ALUMINA REFINERY PROJECT AT KUSUMSHILA, ODISHA .ALUMINA REFINERY PROJECT AT KUSUMSHILA, ... ALUMINA

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  • PRE FEASIBILITY REPORT FOR

    ALUMINA REFINERY PROJECT AT

    KUSUMSHILA, ODISHA

    REPORT No. A811-RP-8342-0101 FEBRUARY 2016

    PREPARED BY

    NEW DELHI NEW DELHI

    This report is prepared for M/s. L & T and it is for use by M/s. L & T or their assigned representatives/ organisations only.

    The matter contained in the report is confidential.

  • Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL All rights reserved

    Document No. A811-RP-83-42-0101

    Rev. No. B

    Page 2 of 67

    PRE FEASIBILITY REPORT FOR

    ALUMINA REFINERY PROJECT, ODISHA

    PRE FEASIBILITY REPORT FOR

    ALUMINA REFINERY PROJECT AT KUSUMSHILA, ODISHA

    (As Annexure to Application made to MoEFCC)

    CLIENT LARSEN & TOUBRO LIMITED

    PREPARED BY ENGINEERS INDIA LIMITED

    NEW DELHI

    EIL JOB No.: A811

    PO No.: L&T/BMP/PFR/2015-16/09 DATED 31-08-2015

    REPORT No.: A811-RP-83-42-0101

    FEBRUARY 2016

  • Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL All rights reserved

    Document No. A811-RP-83-42-0101

    Rev. No. B

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    PRE FEASIBILITY REPORT FOR

    ALUMINA REFINERY PROJECT, ODISHA

    TABLE OF CONTENTS

    1. Executive Summary

    2. Introduction of the project/ Background information

    2.1 Identification of project and project proponent

    2.2 Brief description of nature of the project

    2.3 Need for the project and its importance to the country and or region

    2.4 Demand-Supply Gap

    2.5 Imports vs. Indigenous production

    2.6 Export Possibility

    2.7 Domestic / export Markets

    2.8 Employment Generation (Direct and Indirect) due to the project

    3. Project Description

    3.1 Type of project including interlinked and interdependent projects

    3.2 Location with coordinates.

    3.3 Details of alternate sites considered

    3.4 Size or magnitude of operation

    3.5 Project description with process details

    3.6 Raw material required and Finished Product.

    3.7 Resource optimization/ recycling and reuse

    3.8 Availability of water its source, Energy/ power requirement

    3.9 Management and disposal of wastes (liquid and solid)

    3.10 Schematic representations of the feasibility drawing

    4. Site Analysis

    4.1 Connectivity.

    4.2 Land Form, Land use and Land ownership

    4.3 Topography (along with map)

    4.4 Existing land use pattern

    4.5 Existing Infrastructure

    4.6 Soil classification

    4.7 Climatic data from secondary sources

    4.8 Social Infrastructure available

    5. Planning Brief

    5.1 Planning Concept: Town & Planning/ Development authority Classification

    5.2 Population Projection facilities Country Planning/ Development authority

    Classification

    5.3 Land use planning

    5.4 Assessment of Infrastructure Demand (Physical & Social).

    5.5 Amenities/Facilities.

  • Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL All rights reserved

    Document No. A811-RP-83-42-0101

    Rev. No. B

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    PRE FEASIBILITY REPORT FOR

    ALUMINA REFINERY PROJECT, ODISHA

    TABLE OF CONTENTS (Contd.) 6. Proposed Infrastructure

    6.1 Industrial Area (Processing Area)

    6.2 Residential Area (Non Processing Area)

    6.3 Green Belt

    6.4 Social Infrastructure

    6.5 Connectivity

    6.6 Drinking Water Management

    6.7 Sewerage System

    6.8 Industrial Waste Management

    6.9 Solid Waste Management

    6.10 Power Requirement & Supply I source

    7. Rehabilitation and Resettlement (R & R) Plan

    7.1 R&R Policy to be adopted.

    8 . Project Schedule & Cost Estimates

    8.1 Project Schedule

    8.2 Estimated Project Cost

    9. Analysis of proposal

    9.1 Financial and social benefits

    9.2 Conclusions & Final Recommendations

    Annexures 1. List of Aluminium Smelters

    2. Table of Annual Operating Cost & Annual sales Revenue

    3. Project Execution Bar Chart Schedule

    4. Evaluation of alternative sites

    5. Site Location Drawing No. A811-00-83-42-1101

    6. Table Top Layout Drawing No. A811-00-83-41-0001

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    PRE FEASIBILITY REPORT FOR

    ALUMINA REFINERY PROJECT, ODISHA

    1. EXECUTIVE SUMMARY

    Engineering major M/s Larsen & Toubro Limited (L&T) intends to set-up a Greenfield

    Alumina Refinery in the state of Odisha. The Alumina Refinery is proposed to be

    located near Kusumshila village in Rayagada district and shall be based on Kutrumali

    and Sijimali Bauxite Deposits in Odisha. L&T has engaged Engineers India Limited

    for preparation of this Pre-Feasibility Report for the above Greenfield Alumina

    Refinery Project in Odisha, prepared in accordance with "Guidelines for Preparation

    of pre feasibility report for obtaining prior environmental clearance in terms of the

    provisions of EIA notification, 2006" and is to be annexed with the application to

    MoEFCC.

    The proposed alumina refinery shall be designed to produce Smelter Grade Alumina

    and operate at a capacity of 3 million TPY in three streams each of 1.0 million TPY,

    including necessary balancing facilities for utilities, offsite and infrastructure.

    Project Outline

    Bauxite Mine** 9.0 Million TPY of Bauxite from Sijimali &

    Kutrumali Bauxite Deposits about 10 Km

    west of Alumina Refinery

    ** a separate related project

    Alumina Refinery 3.0 Million TPY of Alumina in 3 streams

    of 1 million TPY each

    Location of Alumina Refinery Kusumshila, Rayagada Dist. Odisha

    Co-generation Power Plant (CPP) 200 MW with 800 TPH of Process Steam

    (Inside Alumina Refinery Complex)

    Coal Source for Power Plant Ib Valley Coal field / Imported Coal

    Red Mud Disposal Area Close to Alumina Refinery

    Ash Disposal Area Close to Alumina Refinery

    Township Close to Alumina Refinery

    Water Source for Alumina Refinery Nagavalli River, near Kumhargurha

    village

    The site location map (Drawing No. A811-00-83-42-1101 as Annexure 5) shows all

    the above facilities along with the bauxite deposits of Kutrumali and Sijimali. Total

    land requirement for the project is estimated to be about 1400 Ha with the following

    breakup for the plant and various associated facilities:

  • Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL All rights reserved

    Document No. A811-RP-83-42-0101

    Rev. No. B

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    PRE FEASIBILITY REPORT FOR

    ALUMINA REFINERY PROJECT, ODISHA

    Facility

    Approximate

    Area (Ha)

    Alumina Refinery

    (Includes area for Water Reservoir, Green Belt all around the refinery) 790

    Red Mud Disposal + Ash Pond + Run-off Pond 287

    20 Km Rail Linkage to Kevatiguda Road Rly. Stn. 80

    Mine access & conveyor belt 75

    Mine corridor 66

    Township 40

    Rehabilitation Colony 60

    Total Area 1398

    The project envisages a time schedule of 48 months after financial closure. As

    informed by L&T, the project capital cost is estimated to be Rs.13,468 crores with a

    foreign exchange component of Rs 2,385 crores. Annual operating cost works out to

    Rs. 2,995 crores. IRR for the project is estimated to be 14.31% on total capital

    employed.

    Based on the preliminary analysis presented in this report it is concluded that the

    proposed project is technically and financially feasible. The estimated Operating Cost

    is low and is similar to other plants in the regions. However, it is recommended that

    these findings may be studied in further detail through Detailed Feasibility Studies

    before financial closure.

  • Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL All rights reserved

    Document No. A811-RP-83-42-0101

    Rev. No. B

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    PRE FEASIBILITY REPORT FOR

    ALUMINA REFINERY PROJECT, ODISHA

    2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

    2.1 Identification of project and project proponent

    Engineering major M/s Larsen & Toubro Limited (L&T) intends to set-up a Greenfield

    Alumina Refinery in the state of Odisha. The Alumina Refinery is proposed to be

    located near Kusumshila village in Rayagada district and shall be based on Kutrumali

    and Sijimali Bauxite Deposits in Odisha. L&T has engaged Engineers India Limited

    for preparation of this Pre-Feasibility Report for the above Greenfield Alumina

    Refinery Project in Odisha, prepared in accordance with "Guidelines for Preparation

    of pre feasibility report for obtaining prior environmental clearance in terms of the

    provisions of EIA notification, 2006" and is to be annexed with the application to

    MoEFCC.

    Identification of Project

    Project: Alumina Refinery and

    Associated Facilities

    Extent : about 1398 Hectares

    Village : Near Kusumshila

    District: Rayagada

    Odisha state

    Project Proponent

    M/s Larsen & Toubro Limited

    Mumbai

    (Maharashtra State)

    About the Promoter - Larsen & Toubro Limited (L&T)

    L&T is India's largest engineering, construction a