular veins. In spite of lot of geological exploration already done the occurrence of manganese ore and its continuity is still very unpredictable. This plan has been prepared with a view to mine in areas having the highest potential of proved mineral reserve and having relatively large ore zones. This is done with a view to have concentrated workings in order to economize on the other resource requirements. However, there are many other small pockets of ore, where such detailed exploratory drilling may not have been viable and are therefore often ignored at the planning stage. Considering the high demand of high-grade manganese ore, it will be necessary to open up many more production faces simultaneously. It is often very difficult to meet the production demand as per plan due to the sudden disappearance of the ore body in contradiction with the geological predictions. The availability of sufficient high-grade ore also varies with the geological predictions. Under the circumstances, it is sometimes necessary to resort to exploratory mining in new areas based on surface exposures or even where sufficient geological information is yet to be collected. Often such areas are worked for a very short span of time because of very low reserves. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 59

61 Thus, while the development plans for major pits have been covered under section 5.2 below, the smaller ore zones that may be mined mostly as a contingency measure or as an exploratory mining activity has been indicated in the conceptual plan enclosed (MP/JWMM/12/12) BLASTING METHOD: The purpose of the blasting is to induce a heaving effect so that, excavator can load the blasted material easily into dumpers. The requirement of blasting is mainly to break the hard in-situ patches which otherwise cannot be removed. The blasting is carried out with large diameter (83mm) slurry explosive cartridges. Cap-sensitive slurry explosive cartridges are being used as base charge and non-cap sensitive are used as column charge. The blasting will therefore be scattered in the quarry. The details of burden, spacing and explosive consumption pattern are mentioned below, Depth of the hole = 8m (bench height) + 10% as sub grade drilling) = 8.8 m (max) Spacing = 3m Burden = 3m Volume/ hole (in-situ) = 79.2 CuM Specific Gravity = 2.5 Tonnage/ Hole = 198 Tonnes Powder factor = 6.0 Kg/Tonne So, Quantity of explosive/hole = 33 Kg. After charging with 250ms delay DTH & stemming of holes, connection is done with detonating fuse. Cord relay of 25 ms / 50 ms are used for delay in case of normal blasting (i.e. if there is no permanent structure within danger zone not belonging to owner or danger zone is free from intersection of public road etc.). Cord Relay of 25 ms / 50 ms is fixed between holes along the spacing as well as between rows. There after shot is fired electrically after taking clearance from guards posted to prevent un-authorized entry to mine. In case of controlled blasting (i.e in close proximity to roads, hutments etc) bottom initiation pattern by using 250 ms delay Down To Hole (DTH) followed by connection of hole to hole with 17ms Trunk Line Delay (TLD). In case of multi row holes, 42 ms, 65 ms, 100 ms TLD are used for subsequent rows respectively. The charge per delay in all cases is maintained within 66 Kg to minimize the ground vibration and noise caused due to blasting operation. The explosives are brought from Joda West magazine. The explosives are brought in the working hours and blasting carried out. Blasting operation is / and to be carried out in different blocks at scattered day and time, so that same blasting crew can carry out operations in all the blocks. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 60

62 The details of explosives presently used are furnished below in the Table Table Class 2 Class 6 Aquadyne 83mm M/s. IDL Chemicals Ltd., Hyderabad Emulboost 25mm M/s. IDL Chemicals Ltd., Hyderabad Energel 83mm M/s. IDL Chemicals Ltd., Hyderabad Kelvex 83mm M/s. Keltech Energies Ltd., Bangalore Kelvan 83mm M/s. Keltech Energies Ltd., Bangalore Novadyne 25mm M/s Navbharat Fuse Co.(P) Ltd., Rajpur (M.P.) Nova Prime 83mm M/s Navbharat Fuse Co.(P) Ltd., Rajpur (M.P.) Nova Column 83mm M/s Navbharat Fuse Co.(P) Ltd., Rajpur (M.P.) Superdyne 25mm M/s. IDL Chemicals Ltd., Hyderabad Supergel 83mm M/s. IDL Chemicals Ltd., Hyderabad Toeblast 83mm M/s. IDL Chemicals Ltd., Hyderabad Safety Fuse M/s. IDL Chemicals Ltd., Hyderabad Cord Relay M/s. IDL Chemicals Ltd., Hyderabad D. Cord II M/s. IDL Chemicals Ltd., Hyderabad Detonating Fuse M/s. IDL Chemicals Ltd., Hyderabad Detonator M/s. IDL Chemicals Ltd., Hyderabad Electric Detonator M/s. IDL Chemicals Ltd., Hyderabad Raydet (Nonel) M/s. IDL Chemicals Ltd., Hyderabad Future Proposal: The site mixed emulsion (SME) will be used by replacing the usage of explosive with cartridge form after grant of permission and license as applicable. The blasting parameters for proposed SME usage comensurating the present parameters are given below in Table Table Blasting Parameters Existing (Cartridge form) Proposed (SME) Drill hole diameter[mm] Bench height [m] 8 8 Burden[m] Spacing[m] Stemming[m] Sub grade drilling[m] Charge per hole[kg] Booster[gm] Further to the mentioned parameters, there may be scope to change the parameters considering the strata and field conditions. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 61

63 Year 5.2 YEARLY PIT-WISE DEVELOPMENT PLAN: The development of the respective quarries has been proposed starting from the ultimate pit limit at the top that has been established from the geological sections. The overburden quantities that have to be removed in the respective quarries have been arrived at based on the stripping ratios. The quantities of overburden proposed to be removed year wise have been mentioned under section 6.1 below. The manner in which the overburden is generated during the next 5 years is proposed to be dumped have been covered under section 6.2 below. The yearly proposed excavation plans for the next 5 years are shown in drawing no s MP/JWMM/6A/12, MP/JWMM/6B/12, MP/JWMM/6C/12, MP/JWMM/6D/12 & MP/JWMM/6E/12 for D Quarry, H Quarry, Old H Quarry, Gangaigora & Sankhaburu Quarry and I Quarry respectively. The corresponding yearly proposed excavation sections for the next 5 years are shown in drawing no.mp/jwmm/7/12 respectively. The Composite plan showing the five year excavation is shown in the drawing no. MP/JWMM/06 A-1/12, MP/JWMM/06 B-1/12, MP/JWMM/06 C-1/12, MP/JWMM/06 D-1/12 & MP/JWMM/06 E- 1/12. The year-wise excavation plan is given in the Table no (A) to (F) ROM shown in Tonne is determined by considering the Conversion factor of 2.5, multiplied with figures in CuM. The saleable ore is determined by considering recovery of 85 % of the ROM ore. The generation of sub-grade mineral and mineral fines (-6 mm) / Rejects are around 10% and 5% of ROM production respectively. Sub Grade Mineral: The Mn. content >10% & <25% in ROM of all size is considered as Sub Grade Mineral. Mineral Fines: The fines generated during manual processing (dressing and sizing) of ROM (Size : < 6 mm) is considered as Mineral Fines. The mineral fines do not have a regular market throughout the year. It has got limited use and occasionally consumed by ferro alloys making plants. Table (A) D' Quarry Overburden (CuM) ROM (CuM) Total Excavation (CuM) ROM (MT) Production (MT) Sub Grade Minerals (MT) Mineral Reject (MT) Stripping Ratio (CuM of OB / T of ROM) Total JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 62

64 Year Overburden (CuM) ROM (CuM) Table (B) H (Old & New) Quarry Total Excavation (CuM) ROM (MT) Production (MT) Sub Grade Minerals (MT) Mineral Reject (MT) Stripping Ratio (CuM of OB / T of ROM) Total Year Overburden (CuM) ROM (CuM) Total Excavation (CuM) Table (C) I ' Quarry ROM (MT) Production (MT) Sub Grade Minerals (MT) Mineral Reject (MT) Stripping Ratio (CuM of OB / T of ROM) Total Year Overburden (CuM) ROM (CuM) Total Excavation (CuM) Table (D) Gangaigora Quarry ROM (MT) Production (MT) Sub Grade Minerals (MT) Mineral Reject (MT) Stripping Ratio (CuM of OB / T of ROM) Total JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 63

65 Year Overburden (CuM) ROM (CuM) Table (E) Sankhaiburu Quarry Total Excavation (CuM) ROM (MT) Production (MT) Sub Grade Minerals (MT) Mineral Reject (MT) Stripping Ratio (CuM of OB / T of ROM) Total Year Overburden (CuM) ROM (CuM) Table (F) Joda West Manganese Mine Total Excavation (CuM) ROM (MT) Production (MT) Sub Grade Minerals (MT) Mineral Reject (MT) Stripping Ratio (CuM of OB / T of ROM) Total The year-wise bench-wise generation of Overburden and ROM is given in the table no (A) to (E). It is also expected to develop the benches beyond the proposed extent due to safe guard the workings as well as haul road damaged due to surface run offs etc. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 64

66 Year Extent of Working 2450N- 2950N & 4525E- 5000E 3010N- 3180N & 4810E- 4780E 2450N- 2950N & 4525E- 5000E 3080N- 3240N & 4900E- 5160E 2525N- 2875N & 4525E- 4900E Table (A) D Quarry Level (mrl) From To OB (CuM) ROM (CuM) Total Excavation (CuM) Total Total N JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 65

67 3300N & 5000E- 5180E N- 2950N & 4500E- 4900E 3060N N & 4960E E Total Total JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 66

68 3100N N & 4900E E Total Table (B) H Quarry Year Extent of Working Level (mrl) From To OB (CuM) ROM (CuM) Total Excavation (CuM) N- 2200N & 3525E- 3825E 1200N- 1450N & 3675E- 3975E 2050N- 2250N & Total JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 67

69 E- 3750E 1150N- 1400N & 3550E N- 2235N & 3450E- 3800E 1150N- 1400N & 3525E- 3700E 1900N- 2200N & 3450E- 3700E Total Total JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 68

70 E- 1400E & 3500E- 3700E 2000N- 2325N & 3400E- 3650E 1150N N & 3650E- 3900E Total Total JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 69

71 Table (C) I Quarry Year Extent of Working Level (mrl) From To OB (CuM) ROM (CuM) Total Excavation (CuM) N- 4150N & 5630E- 5740E 3980N N & 5600E E 3980N N & 5590E E Total Total Total Table (D) Gangaigora Quarry Year Extent of Working Level (mrl) From To OB (CuM) ROM (CuM) Total Excavation (CuM) N- 3010N & 5830E- 5960E 2810N- 3000N & 5850E- 5970E Total Total JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 70

72 Year Extent of Working 2260N- 2400N & 5570E- 5700E Table (E) Sankhaiburu Quarry Level (mrl) From To OB (CuM) ROM (CuM) Total Excavation (CuM) Total YEARLY PRODUCTION PLAN: The yearly production plan for manganese ore proposed for the next 5 years from the different quarries of Joda West is given in Table below. Table (All figures in tonnes) Year Pit TOTAL D'Quarry H'Quarry I'Quarry Gaigaigora Sankhaiburu Total It is expected that incidental to the above manganese ore production around 5,000 tonnes / annum of iron ore is likely to be produced initially. The production of iron ore may go up to 10,000 tonnes / annum in subsequent years. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 71

73 5.4 DEPLOYMENT OF MACHINERY: 5.4.1: Considering the average yearly excavation during next 5 years plan period as mentioned under Section 5.2, Table (F), the required fleet size has been calculated for Shovel, Dumper and Wagon Drill and given in the Table no (A) to (C). The proposed fleet of ancillary equipments to be deployed is given in Table (D). The proposed requirement of manpower is given in Table below. JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 72

74 Table (A) - (Shovel) Sl.No. Description Unit Shovel Type Calculation Volvo-460 Volvo-360 Volvo-290 Details Remarks a. Excavation Required / Year CuM b. Tonnage Factor T/CuM In-situ Density c. Excavation Required / Year Ton a x b d. Average Working Days per year Days e. No.of Working Shift / Day No f. Avg. Working Hour / Shift Hour g. Bucket Capacity Choosen for operation CuM h. Fill Factor Medium Hard & Soft rock i. Bucket Load Capacity per pass Ton e x f x g x h j. Cycle time for One Bucket Second k. Effective Time in an hour Minute l. No. buckets can be loaded per hour Nos (k X 60) / j m. Tonnage can be handled per hour Ton i X l n. Tonnage reqd.to be handled per hour Ton c / (d X f) o. Shovel working hours required Hour n / i p. Available Hours for one Shovel (70%) Hour d X f X p q. No. of Shovels required to be in operation No o / p r. Rounded up No JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 73

75 Table (B) (Dumper) Sl.No. Description Unit Shovel Type Calculation Volvo-460 Volvo-360 Volvo-290 Details Remarks a. Excavated (OB+Ore) to be handled / Year CuM b. Tonnage Factor T/CuM c. Excavated (OB+Ore) to be handled / Year Ton a X b In-situ Density d. Average Working Days per year Days e. No.of Working Shift / Day No f. Avg. Working Hour / Shift Hour g. Effective Time in a hour Min h. Dumper Capacity Choosen Ton i. Shovel Bucket Capacity Choosen CuM j. Lead Distance KM k. Travel Speed Km/Hr l. Travel Time (To & Fro) Min (j X 2)/(k X 60) m. Loading Time Sec n. Bucket Load Capacity per pass Ton Pt.I of Shovel Calculation o. No.of swing for loading one dumper Nos h / n p. Time required for loading of one dumper Min m X o / 60 q. Dumper unloading time Min r. Spotting time & Delays Min s. Total Cycle Time Min l + p + q + r t. No. of trips can be make in a hour Nos g / s u. Production/Dumper/Shift MT f X h X t v. Prodution per shift required MT c / d x. Dumpers required Nos v / u y. Addl. requirement (20% non availability) Nos x X 0.2 z. No.of Dumpers Required for operation Nos, x + y JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 74

76 Table (C) (Wagon Drill) Sl.No. Description Unit Wagon Drill Calculation (100 mm dia) Details Remarks a. Excavated (OB+Ore) to be handled / Year CuM b. Tonnage Factor T/CuM 2.5 In-situ Density c. Excavated (OB+Ore) to be handled / Year Ton a X b d. Overburden & Ore reqd. to be blasted Ton b X % Hard Rock e. Average Working Days per year Days 300 f. Blasted material required / day Ton 6613 d / e g. No.of Working Shift / Day No. 1 h. Avg. Working Hour / Shift Hour 6 i. Effective Time in a hour Min 50 j. Spacing Mtr. 3 k. Burden Mtr. 4 l. Bench Height Mtr. 6 m. Yield / Hole Ton 180 b X j X K X l n. No. of holes required / shift Nos. 37 f / m o. Effective Length of the hole 6.6 l X % sub grade drilling p. Drilling reqd / shft Mtrs 242 n X o q. Drilling reqd / year Mtrs p X e r. Speed of drilling Mtr / hr 10 t. Possible drilling meterage per shift Mtr. 60 h X r u. Drilling with 80% availability Mtr. 48 t X 0.80 v. Drilling / machine / year Mtr u X e x. Drilling Machine machine required Nos. 5 q / v JODA WEST MANGANESE MINES, AT/P.O.: BICHHAKUNDI, VIA: JODA, DIST: KEONJHAR (ORISSA) 75

77 Table (D) (Ancillary Equipment) Equipment Capacity Fleet Category of Manpower Manpower Requirement Standard Force Front End Loader (HM) 1.35 Cu.m 1 Operator 1 1 Jack Hammer drill mm. 1 JH Driller 2 2 Compressor (K G Khosla / Atlas Copco) 365 cfm 2 Operator 2 2 Placer Dumper (Telco) 3.00 Cu.m 1 Driver 1 1 Dozer (BEML) 120 HP 2 Operator 3 3 Water Sprinkler litres 3 Driver 3 3 Explosive Van 10 tonnes 1 Driver 1 1 Jeeps 3 Driver 3 3 Flat Body Truck 1 Driver 1 1 Ambulance 1 Driver 1 1 Crane 3 tonnes 1 Operator : DEPLOYMENT OF MANPOWER The proposed requirement of manpower considering the proposed production as mentioned in Para 5.3 is given in Table below. Table Requirement of Manpower Sl.No. Category No. Remarks 1 Manager : 1 2 Mining Engineer : 1 Qualification & Experience : Whole time Mining Engineer shall have Degree in Mining Engg. from any recognized College / University with minimum ten years of professional experience of working in a supervisory capacity in the field of mining. 3 Geologist : 1 Qualification & Experience : Whole time Geologist shall have post graduate Degree in Geology from any recognized College / University with minimum ten years of professional experience of working in a supervisory capacity in the field of mining. 4 Asst. Manager (Mines) : 2 For Mining, Drilling & Blatsing 5 Asst. Manager (Mechanical Maint.) : 1 76

78 6 Asst.Manager (Electrical Maint.) : 1 7 Surveyor : 1 8 Environment Officer : 1 9 Sr.Mines Foreman : 4 For Mining Operation 10 Mines Foreman / Mining Mate : 6 For Mining Operation & Stack Yard 11 Blaster : 3 12 Blaster Helper : 6 13 Survey Helpers : 4 14 Shovel Operator & Helpers : Dumper Operator : Drill Operator & Helper : Loader Operator : 1 18 Placer Dumper Driver : 1 19 Dozer Operator : 1 20 Water Sprinkler Driver : 3 21 Explosive van Driver : 1 22 Light Vehicle Driver : 3 23 Truck Driver : 1 24 Ambulance Driver : 1 25 Crane Operator : 1 26 Mechanic / Fitter : Electrician : 3 28 Maintenance Helper : 7 29 Clerk : 4 30 Sampler : 2 31 Sampling Helper : 4 32 Piece Rated (Mazdoor/Reja) : 600 Assumption : OMS=1MT/Manday Total

79 6.0 HANDLING OF WASTE / SUB-GRADE MATERIAL: 6.1 GENERATION AND DISPOSAL OF WASTE: The stripping ratio has been estimated based on total overburden and spoils that has to be removed to mine out the proved and probable mineral reserve during the scheme period. The stripping ratios for the various quarries of Joda West are given in Table 6.1(a) below. Table 6.1 (a) Stripping Ratio (CuM of OB / MT of ROM) D Quarry H Quarry I Quarry Gangaigora Sankhaiburu Joda West (Avg) The yearly generation of overburden from the respective quarries has been based on the pit design corresponding to the yearly planned production given under section 5.3, is given in Table 6.1(b) below. Table 6.1(b) (All figures in cum.) Year Pit TOTAL D'Quarry H'Quarry I'Quarry Gaigaigora Sankhaiburu Total Present Dump Dimensions: D Quarry ( D#1): Length : 644m (max) Breadth : 296m (max) Height : 69m (5 lifts of 15m max of each lift) Area : ha. Remarks : Active D Quarry(Extension) (D#2) Length : 140m (max) Breadth : 114m (max) Height : 22m (1 lift) Area : ha. Remarks : Passive and fully rehabilitated by plantation. 78

80 D Quarry (Old) (D# 3) Length : 234m (max) Breadth : 114m (max) Height : 7m (1 lift) Area : ha. Remarks : Active Gangaigora (D#5) Length : 168m (max) Breadth : 129m (max) Height : 9m (1 lift) Area : ha. Remarks : Active Gangaigora (D#5a) Length : 268m (max) Breadth : 102m (max) Height : 16m (1 lift) Area : ha. Remarks : Passive & 2.06 ha stabilized by plantation Sankhaiburu (D#6) Length : 296m (max) Breadth : 246m (max) Height : 18m (1 lift) Area : ha. Remarks : Passive & fully stabilized by plantation H Quarry (D#8) Length : 416m (max) Breadth : 306m (max) Height : 71m (7 lift) Area : 8.00 ha. Remarks : Active H Quarry (D#9) Length : 330m (max) Breadth : 214m (max) Height : 47m (2 lift) Area : ha. Remarks : Passive & 3.03 ha has been rehabilitated by plantation. 79

81 H Quarry (D#10) Length : 581m (max) Breadth : 122m (max) Height : 15m (1 lift) Area : ha. Remarks : Passive & rehabilitated by slope plantation. H Quarry (D#11) Length : 132m (max) Breadth : 93m (max) Height : 15m (1 lift) Area : ha. Remarks : Passive H Quarry (D#12) Length : 56m (max) Breadth : 51m (max) Height : 11m (1 lift) Area : ha. Remarks : Passive Build up of Dumps The existing waste dumps as mention in Para 6.1, Table 6.1.(C) shall be further extended by dumping the overburden till Further the overburden generated shall be backfilled in to the Old D Quarry (5), Old H Quarry (2, 3 & 6). The old H Quarry (5) will be back filled with the overburden from Khandbond Iron & Manganese Mines under same management control. These old quarries are proved as devoid of any mineralization and the sections are shown in drawing no. MP/JWMM/05/12 Sheet 03 to 06. The proposed waste dump plans and sections for D Quarry, H Quarry, Gangaigora & Sankhaiburu and back filling of Old H Quarry (5) are shown in drawing no. MP/JWMM/08/08 Sheet.01 to Sheet 05. The position of existing dumps and position at end of planned period is given in the Table (a) below. 80

82 Existing Yearly built-up Table 6.1.1(a) Dump Dimension & capacity Status D Quarry (D#1) H Quarry (D#8) H Quarry (D#11) Gangaigora (D#5) Back filling of Old H'Quarry (5) by overburden from Khandbond Iron & Mn.Mine Ref.Drg. MP/JWMM/08/08 Sheet MP/JWMM/08/08 MP/JWMM/08/08 MP/JWMM/08/08 MP/JWMM/08/08 01 Sheet 02 Sheet 03 Sheet 04 Sheet 05 Length 644 mtr.(max.) 416 mtr.(max.) 132 mtr.(max.) 168 mtr.(max.) 236 mtr. (Max) Breadth 296 mtr.(max.) 306 mtr.(max.) 93 mtr.(max.) 129 mtr.(max.) 145 mtr. (Max) Top Level 630 mrl 609 mrl 571 mrl 554 mrl 551 mrl (Quarry top) Bottom Levl 556 mrl 533 mrl 549 mrl 534 mrl Height 74 mtr. 76 mtr. 22 mtr. 20 mtr. 520 mrl (Quarry bottom) Terraces 5 lift of 15 mtr. max for 8 lift of 10 mtr. max. 2 lift of 10 mtr. max 1 Lift each lift for each lift for each lift Opencast Void Area ha ha ha ha ha Capacity 38 lakh cum 15 lakh cum 1.75 lakh cum 1.50 lakh cum 4.30 lakh cum At end of to 562 mrl with 580 mrl with 3 Lifts Back filling of Up to 553 mrl with 1 2 lift (Lateral (Lateral extension over H Quarry (6) up to lift after filling the extension over existing terrace) 558 mrl void existing area) At end of At end of At end of At end of Up to 600 mrl with additional 2 Lifts (Lateral extension over existing terrace) Up to 630 mrl with additional 3 lifts (Lateral extension over existing terrace) The OB will be accommodated in a retreat manner over the area available as at end of mrl with additional 2 lift 602 mrl with additional 2 lift 612 mrl with additional 1 lift 622 mrl with additional 1 lift 564 mrl with 1 lift. 564 mrl with additional 1 lift. Up to 580 mrl with additional 1 lift. No proposal for disposal of waste 550 mrl with 1 lift 560 mrl with additional 1 lift 31m depth 565 mrl with additional 1 lift 575 mrl with additional 1 lift No proposal for disposal of waste 81

83 Status D Quarry (D#1) H Quarry (D#8) H Quarry (D#11) Gangaigora (D#5) Back filling of Old H'Quarry (5) by overburden from Khandbond Iron & Mn.Mine Ref.Drg. MP/JWMM/08/08 Sheet 01 MP/JWMM/08/08 Sheet 02 MP/JWMM/08/08 Sheet 03 MP/JWMM/08/08 Sheet 04 MP/JWMM/08/08 Sheet 05 Length 1000 mtr.(max.) 712 mtr.(max.) 285 mtr.(max.) 170mtr.(Max.) 236 mtr. (Max) Breadth 700 mtr.(max.) 435 mtr.(max.) 182 mtr.(max.) 158 mtr.(max.) 145 mtr. (Max) Proposed Top Level 630 mrl 609 mrl 580 mrl 560 mrl 575 mrl At the end of 5 years planned period Present Bottom Level 556 mrl 533 mrl 555 mrl 534 mrl 530 mrl Height 74 mtr. 76m. Height 25m. Height 26m. Height 25m. Height with 2 lift above the ground. Terrace 8 Lifts 8 Lifts 3 Lifts 2 Lifts Max. Lift Height 10m (max) 10m (max) 10m (max) 10m (max) above super adjacent ground 10m Method of Dumping Retreating (Subject to Statutory Clearances) Area ha. 22 ha ha ha ha. Addl.Capacity lakh cum lakh cum 3.50 lakh cum 1.50 lakh cum 2.50 akh cum above ground & 2.1 lahs cum after merger with Dump D#11 Total Capacity lakh cum 35 lakh cum 5.25 lakh cum 3.00 lakh cum 8.60 lakh cum Terrace Slope 37 Deg. 37 Deg. 37 Deg. 37 Deg. 37 Deg. Overall Slope 27 Deg 27 Deg 27 Deg 27 Deg 27 Deg Remarks This dump will cover the old dump no. D#3 and back fill the Old D Quarry (5) This dump will cover the old dump no. D#12 and back fill the Old H Quarry 2 & 3 This dump will extend towards Old H Quarry (6) for its back filling. - 82

84 In addition to this, the overburden generated (~50,000 CuM) from I Quarry will be used for making of alternate road from Bichhakundi village to Joda within the lease area. The surplus overburden will be disposed off over the dump no D#1 (near D Quarry). The Old H Quarry no. 5 will be back filled with overburden transported from Khandbond Iron & Manganese Mine which is under same management control during and shown in the Drawing No.MP/JWMM/08/12 Sheet. No. 05. As desired, the specific permission has been sought from the Dept. of Mining & Geology, Govt. of Odisha for disposal of overburden from Khandbond Iron & Mn.Mine within the Joda West lease. The copy of the letter in this regard is enclosed as Annexure I-I for kind reference. Further, an undertaking by the applicant to submit the specific approval before commencement of disposal of overburden generated from Khandbond Iron & Manganese Mine at Old H Quarry (No.5) of Joda West Manganese Mine is also being enclosed as Annexure-I-J. As had been proposed in the earlier approved mining plan and schemes, the following precautions will be undertaken as; a) Retaining Wall (stonewalls) of m width, 1m height and garland drains of 1m width, 1m depth shall be provided around downhill of the dumps to arrest and guide any wash offs of the material dumped. b) The edges of each terrace shall be inward slope to guide the rain water while preventing the formation of gullies. c) The slope angle of the dumps shall be maintained by dozing and leveling at suitable intervals. d) Concurrent reclamation of dumps will be done as per the practice mentioned in section 9.0.The amount of area likely to be degraded by way of dumping and proposed retreating method is given in Table No (b) Year Nature of Dump Area at beginning of the year (ha) Table (b) Additional area degraded during the year (ha) Area to be rehabilitated during the year (ha) Balance area at the end of year (ha) Overburden Total

85 6.2 GENERATION AND STACKING OF SUB-GRADE MINERAL: Sub-grade ore had been defined in section 5.3 of the approved mining plan as manganese ore having Manganese content of 10% to 20%. The threshold value of sub-grade mineral is kept at 10% Mn as recommended by IBM. The generation of sub-grade mineral as per estimates is around 10% of the total ROM. 5% of the production is considered as fines (-10 mm.), which is taken as mineral rejects. Sub-grade manganese ore having Mn. content of 10% to 25% generated in course of mining are stacked at different location and duly shown in the Surface Plan (Drawing No. MP/JWMM/2A/12). The detail dimension of sub-grade dump is given below; I Quarry - Sub Grade Dump (D#7a) Length : 294m (max) Breadth : 193m (max) Height : 48m (2 lift) Area : ha. Remarks : Passive & Plantation on slope is continuing for rehabilitation. H Quarry - Sub-Grade Dump (D#7b) Length : 164m (max) Breadth : 116 m (max) Height : 17 m Area : ha Remarks : Active and continued during this scheme period for stacking of sub grade ore from H Quarry and I Quarry. Gangaigora Sub-Grade Dump (D#7d) Length : 166m (max) Breadth : 133m (max) Height : 8 m Area : ha Remarks : Active and continued during this scheme period for stacking of sub grade ore from Gangaigora and Sankhaiburu Quarry. D Quarry - Sub-Grade Dump (D#7e) Length : 390m (max) Breadth : 140 m (max) Height : 17 m Area : ha Remarks : Active and continued during this scheme period for stacking of sub grade ore from D Quarry. 84

86 H Quarry Sub-Grade Dump (D#7f) Length : 168m (max) Breadth : 80 m (max) Height : 10 m Area : 0.95 ha Remarks : Passive and rehabilitated by plantation.. H Quarry Sub-Grade Dump (D#7h) Length : 75m (max) Breadth : 55 m (max) Height : 17 m Area : ha Remarks : Active and continued during this scheme period for stacking of sub grade ore from H Quarry. H Quarry Sub-Grade Dump (D#7j) Length : 168m (max) Breadth : 103 m (max) Height : 21 m Area : ha Remarks : Passive and is being rehabilitated by plantation. The yearly generation of sub-grade ore and mineral rejects from various quarries as defined above is estimated and given in Table 6.2.1(a) & 6.2.1(b) below. The sub-grade mineral and mineral rejects produced shall be stacked separately from the overburden and waste dumps. Table 6.2.1(a) Generation of Sub-Grade Mineral (All figures in tonnes) Year Pit TOTAL D'Quarry H'Quarry I'Quarry Gangaigora Sankhaiburu Total

87 Table 6.2.1(b) Generation of Mineral Rejects (All figures in tonnes) Year Pit TOTAL D'Quarry H'Quarry I'Quarry Gangaigora Sankhaiburu Total SUB-GRADE MATERIAL AVAILABLE: The quantity of sub-grade mineral available in the existing stacks and its grade as on is 4,42,000 CuM with Mn content 10 15%. The stack-wise quantity is furnished below in Table Sub Grade Ore Stack No. Stacked Quantity (cum) as on Stacked Quantity (cum) as on D # 7b D # 7d D # 7e D # 7h D # 7a D # 7f D # 7j Total Remarks Active and continued during this scheme period. Passive in nature and under rehabilitation by plantation As had been proposed in the earlier approved mining plan and schemes, the following precautions will be undertaken as; a) Retaining Wall (stonewalls) of m width, 1m height and garland drains of 1m width, 1m depth shall be provided around downhill of the stacks to arrest and guide any wash offs of the material dumped. b) The edges of each terrace shall be inward slope to guide the rain water while preventing the formation of gullies. c) The slope angle of the stacks shall be maintained by dozing and leveling at suitable intervals. 86

88 7.0 USE OF MINERAL: 7.1 CHANGES PROPOSED IN THE USE OF MINERALS: There is no change in the use of mineral. As mentioned in the approved mining plan, manganese ore is mostly being mined to cater to the requirements of its Ferro Alloys Plant at Joda, Jamshedpur Works and other Conversion Units. The company is also purchasing certain amount of ore to meet its requirements at the Ferro Alloys Plant, Joda at a very high cost. This was mainly because of its inability to produce the required quantities of high grade ore with Mn : Fe ratio greater than 5.3 :1. In the course of producing higher grade manganese ore, a surplus quantity of medium and low grade manganese ore shall be produced. We propose to beneficiate low grade manganese ore to enrich the Mn. Content and reduce Mn:Fe ratio for utilization of the same by our plants from FY 16 onwards for which R &D initiatives are in conclusive stage. Further, as mentioned in section 5.3 of this scheme of mining, some small quantities of iron ore is likely to be produced incidental to manganese ore production. This ore may either be utilized in the company s Sponge Iron Plant at Joda or sold to other outside parties depending upon its quality. 7.2 CHANGES IN SPECIFICATIONS: There is no change in the specifications of the manganese ore to be produced from the mine. However, the Ferro Alloys Plant, Joda presently requires an Mn:Fe ratio of 5.3:1 in the manganese ore as against its earlier requirement of Mn:Fe ratio of 4.8:1 as mentioned in the approved mining scheme. The specifications of ore required for Ferro manganese alloy production is as follows: Mn. Fe. SiO2 Al2O3 P Mn/Fe 46-48% 8-9% 4.5-5%(Min.) 4%(Max.) 0.15%(Max.) 5-6 Specification of ore produced: Grade Type Chemical Specification Physical Spec. Chemical Grade / Dioxide Mn > 48 % & Fe < 4 % mm, mm - 6 mm High Grade Mn > 46 % mm, mm - 6 mm Medium Grade Mn > 35 % & Fe < 26 % mm, mm - 6 mm Low Grade Mn > 25 % & Fe < 35 % mm, mm -6 mm Sub Grade Mineral Mn>10% & <25% & All Size 87

89 The different grades of ore from all the quarries/mines of the Company are ultimately blended in the plant to meet the desired specification as mentioned above for production of Ferro manganese / other alloys. The typical chemical analysis of the above ore types analyzed at Company s Geological Laboratory is given in Table This laboratory at Joda is recognized by the Directorate of Geology, Govt.of Orissa, and letter in support of the same is enclosed as Annexure-IX. Table : (Typical chemical analysis) Grade Chemical Analysis O/S% U/S% Ratio Mn% Fe% SiO 2% Al 2O 3% P% +75mm -10mm Chemical High Medium Low EFFORTS MADE FOR UTILIZATION OF SUB-GRADE MINERAL INCLUDING FINES: The fines generated in the course of mining are approximately 5% of the production and is stored separately for future use. Further to increase the recovery of residual lumps from the existing fines, screening will be done during dry season only. 8.0 MINERAL BENEFICIATION: The manganese ore is being dressed, sorted, sized and graded manually at sorting yard. These activities are highly labour intensive. Despite the availability of time-proven material handling and sizing equipment such as vibro-feeders, belt conveyors and conventional crushing equipment, the ROM ore is sized and sorted manually with respect to grade (%Mn) by visual inspection based on their expertise/experience. To improve upon the quality, productivity and safety, we are proposing to install a dry crushing and screening plant along with a mechanical sorter which is found to be successful at pilot scale for our ore. Tata Steel s Manganese group of Mines, Joda produces ~ 5 lakh tons/annum high and low grade manganese ores by semi mechanized mining. Around 17.5% of ore material is get converted into low grade fines, Chips and lumps (Mn: 15-35, Mn/Fe: <1) as sub grade mineral or mineral rejects. The preferred feed size of Manganese ore for ferro Alloys making is -75, +10mm size lumps. These low grade resources cannot be used in the Sub-merged arc furnace and these are dumped at different subgrade/mineral reject dumps. Tata Steel Mn mines are producing ~50,000 ton/annuam of such low/ sub grade ore and existing dumps contain ~ tons of such material at Joda West, Bamebari and Malda Mines. R &D studies have been carried out to utilize these resources in a cost effective and environmental friendly manner. R &D studies find that these fines can be beneficiated and agglomerated to use in ferro alloys making process. 88

90 Future proposal for mechanized processing of Manganese Ore :- As a part towards mechanization, crushing, screening and mechanical sorting (based on Radiometric X-Ray technology) unit is proposed to be commissioned during the scheme period for mechanizing the subsequent processing of the ROM. The plant shall have a capacity up to100 TPH to crush the ROM to -75mm size. The screening shall be done at 10 mm size. The products of mm shall be shifted to stack yard for preparation of stacks in geometrical shape. The fines (-10mm) shall be shifted to the mineral reject stacking area by using loader and dumpers. The waste generated if any shall be shifted to waste dumps. The above unit shall be of dry process and the following environment protection measures shall be taken to control the air pollution: Enclosures shall be provided to trap the dust while crushing, screening and conveying. Water spray shall be provided at all transfer points. A beneficiation process flow sheet is in process to explore to upgrade these ores using high intensity magnetic separators and reduction roasting followed by low intensity magnetic separation. Beneficiation and agglomeration test is being carried out to demonstrate the beneficiation process flow sheet at R & D, Tata Steel, IIMT- Bhubaneswar and Mintek Laboratrory of South Africa. High Intensity magnetic separation can upgrade the Mn ore upto usable for Silico manganese Production and detail test work on reduction roasting process is in progress to upgrade this resource, which can be used for Ferro manganese making. In view of mineral conservation and proper utilization of low grade manganese ore produced from Joda West Mn. Mines and other surrounding manganese mines of Tata Steel Ltd. We propose to commission a beneficiation plant during FY 16 which will be a first of its kind in India for beneficiation of low grade unusable ore being produced from our mines. The details of study for beneficiation of Low/ Sub Grade Manganese Ore and Fines carried out so far:- Reduction roasting has been explored to convert the feebly magnetic hematite to magnetite using coal but techno economics can be able debateable issue. The high intensity magnetic separator can recover the feebly magnetic particles but particle size as well as liberation characteristics play a crucial role in this process. Reduction roasting studies were carried out for temperature range 500 to C using various types of reductant. These studies were carried out and major findings are: 1. Roasting in coarser sizes (>6mm) is not successful and <3mm is most suitable size. 2. FeMn grade product (Mn >46%, Mn/Fe >7%) can be achieved at yield depends on roasting temperature ( C) and time. Weight Recovery was 37-45%, and test work in progress to optimize that. 3. R&D Tata Steel and MINTEK, South Africa is doing detailed test work (tempt: 800, 900,1000 o C, Time: 2,4 and 6 hours, Ore types : 5) to produce high grade Mn ore concentrate using Low grade ore fines. 89

91 4. Yield and product grade is sensitive to sources of low grade at different mines sites and composition (Fe & SiO 2). Sintering Process also carried out for agglomerate the Mn ore fines and found tto be commercially viable to utilize the ore fines. So, the area of work to commercialize this project are as follow: 1. Techno-economic studies of different process flow sheets (Fig. 7 ) 2. Material balance for beneficiation plant inputs and output disposal plans 3. Detailed Project Report for Sinter plant and beneficiation plant 4. Statutory requirements for beneficiation and sinter plant. Figure 7 90