Pre-Feasibility Reportenvironmentclearance.nic.in/.../18_Dec_2017_200912130A0QDTFB1MS… · 1...
Transcript of Pre-Feasibility Reportenvironmentclearance.nic.in/.../18_Dec_2017_200912130A0QDTFB1MS… · 1...
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Pre-Feasibility Report
for
Upgradation of Wet Iron Ore Grinding
System to Beneficiation Circuit in
existing 1.2 MTPA Iron Ore Pellet Plant.
for
MSPL Limited
“Baldota Bhavan” 117, Maharshi Karve
Road,
Mumbai 400020. Maharashtra.
Ph: (+91) (22) 22030989
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Pre-Feasibility Report
1.0 INTRODUCTION
MSPL Limited (MSPL) has established a 1.2 MTPA Iron Ore Pellet Plant over 41
Acres, at Survey no. 2, 8, 9, 12 to 15, 132, 136 & part of 5, 6, 7, 16, 17 at Village:
Halavarthi, Tahsil: Koppal, District: Koppal, Karnataka. Government of Karnataka
has issued Environmental Clearance for establishment of pellet plant vide letter no.
FEE 28 ECO 2010 dated: 1/12/2010.
Karnataka State Pollution Control Board has granted consent for operation,
combined consent order no. KSPCB/SEO/MINES/2010-11/673, Dated: 08.12.2010.
Honourable NGT vide order dated 27.05.2014 directed that such projects require
Prior Environmental Clearance under EIA Notification 2006 from MOEF & CC ,
New Delhi.
With above direction Karnataka State Pollution Control Board had issued a letter
vide PCB/MINI/LIMESTONE/2014-15/3579 Dated 16th Oct 2014 to MSPL Ltd, to
obtain EC from MOEF&CC.
The TOR was prescribed for undertaking detailed EIA-EMP study in addition to generic
TOR vide Letter No. F.N. J-11011/383/2014-IA.II (I) Dated: 8th April 2015.
The EC was accorded to the project by MOEF&CC vide their Letter no No. F.N.
J-11011/383/2014-IA.II (I) Dated: 23rd September 2016.
1.1 PURPOSE OF THIS PRE FEASIBILITY REPORT
The purpose of this Pre Feasibility Report is to help the regulatory authority to
review the proposed modification in the existing pellet plant and its impact on
environment due to the addition of beneficiation circuit. MSPL Limited obtained
two mining leases having low grade Iron ores for captive consumption in the E-
auction from the Govt of karnataka . These mines are allotted for captive use at
MSPL Pellet Plant. As per the procedures laid by Hon'ble Supreme court ICFRE
conduct the inspections and survey and fixed the production capacities to these two
mines based on a) Resources of low grade ores b) Dumps capacity and c) Road
capacity reaching pellet plant. The quality of ore available to the process is in the
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range of 53-54% of Fe while the existing process is meant to be operated at 63%
plus Fe. This Pre Feasibility Report (PFR) accordingly addresses the change in
environmental concerns for Pellet plant (Stand-Alone) of 1.2 MTPA capacity of
M/s MSPL Limited, located at Village: Halavarthi, Tahsil: Koppal, District:
Koppal.
This is to bring your kind notice that neither there will be product mix change nor
there will be change in the quantity of production which remain unchanged at
1.2 MTPA Pellet. Since this proposal is for up-gradation of existing wet process of
IOGS (iron ore grinding system) unit to beneficiate iron ore available in the captive
mines of Karnataka state having 53 to 54 % of Fe to 63% plus Fe suitable to be
process through this pellet plant.
1.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT
1.2.1 The Company
M/s MSPL Limited is a flagship company of the Baldota Group of Companies; a
leading iron ore mining, processing and export company with 53 years of expertise
behind.
In addition to mining, MSPL also own and operate wind farms, with a total
installed capacity of 215.75 MW. The wind farms are situated across Karnataka,
Maharashtra, Rajasthan and Gujarat.
MSPL is an ISO 9001:2000, ISO 14001:1996 and OHSAS 18001:1999 certified
company. MSPL is also the first unit certified, in the Indian mining sector, for
upgrades to ISO 9001:2000 and ISO 14001:2004 status, as certified by Bureau
Veritas. MSPL have been honoured with numerous awards, by the Central
Government of India and the State of Karnataka, for outstanding contributions to
the Indian iron ore industry.
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1.2.2 Project Proponent
Name and Address of project proponent:
Name of the Unit M/s MSPL Limited
Regd. OfficeBaldota Bhavan, 117, Maharshi Karve
Road, Mumbai – 400020
Plant Location
Survey no. 2, 8, 9, 12 to 15, 132, 136 &
part of 5, 6, 7, 16, 17. Village:
Halavarthi, Tahsil: Koppal, District:
Koppal.
Contact Person Dr. Meda Venkataiah
E-mail [email protected]
Mobile No. 9900256797
2.0 TYPE OF THE PROJECT
The pelletizing plant of 1.2 MTPA capacity is situated at Halvarti village of the
Koppal district in the State of Karnataka, mainly for utilization of iron ore fines
available from the mines being operated by the Baldota group and other mines in
the Bellary area of Karnataka. The available techniques of pelletizing process
include: grate kiln, travelling grate and shaft furnace. The technique of Grate-kiln
technology is adopted by MSPL Limited for 1.2 million TPA pellet project. The
present proposal is for Upgradation of Wet Iron Ore Grinding System to
Beneficiation Circuit in existing 1.2 MTPA Iron Ore Pellet Plant. This
upgradation will be helpful to utilize low grade Iron Ore Fines from captive mines
and mineral conservation by the existing Pellet Plant.
2.1 CLEARANCES/CONSENTS AVAILABLE
The following Clearances / Consents have been obtained from State
Government/Central Government for the existing Pellet Plant:
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• Government of Karnataka has issued Environmental Clearance for
Establishment of new Pelletization plant under letter no. FEE 28 ECO 2010
dated: 1/12/2010.
• Karnataka State Pollution Control Board has granted consent for operation,
combined consent order no. combined consent order no.
KSPCB/SEO/MINES/2010-11/673, Dated: 08.12.2010 and existing consent
for operation, order No. AWH-301242 DTD. 20/10/2016 VALID UP TO
30.06.2021.
• MOEF & CC had given Environment Clearance of the project under the
provision of EIA notification 2006. Ministry of Environment, Forest and
Climate change, vide letter No. F J-11011/383/2014-1A II(I) dated 23rd
September, 2016.
• Mining Plans including Progressive Mine Closure Plan have been approved
for both Captive Iron Ore Mines.
• Ministry of Environment, Forest and Climate Change, New Delhi accorded
Environmental Clearance to both Captive Iron Ore Mines.
3 NEED FOR UPGRADATION IN THE PROCESS
The running 1.2 million ton per year pellet plant for which Environment
consents/clearances is already available from both the state Government and Union
Government as stated in para – 1.2 operates by using as mined iron ore fines (-10
mm ). After blending, the average Fe content of the fines are maintained
commensurate to an average Fe of minimum 63% in the pellet which is acceptable
by blast furnaces and coal based sponge iron plants. As mentioned before, the
Group has two operating mines – one high grade (+65%) and the other low grade
(56-60%). The compulsion of maintaining the minimum Fe% in the pellet at 63%
severely limits the proportion of the poorer grade captive iron ore in the pellet
plant. Further, In general, the average grade of iron ore available in Karnataka is
lower than those of Jharkhand, Orissa and Chhattisgarh. The present process
available at the pellet plant would severely limit use of iron ore fines of Fe % lower
than 58% which are abundant in Karnataka with economic price. So it is intended
to introduce a fine iron ore beneficiation circuit in the process to upgrade fine
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ore with 53.5% Fe (average) to a fine ore concentrate (325 mesh – P80) with
63.3% Fe. Even though the concentration process will generate tailings and these
are planned to be stored in an eco friendly way, at an adjacent site for future
profitable use. The fine beneficiated concentrate would go to the hoppers of the
green balling plant in the main circuit of the pellet plant. The present equipment
used for dry grinding of the (-) 10 mm iron fines to 325 mesh would not be used
unless fines not needing beneficiation are used at any time. For such fines the wet
grinding can be used bypassing the beneficiation circuit.
4 NEED OF THE PELLET PROJECT
Iron-making technology was established for conversion of iron ore lumps to hot
metal/Direct Reduced Iron (DRI). However, with mechanized mining, production
of iron ore lumps suitable for efficient iron making operation leads to generation of
significant amount of fines (more than 60%) at the mines, which cannot be used
directly in the Blast Furnaces / Corex units/DR Units. Thus the agglomeration
technologies have been developed for processing iron input to the iron making
processes- which are mainly sintering and pelletizing. Blast furnace operators
worldwide are using either sinter or pellets in varying proportions depending on the
availability and cost consideration. It may be noted that while sinter is extensively
used for iron making in blast furnaces, pellets are used not only for blast furnaces
and Corex units iron making but also for production of DRI / HBI in direct
reduction processes.
Utilization of low grade ore and fines has to play an important role in India. Partly
due to the sponge iron sector; the overall percentage of lumps usage in steel making
(47%) is higher than most other countries. As hard ore reserves is depleting day
by day, lump generation suitable for blast furnace operation is coming down
resulting in production of large amount of surplus fines. Alternative iron
making processes for production of steel may lead to changing pattern of use
material inputs and feed stock causing significant shift in respective share of
lumps and agglomerated iron ore (pellets) and will also enable the use of
ores which could not be utilized earlier. As fines form considerable part of iron
ore resources, value addition to the iron ore fines, through various activities such as
Beneficiation, Pelletization is the need of the hour.
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Presently, most of the coal based sponge iron plants in India, use iron ore lumps.
The requirement is generally 1.6 to 1.8 t/ t of sponge iron. These high requirements
are mainly due to the fines generated in handling the purchased ore from the
sources to the plant. This reduces the kiln campaign length and increases the loss of
ore fines.
Use of pellets with better physical and metallurgical properties for
sponge iron production reduces the accretion formation in the kiln and the
pellets consumption is about 1.6 t/t. Further, the production from the kiln is
expected to increase by 35% to 40%. It is noteworthy that the operations of the iron
ore mines of M/s MSPL Limited at Viom (high grade) and Lyll (Low grade) are in
process. Thus, the iron ore fines so generated, are utilized through pelletizing route
for making mainly coal based sponge iron and sometimes at blast furnaces also..
The use of pellets is however, restricted in the Indian Blast Furnaces mainly due to
high cost of pellets compared to lump ore and captive sinter. But In the face of
shrinking reserves of high-grade ores, low grade ores must now be concentrated
before further processing and used. Pellets form one of the best options, due to
their excellent physical and metallurgical properties. Concentrating iron values in
ore needs grinding to liberate the gangue. Pelletizing is the only agglomeration
process of these beneficiated concentrates. Moreover, due to their high strength
and suitability for storage, pellets can be easily transported over long distances,
with repeated transhipments if necessary.
In view of the encouraging economic growth in the country, which is likely to
continue in the future, M/s MSPL Ltd had taken the decision and set up a pellet
plant.
Secondly, the Hospet-Bellary region in the state of Karnataka is a high potential
zone in terms of Iron and steel and allied industries because of natural resources
like water and raw materials like iron ore, Dolomite etc. The easy availability of
iron ore from nearby mines and water from Tungabhadra reservoir makes it an
attractive area for iron steel industry.
5. The proposed upgradation in the process therefore would bring the following
benefits to the company as well as to the country as a whole.
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• Poorer grade local iron ore fine (with Fe 54-56%) which have a very
restricted use in the Indian/local steel industry will find an outlet leading to
the conservation of iron ore resources in line with our national mineral
policy.
• This would lead to clearing of accumulated low grade fine ore dumps in
nearby mines.
• The company would be able to increase the output of the mine with poor
grade ore and would be able to lengthen the life of the better ore grade mine
by reducing output. This would improve the viability of the pellet
production. The present margin in pellet production from better grade ores is
very thin.
• Even when the company is to buy fine ore from the market in Karnataka,
going for poorer grade fines would give price advantages. Now that demand
of poor grade fine ores from China had dwindled and import of low grade
fine ore is restricted in China.
6. Location:
The Existing operational 1.2 million TPA Iron Ore Pellet Plant is situated at
Survey no. 2, 8, 9, 12 to 15, 132, 136 & part of 5, 6, 7, 16, 17.Village: Halavarthi,
Tahsil: Koppal, District: Koppal, Karntaka. The proposed up-gradation of the
existing Wet process of IOGS (Iron ore grinding system) by introduction of
additional equipments to form beneficiation circuit to the process will be
carried out within the approved boundary of the pellet plant.
7 Project Highlights:
Table 1: Project Highlights
Sr.No.
Particulars Details
1 Project SiteSurvey no. 2, 8, 9, 12 to 15, 132, 136 & part of5, 6, 7, 16, 17.Village: Halavarthi, Tahsil &District: Koppal, Karnataka.
2 Site Co-ordinates
N15o 19’49.9”, E76o12’29.9”N15o 19’35.9”, E76o12’29.5”N15o 19’35.8”, E76o12’12.0”N15o 19’49.4”, E76o12’12.0”
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3 Topo sheet No. 57 A/3
4 Elevation above MSL 515 m
5 Present Land use Industrial
6 Climatic Conditions
Annual Average Maximum Temp 440C,Annual Average Minimum Temp 100CAnnual Average Rainfall 572 mm,Annual Average Humidity 47-68%
7 Nearest Highway NH -63, 1.8 Km : N
8 Nearest AirportHubli, 120 Km : W (Commercial Airport)Baldoa, MSPL : 4 Km : N ( Private Airport)
9 Nearest Railway Station Ginigerea, 4.5 Km : NE
10 Nearest Village Halavarthi, 0.5 Km : S
11 Nearest Town Koppal, 6 Km.: NW
12 Nearest water bodyTungabhadra River, 4.0 km : SETungabhadra Reservoir 9 km (S,SE)
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Figure 2: Specific Location of the Project Site
Source: SOI Toposheet
Halavarti
Kunikeri Tanda
Allanagara
Kidadhala
KanakapuraLingadahalli
Hire Bagnali
Hire Kasinkandi
LachankeriChikka Bagnala
TUNGABHADRATUNGABHADRA
Karkihalli
MundrigiMellekeriHyati
Kunikeri
Hosahalli
ChukkanakalliBahadurabanda
Huvinahalu
Hosa kanakpuraBevinal
GingeraBasapur
BelanaluKOPPAL
BhagyanagarYattinahatti
Mangalpur
Haratattanahalu
GbburGuddanahali
Halhalli
Tavargera
Lebigeri
TenakaaakalluChilavadgi
Naregallu
Daddegallu
Sangapura
Hanumanahalli
Katakkanahalli
Muddaballi
HIRE
HALLA
ICH
HALA
HA
LLA
ADDA HALLA
HIRE
HALLA RS
76°15'
15°20'
15°15'
76°15'
76°10'
76°10'15°25'15°25'
STREAMS
RIVER / NALA
POND
ROAD
HABITATION
GRID
PROJECT SITE
INDEX
RAILWAY LINE
15°20'
15°15'
PREPARED BY-POLLUTION AND ECOLOGY CONTROL SERVICES
Village - Halavarthi, Tahsil - Koppal, District -KoppalState - Karnataka
M/s MSPL Ltd.
10 KM. Radius of Project Site
RESERVOIRRESERVOIR
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Figure 3: The Google Image of the Project Site
Source: Google Earth
8 SIZE / MAGNITUDE OF OPERATION
The existing operational pelletizing plant of 1.2 MTPA capacity is situated at
Village: Halavarthi, Tahsil & District: Koppal, Karnataka. The area of the project is
41 Acres (Total area in possession is 113 Acres).
The Indian steel industry which predominantly uses expensive lump ore is
gradually moving towards usage of sintered ore and pellets. We have forayed into
pellets; with a modest start of 1.2 million tonnes per annum pellet plant. We cater
to the requirements of sponge Iron manufacturers in South India, by providing
customers premium quality pellets which will yield higher metallised Sponge Iron
with reduced production costs.
The present proposal is for Upgradation of Wet Iron Ore Grinding System to
Beneficiation Circuit in existing 1.2 MTPA Iron Ore Pellet Plant. About 2.2 MTPA
Low Grade Iron Ore Fines will be required after commissioning of proposed
Beneficiation Circuit.
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9 Iron Ore Pellet Plant
The Main Plant facilities of the Pellet Plant after up gradation would be as under:
1. Raw Material Yard Existing
2.Dry Grinding units for Bentonite and
CoalExisting
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Fine ore beneficiation circuit
comprising of:
3AScrubber, primary grinding and spiral
concentrator buildingModification/Addition
3BSecondary, tertiary grinding and
magnetic separation building.
Modification/Addition
3CFiltration building for concentrate &
pellets
Modification/Addition
3D Filter cake storage Modification/Addition
3E Thickeners for concentrate & tails Modification/Addition
3F Tailing Filters Addition
4. Disc Pelletizer Building Existing
5.Travel Grate, Rotary Kiln, Annular
Cooler
Existing
6. Product Screening Room Existing
7. De-dusting System Existing
8. Utilities / Services Existing
The layout of the plant after introduction of fine ore beneficiation is given in the
Drawing No. ENVIRO/MSPL/PELLET/EC/GL/001. The original layout of the
pellet plant is with provision for wet grinding of ore with space earmarked and
provision of the equipment. The proposed modifications have been mostly adjusted
within those space provisions.
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Plant Layout
10. PLANT DESCRIPTION
10.1 Raw Material Yard
Iron ore fines for the pellet plant are received from MSPL’s mines by self-
discharging trucks / dumpers. A stockyard of about 60,000 t capacity is available to
store about 10 day’s requirement of iron ore fines.
10.2 Raw Material Preparation
Iron ore fines are currently wet ground in a ball mill and coal & bentonite is ground
in a vertical roller mill. Both the mills and bins of respective feed materials Iron
ore; Bentonite and Coal are provided in the same building. Ground product is
stored in separate silos of iron ore / bentonite and coat bin. After modification, fine
ore will be beneficiated from 53-54% Fe to over 63% Fe through scrubbing-de-
sliming-primary grinding-spiral concentration-secondary/tertiary grinding and
magnetic separation.
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10.2.1 Description of the beneficiation process of fine ore.
The iron ore input is iron ore fines (-) 10 mm. The iron ore material is received in
underground feed hopper. Iron ore is conveyed to 2 nos day bins. There is needle
feeder below the day bins, which discharges the material onto another belt
conveyor. This belt conveyor feed the material to one scrubber. Water is mixed
with iron ore and loose clay particles are dislodged and come into slurry. Output of
scrubber goes to a vibrating screen having 1 mm aperture. Screen coarse size
particle are carried to the primary ball mill through a belt conveyor. Undersize
particles from the screen are sent to de-sliming cyclones at 25µm. De-sliming
cyclone underflow is mixed with primary ball mill output and overflow is sent to
tailing thickener. Output from primary ball mill is fed to sizing hydro-cyclone
targeted at 300µm size. The underflow (+300µm) from this cyclone will route back
to ball mill for further grinding and overflow (-3-00µm) will proceed for further
beneficiation steps.
Sizing hydro-cyclone overflow will pass through de-sliming cyclone to prepare
material (30% solids) for spiral circuit. Material with about 30% solids will pass to
spiral circuit, where two products namely concentrate and tails will be generated.
Spiral concentrate will have superior Fe grade of +63% Fe and will go to final
grinding step. Spirals tails will go to a regrinding mill. The product of regrinding
mill will be fed to magnetic separator circuit. Magnetic circuit concentrate will
have +63% Fe grade and will go to final grinding step. Output of final grinding
mill will be sent to the concentrate thickener. Tails generated from magnetic circuit
will be sent to the tailing thickener.
Material from concentrate thickener will be filtered using pressure filter to product
cake with about 8-10% moisture and will be stacked in the designated area for
pellet manufacturing. Tails from tailing thickener will be sent to tailing filter to
produce cake of about 15-17% moisture. These cakes will be stacked in demarcated
open area inside the plant for a short time before shifting to an environmentally
controlled adjoining area for storage for further use. The tentative location of this
storage is shown a drawing ENVIRO/MSPL/PELLET/GL-002. Since the need to
store tails will arise only after commissioning of the beneficiation circuit, EC for
this site for temporary storage of tails will be sought after words. The land is
already in possession of MSPL and proper environment protection for water and air
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pollution will be taken by providing light vegetation cover on the dumps and
providing a green belt around it.
Quantity of waste generated will be about 0.65 million tonnes per annum.
The summary of the features of the fine ore beneficiation process is given in the
Table below:
Sl.No.
Item Value
1 Annual production of concentrate envisaged 14,00,000 t
2 Feed grade % Fe 53-54
3 Feed size(-) 10 mm
F80 6 mm
4 Product size P 80: 325 mesh
5 Product grade % Fe 63 - 63.5%
6 Annual working hours envisaged 7920 (330 days)
7 Annual feed input of fine ore 22,00,000 t
8 Average Fe in input fines envisaged 53.5%
9 Specific gravity 3.88
10 Yield 70%
The flow chart of the iron ore beneficiation process to be adopted by the company
is given in Annexure-1 and also in the next page.
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11 RAW MATERIAL REQUIREMENT
The main raw material for Beneficiation Circuit will be 2.2 MTPA low grade Iron
Ore. In addition to this additional 1380 m3/day water will be required.
The gross annual requirement of various raw materials (including Moisture) of the
plant and their indicative sizes with probable source are given in table below.
Table 2a: Annual requirement of major raw materials for proposed Iron
Ore Fines Beneficiation unit
Sl.No.
Raw material
AnnualRequirement,
Tons
ProbableSource
1 Iron Ore Fines 22,00,000 MSPL Mines
Table 3b: Annual requirement of major raw materials for Existing Pellet
Plant
Sr.No.
Rawmaterial
AnnualRequirement
Tons
Probable Source
1 Iron OreFines
1348600 Mines of MSPL, situated near Hospet,which is about 35 - 40 km away fromthe plant site and any other source inand around Hospet through E- Auction.
2 Coal 53900 Indigenous/ Imported
3 Bentonite 15300 Gujarat
The average chemical composition of raw materials used for production of acid
Pellets are shown in Table below –
Table 4: Chemical Composition of Raw Materials
Α. Iron Ore Fines
Chemical Composition %
Total Fe SiO2 Al2O3 CaO MgO S P
53-54 12.58 2.78 -- -- 0.006 0.044
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Physical Properties
Grain Size(mm)
Moisture % Density (t/m3) LOI %
< 10 < 10 2.2 --
Iron Ore Transportation
The Iron Ore fines for the pellet plant will be supplied from two captive mines of
MSPL, situated in Sandur Tehsil , Bellary District which are about 70 - 73 km
away from the plant site. These fines shall be transported from mine by tarpaulin
covered trucks. The transportation route map of the iron ore fines from mines to
plant site is attached as Annexure 3.
The specific requirements of raw materials (Dry & Net) kg / t of Pellets is as under
Table 5: Raw Material (dry & net). Kg/t of pellets
Sr.No. MaterialSpecific Consumption
Kg/ t
1 Beneficiated Iron Ore Fines 1023.55
12 WATER REQUIREMENT
In the pellet plant, for pellet making process water is required for process, cooling
of equipment, dust suppression, fire fighting and drinking and sanitary needs the
estimated water requirement is briefly 514.06 m3/day.
However the fine ore beneficiation process will require water to the extent of
difference between the water content of the outgoing filter concentrate cake (about
10%) and tailing cakes (15-18%) and the water intake with the fine ore from the
mine (about 4-6%). To this quantity, the process loss, blow down loss and
evaporation loss of the circulating water need to be added. For the beneficiation
process, the gross make up water requirement will be 0.455X106m3/Year or
1380m3/day.
The total estimated make up requirement of water for the pellet plant with fine ore
beneficiation at rated capacity therefore come to 1894.06 m3/day. (78.9 m3/Hr) The
water is proposed to be made available from the rain water storage at the site and
water from TB dam as per present allocation from Karnataka Government.
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Table 6: Water requirement
Sr.No.
Purpose Qty (m3/day)
1Beneficiationprocess
1380
1 Pelletizing Process 302.11
2 Cooling of pellets 196.61
3 Domestic 15.94
Total1894.06Or 78.9 m3/Hr
In beneficiation most of input water is in the form of retained water with the filter
cakes of the concentrate and tails. This water is totally evaporated finally and no
effluent loss is expected. In the cooling towers, the blow down is about 2-3%. This
water is used for plantation and spraying in the raw material yard to contain dust. .
The water requirement met from surface water resources. The water from
Tungabhadra Dam is pumped to the RCC Filtered water storage tank. The
Tungabhadra Dam Board had sanctioned a total of 2.5 MGD.
13 POWER REQUIREMENT
The power requirement for the proposed Modification and Pellet Plant is 15 MW
and will be met by the Karnataka State Electricity Board sanctioned quota. Power
will be received at 220 kV from Utility (GESCOM) and stepped down to 33 KV
and again to 6.6kV for further distribution. The maximum demand of the total plant
covered under this report is about 15 MW at 0.95 p. f. with an annual energy
consumption of 80 million units.
210kV supply will be stepped down to 33 KV through 1 No. of 63 MVA power
transformer. This is installed in the 220 KV switchyard at MRSS. The control and
Relay panels for the 220 kV bays are installed in the control/switchgear building
adjacent to the switchyard. A 6.6kV switchboard is installed in the switchgear
Room to feed the loads of Ball Mill and stockyard area. The 6.6kV switchboard
will also feed a separate 6.6kV substation to feed the Mixing, Balling, induration
and screening areas. 6.6/0.433kV substations are located at different load centres to
cater to LT loads of the plant Reactive power compensating equipment has been
provided in the 6.6kV buses at MRSS to maintain a power factor of 0.95.
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Illumination of the plant for the required level of illumination will be as per
industry standards.
14 MANPOWER REQUIREMENT
The present project is providing direct employment to nearly 286 workers. The
local persons have been given preference in employment as per the qualification
and technical competencies. Necessary training has been given to train the
unemployed youths of the nearby villages. Indirect employment opportunities have
been created in the periphery of the project automatically as the project started
operation in the region.
In order to operate and maintain the plant facilities, including its technical
general administration needs, the manpower in the Iron Ore Pelletization Plant is
estimated as 305. The above manpower covers the top management, middle and
junior level executives and other supporting staff including workforce. The
category wise break-up of manpower is indicated in the following table.
Table 7: Category-wise break-up of Manpower
Sr. No Category Man Power Total
Existing Addition
1 Managerial 30 - 30
2 Technical 68 - 68
4 Skilled 129 5 134
5 Semi-skilled 44 10 54
6 Un-skilled 13 3 16
7 Clerical 2 1 3
Total 286 19 305
15 ENVIRONMENT MANAGEMENT
The pollutants in the form of solids, liquids and fugitive emission will be generated
from operation of Beneficiation Circuit. Pollution of the environment not only
adversely affects all life forms, but also shortens the life of plant and equipment.
This vital aspect, therefore, has been taken into account while planning the plant
and equipment and adequate measures are being taken to limit the emission of
pollutants within the stipulations of statutory norms. Adoption of technology like
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recovery of dust/ash for re-use as raw material fulfils the twin objectives of
material conservation and pollution control.
15.1 Air pollution
Proper Dust Suppression is proposed in stock yard of Iron Ore Fines, sprinkling on
internal roads, regular check up & maintenance of vehicles, it will be ensured that
all trucks/dumper caring Iron Ore Fines ore covered by Tarpaulin.
A stack of 75 m Height have been provided in Existing Pellet Plant.
The MSPL is getting screened raw material and is stock piled in the premises.
Spraying of water on the stockyard stockpiles controls any fugitive emissions from
this area.
An ESP located near the travelling grate does the process de-dusting of the drying
& induration area.
Plant de-dusting system for all the material transfer points and screens is carried
out by a bag filter system. Dust collected from the bag filters is re-circulated
Pulverised coal is used as fuel for induration of pellets in rotary kiln of Induration
area. Coal is pulverized in vertical roller mill. This mill is located in the same
building of Ball mill for grinding iron ore and bentonite. The mill is connected to
the cyclone, bag filter and an ID fan. Ground coal is collected in a bin below the
bag filter. Product from cyclone is also fed to the ground coal bin. 2 nos of ground
coal bins/hoppers are provided below the ground coal bin.
The dried waste gas will be discharged into the air through the chimney.
15.2 Water pollution
15.2.1 Fine ore beneficiation
The fine ore beneficiation needs process water for making iron ore slurry to be
passed through the various equipments as needed for wet concentration of Fe in the
ore. However most of this water comes back to the circuit from the thickeners and
filters used for making the final concentrate and tailing cake. The major use of the
water is to account for the difference in the water contents of the concentrate (8-
10%) and the tail (15-18%) and the water input with the fine ore (-) 10 mm (4-6%).
Water losses are due to evaporation and other process losses and blow down of the
23
tanks (about 2-3%). The major used water therefore goes with the product and the
tails which eventually gets evaporated in the drier or naturally. The process water
lost is accumulated in a tank and used for irrigation and spraying in the yard. Thus
the Fine ore beneficiation plant would also maintain a zero discharge of water
from the units.
15.3 NOISE POLLUTION
The physical description of sound concerns its loudness as a function of frequency.
Noise in general is sound which is composed of many frequency components of
various loudness distributed over the audible frequency range. Various noise scales
have been introduced to describe, in a single number, the response of an average
human to a complex sound made up of various frequencies at different loudness
levels. The most common and universally accepted scale is the 'A' weighted
network dB (A). The scale has been designed to weigh various components of noise
according to the response of a human ear.
The major sources of noise generation in the pellet plant are from fixed plant
installations and external transport movements.
The common noise generating sources from the fixed installations are screens,
vibrators, conveyors and rotary kiln and the ball mills. Apart from these, another
noise generating source is DG set which will be operated occasionally i.e. used as a
standby source of electricity. However, ID Fans are the major noise-generating
source.
Trucks carrying the raw material into the plant premises and the finished product
from the industry are the main sources of noise pollution.
Various measures to reduce noise pollution include reduction of noise at
source, provision of acoustic lagging for the equipment and suction side
silencers, selection of low noise equipment. In some areas where due to
technological process, it is not feasible to bring down the noise level within
acceptable limits, personnel working in these areas are provided with noise
reduction aid such as ear muffler and also the duration of exposure of the
personnel are limited as per the norms.
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15.4 SOLID WASTE MANAGEMENT
For the overall pellet plant, the pelletizing process practically generates no solid
waste. A very small quantity of coal fines and iron ore fines will be generated and
also dry dust from air pollution control equipment, which will be reused, in the
industrial process. Hence there is no solid waste generation.
The fine ore beneficiation process however will generate tailing to the extent of
about 35% of the input iron ore which would have Fe content 33.4% on an average
in compliance with the latest IBM norm. At rated output of the plant, the annual
generation of such tailing would be 650,000 t. The generated tailings from the tail
slurry filter would be transported to a designated site inside the plant boundary for
a few days till it is moved to a designated dumping yard outside the plant boundary
within MSPL land to the east of the existing plant fencing to be stored for a few
years till these tailings are reused. The proposed dumping site will be
environmentally protected by providing green belt around and individual dumping
stacks will be provided with a light green over growth. Proper garland drain will be
constructed around dumping site to collect rain water / surface water. The
temporary stocking of the tails inside the plant boundary is shown in the plant
layout drawing and the proposed dump site in the adjoining land is shown in the
overall site drawing. A survey map showing the area identified for storing tailings
is enclosed as Annexure 2. We have identified about 12.20 Acres of land for
storing tailing. In addition to this it is also prosed to utilize this tailing for land
filling on adjacent land where ISP is proposed.
The dried domestic sludge generated from sewage treatment plant will be used as
manure for green belt development.
16. GREEN BELT
Adequate green belt is provided all around the pellet plant and inside the plant
premises. Locally available types of trees are planted. The detailed layout of the
plant has been prepared with indicative area of plantation for the whole plant.
The plantation has been done in a phased manner before commencement of
operation of the Pelletizing Plant. The green belt is shown in the plant layout.
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17. A Summary of this report is presented in a tabular form in the next
few pages.
Summary
A Comparison between the present operating process and conditions and
those proposed after introduction of fine ore beneficiation.
Sr.No
Parameter Existing After modification
1 ProcessPellet making withhigh grade(av. 63.5%)fine ore input
Pellet making with lowgrade fine ore (53-54%)input
2 Product
1.2 million tonsPellets for use insponge iron kilns andblast furnaces mostly.
1.2 million tons Pelletsfor use in sponge ironkilns and blast furnacesmostly.
3 Input iron oreOre fine (-) 10 mm1.3486 million tons;Fe 63-65%
Ore fine (-) 10 mm 2.2million tons; Fe 53-54%
4Other process rawmaterials
Unchanged
5 Process steps
• Wet grinding ofore fines andother rawmaterials
• Proportioning• Balling to green
pellets• Heat induration
to hardenedpellets
• Cooling• Despatch
• Wet grinding ofore fines andbeneficiation ofiron content.
• Dry grinding ofother rawmaterials
• Proportioning• Balling to green
pellets• Heat induration
to hardenedpellets
• Cooling• Despatch
6 Area of the plant41 acres out ofavailable 113 acres
41 acres out ofavailable 113 acres.The modification wouldbe limited to theexisting plant site.However, some of theadjoining available landto be utilized to storetailing after passingthrough the filterationfor a few years till theirreuse.
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Sl.
No.
Parameter Existing After Modification
6Make up water
requirement21.4 m3/Hr 78.9 m3/Hr
7Environment
impact
7.1 Air pollution
The pellet plant usesESP and bag filter tocollect dust from theeffluent gases aswell as from theambient air insidethe plant. Theprocess dust iscollected andrecycled in theprocess.
Spray is used toreduce dust in theyards and junctionhouses.
The same steps willcontinue. No sourceemission from thebeneficiation circuit. Thefugitive emission will bemainly due to handlingand storing of Iron OreFines, transportation ofIron Ore Fines.
Proper Dust Suppressionis proposed in stock yardof Iron Ore Fines,sprinkling on internalroads, regular check up &maintenance of vehicles, itwill be ensured that alltrucks/dumper caring IronOre Fines Ore covered byTarpaulin.
7.2 Water pollution
The existing processuses very littlewater. Zerodischarge of water ispracticed.
Introduction ofbeneficiation will requiremore make up water asexplained above. Most ofthese water will beultimately be evaporatedeither in the atmosphere orat the raw mix driers.Water spilled from theprocesses and tank blowdowns will be collectedand used for spraying inthe yards as well as forplantation. Zero dischargeof water from the plantsite will be maintained.
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Sl.
No.
Parameter Existing After Modification
7.3Solid waste
generation
In the present processthe entire solid waste iscollected and re-used inthe process. So there ispractically no solidwaste generation.
With beneficiation of
fine low grade ores, a
rejected portion called
tailing will arise which
is approximately 35%
of the overall iron ore
through put. This will
be very low in Fe about
28.2% and mostly of
silica and alumina. The
tailings will be
temporarily stored
within the plant
boundary for drying
and then shifted to an
adjoining site (land
owned by MSPL) for
storage for a few years
till it is used at the
filling work of the
upcoming steel plant in
the site or used by
employing some of the
upcoming technologies
for recovery of silica
and alumina. A survey
map showing the area
identified for storing
tailings is enclosed as
Annexure 2. We have
identified about 12.20
Acres of land for storing
tailing. In addition to this it
is also proposed to utilize
this tailing for land filling
on adjacent land where ISP
is proposed.
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Sl.
No.
Parameter Existing After Modification
8
Overall advantages
of this proposed
modification
(1) Poorer grade local iron orefine including those owned byMSPL (with Fe 54-56%) whichhave a very restricted use in theIndian/local steel industry willfind an outlet leading to theconservation of iron oreresources in line with ournational mineral policy.
(2) This would lead to clearingof accumulated low grade fineore dumps in nearby mines.
(3) The company would be ableto increase the output of themine with poor grade ore andwould be able to lengthen thelife of the better ore grade mineby reducing output. This wouldimprove the viability of thepellet production. The presentmargin in pellet productionfrom better grade ores is verythin.
(4) Even when the company isto buy fine ore from the marketin Karnataka, going for poorergrade fines would give priceadvantages. Now that demandof poor grade fine ores fromChina had dwindled and importof low grade fine ore isrestricted in China.
(5) In the present highlydepressed price situation of ironore and pellets the modificationwould bring cost reduction ofthe manufactured pelletsthereby providing better marginfor the company.
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ExistingPellet Plant
ProposedTailingStorage Area
Annexure 2
Survey Map showing Tailing Storage Area