ALUMINA REFINERY PROJECT AT KUSUMSHILA,...

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

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ALUMINA REFINERY PROJECT, ODISHA


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



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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.



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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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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:



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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.



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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 and manufacturing conglomerate with

additional interests in electrical, electronics and Information Technology. L&T meets

vital requirements in diverse fields of human interest, with a product range that

stretches from engineering and construction of complex chemical/ mineral/ petro-

chemical projects to nuclear power reactors, from earth moving equipment to rocket

motor casings, just to name a few. L&T has also diversified from the traditional

construction business and has taken a number of developmental initiatives in the

areas of power and infrastructure. The present proposal is in furtherance of its

development initiatives in the field of mines and metals. During 2014-15, the

consolidated revenue was in excess of Rs. 92,000 Crores. It operates in over 40

countries worldwide.

2.2 Brief Description Of Nature Of The Project

Alumina refinery is a chemical plant to convert bauxite produced in the mines to

metallurgical grade alumina which would be used as raw material in aluminium

smelter to produce aluminium metal.



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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

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

Alumina is the basic raw material for aluminium metal. The alumina refinery forms the

intermediate step from bauxite mining to production of aluminium metal. The project

is site specific to the extent that it has to be in close proximity to bauxite deposits and

has been accordingly proposed to be located near Sijimali and Kutrumali bauxite

deposits.

The project is expected to help in overall development of the area. The proposed

project is expected to generate significant employment in the economically backward

area of Rayagada district of Odisha, with a high employment generation potential.

Local entrepreneurs will also benefit from increased flow of outsiders and increased

purchasing power of the community

2.4 Demand-Supply Gap for Alumina

As per CRU analysis of July 2015, global alumina capacity which is presently at

about 138 million tpy is forecast to grow consistently over the next ten years,

reaching to about 180 million tonnes by 2024. Metallurgical grade alumina capacity

expansion, primarily in China, will be the main driver for this growth. China's net

alumina investment requirement is expected to peak in 2025 at 10 million tpy, while

the world, except China, is forecast to require 15 million tpy of net new alumina

capacity over the period to 2040.



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The emergence of Malaysia as a strong bauxite supplier has delayed but not

eliminated the need for new bauxite supply. CRU forecasts that the trihydrate bauxite

market will once again return to deficit once Malaysian reserves are depleted. As the

Indonesian unprocessed minerals export ban is forecast to remain in place, bauxite

projects in various parts of South East Asia, Australia and the Atlantic (particularly

western Africa) have to be developed to supply global alumina capacity growth in

China, the Middle East and India.

The growing gap between demand and supply which is likely to develop over the next

25 years offers the likelihood of several bauxite and alumina projects to come on

stream.

Long-term demand growth of 3.5 to 4% per year can be expected for Alumina. By

2030, alumina market is expected to be in balance with the demand projections.

From then on, it would call for investments in new alumina refineries. Following are

the probable alumina projects at various stages of development: Following table

shows the expected growth pattern:

GLOBAL ALUMINA MARKET PROJECTIONS, 2007- 2030

Based on the above projections, it may be inferred that there is sufficient market

potential for setting-up the proposed alumina refinery project. This will meet the

growing demand for alumina as a source for aluminium metal in the world market.

2.5 Imports vs. Indigenous production

Presently India is net exporter of Alumina. It is proposed to export the alumina

produced from this project to world market. The project will provide value addition to



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bauxite produced from the mines and alumina from the plant will be raw material feed

to aluminium smelters.

2.6 Export Possibility

The entire quantity of 3 million TPY of alumina produced by the alumina refinery is

proposed to be exported. The global demand supply gap mentioned at section 2.4

provides ample opportunities for exporting the entire production of alumina through

Visakhapatnam in Andhra Pradesh

2.7 Domestic / Export Markets

Since the entire production of alumina is proposed to be exported, domestic markets

do not affect the project.

Export market for alumina is spread world over, with a major concentration in Middle

East, US and Europe. A list of aluminium smelters world over which have a ready

market for alumina is placed at Annexure 1.

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

The proposed project will generate significant employment in the economically

backward area of Rayagada district. The employment generation potential of the

project is estimated (refer section on Manpower) to be as follows:

6000 workers during Construction period.

1200 Employees directly employed for Operation phase.

4800 persons get indirect employment during Operation phase.

The population comprising of above-mentioned group will have high purchasing

power which will have a further effect on the economy of the region leading to

increased revenue to the State.

3. PROJECT DESCRIPTION

3.1 Type of project including interlinked and interdependent projects

Alumina Refinery is a chemical plant that removes silica and other deleterious

material from the bauxite produced from the mines to get Alumina, which is

chemically Al2O3. As such the alumina refinery is dependent on a separate bauxite

mining project at the upstream end for sourcing of bauxite required for the alumina

plant.

Bauxite for this plant is proposed to be produced from Sijimali and Kutrumali bauxite

deposits of the East Coast Bauxites, which are known for their high gibbsitic alumina



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and low reactive silica contents. Brief details about the two deposits are placed in the

following paragraphs.

a) Kutrumali Deposit

This is smaller of the two deposits with plateau area of about 7.0 square Km. In

terms of Prospecting Licences granted to it, L&T carried out the exploration of this

deposit by engaging NALCO, MECL and internal resources. Based on this

exploration work, Mine Plan was prepared by M/s M.N. Dastur & Co., Calcutta and

submitted to the Odisha Government and Indian Bureau of Mines (IBM) and the

same was approved by IBM. Reserve estimation and projected bauxite grade for

Kutrumali Bauxite Deposit are as follows:

Particulars Value

Mineable Reserves 47 Million Tones

Total Al2O3 % 43.76

Total SiO2 % 1.75

b) Sijimali Deposit

This is larger of the two deposits with plateau area of about 16 square Km. In terms

of Prospecting Licences granted to it, L&T carried out the exploration by engaging

MECL and internal resources. Based on the exploration work, Mining Plan was

prepared by M/s M.N. Dastur & Co., Calcutta and submitted to Odisha Government

and IBM and the same was approved by IBM. Reserve estimation and projected

bauxite grade for Sijjimali are as follows:

Particulars Value

Mineable Reserves 202 Million Tonnes

Total Al2O3 % 45.61

Total SiO2 % 2.12

Bauxite Mining & Transport

Bauxite is mined by open cast mining method. ROM is primary crushed to -150 mm

size and transported through a long distance conveyor to the alumina plant at an

aerial distance of 10 Km.

3.2 Location of the Project with boundary and co-ordinates

The proposed plant site is at Kusumshila in Rayagada district of Odisha. Project

Location is shown in the part map of India (Figure 3.1). The Project Area comprises

the following facilities:

Core Plant facilities of the Alumina Refinery

Red Mud Disposal Area

Ash Pond + Run-off Pond

Infrastructure (includes 24 Km Rail Linkage to Indian railways)

Township

Rehabilitation Colony



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Areas earmarked for various facilities is as follows:

Facility Approximate

Area (Ha)

Alumina Refinery



20 Km Rail Linkage to Kevatiguda Rly. Stn. 80


Mine corridor 66

Township 40


Total Area 1398

Fig 3.1 and 3.2 shows the project site. 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.

Core Plant site

The core plant for the alumina refinery is located at an approximate latitude of

19°27’N and longitude 83°17’30”E. This site is bounded by a single lane metallic

Major District (MD) road and the Nagavalli river in the east, Ajaygarh and Bijaynagar

hills on the west, the Narayanpur village on the north and the Alanda hills on the

south. The approximate average elevation of the site is 380 m R.L. The area is partly

agricultural land under private ownership and is partly barren land with open scrubs.

Red Mud & Ash Pond Sites

This land is located 19°29’N and longitude 83°17’30”E near Siripur village.

Kalyanasinghapur is located to the north east. Ajayagarh & Bijaynagar hills on the

west of this site., Narayanpur village and the Kusumshila plant site are located south

of the site. Mostly this is a levelled land but part of this is barren land with open

scrubs of slightly undulating topography. Part of this is private agricultural land and

some part is Government land.

Township Site

The township is expected to cater to around 1100 families. This land is tentatively

located at an approximate latitude of 19°30’N and longitude 83°18’30”E. It is bound

by the MD road on its west. The alumina plant site is about 5 Km south of this site.;

Kalyansingpur is towards its North and Siripur village towards its South. The land in

this area is private agricultural land.



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Rehabilitation & Resettlement Colony

As per a socio-economic survey carried out in the project affected area, it is expected

that there will be about 1040 project affected households. Out of this, about 800

households as per definition of R&R policy would be displaced. To accommodate

them, a separate R&R colony with an area of about 60 Ha is proposed, with all

integrated facilities. This colony is proposed to be located to the south-west of

Sikarpai village and close to MD road. This land is tentatively located at an

approximate latitude of 19°23’N and longitude 83°18’E.

Infrastructure Facilities for the selected site

The Kusumshila site is connected to Rayagada through a single lane metalled major

district (MD) Road and State Highway No. 4. The MD road takes off north-westward

from J.K. Pur and extends up to Kalyanasinghapur.

This area is served by two railway lines of southeastern railway, the Raipur-

Vizainagaram (R-V) double line in the east and the single line Koraput - Raygada (K-

R) line in the south.

Grid power is proposed to be drawn on need basis from GRIDCO substation located

at Theruballi near Rayagada at a distance of about 34 kms.

Water is proposed to be drawn from Nagavalli River near Kumhargurha village .


Document No. A811-PFR-83-42-0001

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FIG. 3.1:





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Fig. 3.2: Site Location Map



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3.3 Alternative Sites Considered

The selection of site for the alumina plant and associated facilities like Co-generation

power plant, Red mud, Ash disposal area, Township etc. has been based on various

considerations as described below. The Land requirement has been estimated with a

view to accommodating various facilities for the 3.0 million TPY capacity of the

Alumina Refinery.

Major considerations

Prime determining factors for plant location has been Proximity to:

Captive Bauxite Mine

Water Source,

Rail connection to the main network of Indian Railways

Availability of plain land

Minimization of forest land and

Environment sensitivity of the selected area

Identification of Feasible Sites

Three locations were identified in this area for the proposed Alumina Refinery.

a) Rampur Region;

b) Kusumshila region;

c) Majhiguda region.

While Rampur region was identified on the western side of the bauxite deposits,

Kusumshila and Majiguda were identified on the eastern side of the deposits. All the

three regions generally consist of both private land and Government land.

On an objective analysis of the three alternative sites, Kusumshila was identifies as

the best option. The detailed evaluation is presented in Annexure 4. The summary of

finding is as under:

1. Rampur location is eliminated primarily due to two reasons viz,

a. Railway connectivity is not feasible

b. Conveyor will be too long and its route will pose challenges of adverse

terrain





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2. Although the factors relating to the other two sites viz, Kusumsila and

Majhiguda are generally comparable, Kushumsila is preferred due to the

following reasons

a. Proximity to bauxite deposits, being shorter by 6 Km than Majhiguda. This

is likely to reduce power consumption by about 3 MW as compared with

Majhiguda and avoid crossing of a state highway and a major river, which

entails considerable capital cost, noise pollution and additional land.

b. Lower capital cost of about Rs 220 Crore, as compared to Majhiguda, due

to difference in conveyor length.

c. Lower operating cost of Rs 9.0 crore per year on recurring basis, due to

lower power consumption of conveyor.

d. Avoidance of potential environmental impacts in form of noise and dust for

the increased length of conveyor.

e. Comparatively less acquisition of private land.

3.4 Size & Magnitude Of Operations

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

The refinery shall be designed to 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.

3.5 Project Description

Brief process description of the alumina refinery is as follows:

Primary crushed bauxite received from the mines will be blended in stockpiles to be

created by a stacker and subsequently reclaimed by means of reclaimers.

The blended bauxite will be reclaimed by reclaimers and crushed to nominal 30 mm

size in Secondary Crushing Unit. Wet grinding of the secondary crushed bauxite with

recycled process liquor (caustic soda solution) shall be performed in close-circuit

overflow type ball mills.

Ground bauxite slurry from ball mills shall be heated and fed to desilication tanks.

After preheating desilicated bauxite slurry and recycled spent liquor shall be fed to a

train of medium pressure digesters where the alumina content of the bauxite shall get

dissolved in the caustic soda solution. The digested slurry shall be flashed in a

series of flash tanks and finally in blow off tank to bring its pressure down to





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atmospheric pressure. Flash vapours from the flash tanks shall be utilized for

preheating incoming streams.

The liquor to be fed to the Digesters shall be supplied from an evaporation plant of

multiple effect type. The evaporation plant is required to maintain the water balance

of the closed circuit process.

A side stream from the evaporation discharge shall be treated in the oxalate removal

plant to control the organic impurities.

The blow off slurry from digestion area shall be sent to a High Rate Thickener (HRT)

for separation of red mud and pregnant liquor. Underflow slurry from the mud

thickener shall be washed with hot wash water in a cascade of counter current mud

washers. The caustic recovered from the washing circuit in form of first washer

overflow is taken back into the system at blow off tank of the Digestion Area.

Washed mud from the underflow of the last washer is disposed of to Mud Disposal

area by means of high-pressure positive displacement pumps. A side stream of

second washer overflow is treated with lime slurry in the liquor causticization unit to

improve the causticity of the liquor.

Flocculent solution will be added as settling aid to mud settlers and washers. The

overflow of the mud settlers shall be filtered in the security filtration area to remove

the final traces of red mud particles.

Lime slurry shall be prepared by slaking burnt lime and supplied from the Lime Plant

to various consumption points within the alumina refinery.

The filtered liquor from Security Filtration area shall be allowed to exchange heat with

outgoing spent liquor in batteries of Plate Heat Exchangers in the Heat Interchange

Area.

The cooled pregnant liquor from the Heat Interchange Area shall be transferred to a

line of precipitator tanks in series where the dissolved alumina from the liquor shall

precipitate out in form of aluminium tri-hydrate. In addition to Inter-stage cooling,

controlled quantities of pre-precipitated coarse and fine hydrate seed slurry is added

to enhance the precipitation process.

Hydrate slurry from the Precipitation Unit shall be classified on the basis of particle

size in the Hydrate Classification area in two stages of hydro-cyclone clusters namely

primary and secondary.

Three streams of classified hydrate slurry namely Primary Cyclone overflow, primary

cyclone underflow and secondary cyclone underflow shall be filtered in vacuum





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rotary disc filters and reslurried to produce washed fine seed slurry, coarse seed

slurry and product hydrate slurry respectively. The first two streams shall be pumped

to precipitation area for seeding the pregnant liquor and the product hydrate slurry

shall be sent to hydrate filtration unit.

Product Hydrate slurry shall be re-filtered and washed in Hydrate Filter area in

Horizontal Pan Filters to minimize the leachable soda content of the hydrate cake

prior to calcination.

Adequate storage facilities for storage of hydrate shall be provided in the Hydrate

Storage Area in order to take surges of hydrate production and downtime of

calcination area.

The filtered and washed hydrate cake shall be calcined in the Calcination Plant of

stationary calciner units to produce the final product alumina meeting international

standard.

Suitable facilities for calcined alumina storage and wagon loading shall be provided

for dispatching the product alumina to Vishakhapatnam Port.

3.6 Raw Material Requirement

Bauxite

Main raw material for production of alumina is Bauxite, which will be sourced from

captive mines of Kutrumali and Sijimali and conveyed to the alumina refinery through

a long distance Cable Belt conveyer or any other state-of-the-art conveyor.





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Quantity of bauxite required is approximately 9.0 million TPY for alumina refinery

capacity of 3.0 million TPY.

Other than bauxite, various other raw materials, utilities and consumables required

for production of alumina have been described as follows:

Coal

Coal is required to generate steam for process use and power generation via steam

turbines. It is proposed to source 50 % coal from Ib Valley coal mines of Odisha. Rest

of the requirement would be met through imported coal. Coal shall be transported

and delivered to site by Rail transport. Quantity of coal required is approximately 1.8

million TPY for alumina refinery capacity of 3.0 million TPY.

Heavy Fuel Oil (HFO) and Diesel (HSD and LDO)

Heavy Fuel Oil is required for calcinations of Hydrate to Alumina. Requirement is

241,100 TPY for alumina refinery capacity of 3.0 million TPY. HFO and Diesel will be

transported by Rail to the Alumina Plant. Diesel is required for use in Alumina Plant &

Mine. Quantity of diesel required is 13,500 TPY. It is proposed to source HFO, HSD

and LDO from HPCL/IOCL/BPCL, Vishakhapatanam from where the Fuel oil shall be

transported to the Alumina Refinery by rail.

Caustic Soda

Caustic Soda is used for digestion of Bauxite in the process. The plant requirement

will be approximately 180,000 TPY at 100% NaOH solution for alumina refinery

capacity of 3.0 million TPY. It is proposed to import Caustic Soda and transport it to

the refinery through rail.

Lime

Lime is used for causticization of Liquor impurities, phosphorous removal and filter

aid preparation. Requirement will be approximately 90,000 TPY at 100% available

CaO for the alumina refinery. Corresponding quantity of lime with 65-70% active CaO

content can be transported by rail and trucks. Lime and would be sourced mainly

from local suppliers from Odisha and MP.

Flocculants

Flocculants, liquid and powder type, are used on the residue to assist in residue

separation and settling in the Settler & Washers, and on the white side for hydrate

settling in the fine seed thickness. The total quantity of flocculants required is





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approximately 2020 TPY for alumina refinery capacity of 3.0 million TPY. Flocculant

will normally be transported by trucks.

Sulphuric Acid

Sulphuric Acid is used in the refinery for chemical cleaning services. Estimated

requirement of Sulphuric Acid is approximately 1125 TPY for alumina refinery

capacity of 3.0 million TPY. It is proposed to transport the same to the alumina

refinery through trucks.

Filter Cloth

Several Indian manufacturers are supplying Filter Cloth to Alumina producers in

India. However, any specific quality Filter Cloth related with particular service

requirement can be imported if the same is not available in India.

Finished Product

Alumina

Alumina Refinery shall produce 3 million TPY alumina, which shall be transported to

Vishakhapatnam port in the state of Andhra Pradesh through rail and will be exported

from the port. The facilities to be provided in the port shall include storage, handling

and loading / unloading facilities for alumina.

UTILITIES & SERVICES

Steam & Power Plant

General

Supply of steam is an essential requirement for the alumina refinery. Bauxite

digestion being an endothermic reaction, which is carried out at approximately 150

degree C. Steam is used for heating the Bauxite Slurry in Digestion Unit. Steam is

also required for evaporation of water from the Bayer’s Circuit for maintaining the

water balance of the process. Apart from these major requirements, steam is also

used in minor quantities in other process areas such as Pre-desilication, Liquor

Causticization and heating of wash water. It has been a common practice to install

co-generation plant for meeting the requirement of steam as well as power which is a

byproduct for alumina projects.

For this region, the cheapest fuel for producing steam is coal, which is abundantly

available in Odisha, and coal based co-generation plant are well proven in alumina

industry.





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In view of the above, it is proposed to install a co-generation plant for this project

such that steam is produced at a higher pressure and the same is expanded through

back-pressure type turbo generators to the pressure required for the alumina circuit.

The byproduct power is utilized for meeting the requirement of the process plant,

mines and the township. The power produced in the co-generation plant shall be

synchronized with grid supply such that surplus power can be banked with GRIDCO

(Odisha) while minor temporary shortage will be met from the grid. For short

durations, during instability of the grid, it would be possible to operate the plant in

“Islanding” mode also.

Boiler and Turbine Configuration

It is proposed to provide five Nos. pulverized coal fired boiler each of 300 TPH steam

generation capacity at 67 Kg/ cm2 pressure and 490° C temperature. Out of the five

boilers, four will normally be in operation while the fifth one will be under maintenance

or kept as stand by.

For power generation, it is proposed to provide five nos. extraction cum back

pressure turbine generators (TG) each of 40 MW capacity such that normally four

TGs are kept in operation while the fifth is under maintenance or kept as stand by.

A pressure reducing and desuperheating station (PRDS) will be provided equivalent

to the capacity of one TGs such that in the event of failure of one of the TGs in

operation, the normal steam demand of the alumina refinery can still be met at the

required pressure.

Four chains of deminerlizing (DM) unit will be provided for production of DM Water

sufficient for operation of the boilers without return of condensate from the alumina

refinery.

The boiler will be fired by pulverized coal, and as such will be provided with matching

facilities for storage, handling, crushing, grinding and feeding of coal. Suitable

facilities shall be provided for collection of fly ash and bottom ash from the boilers.

The collected ash will be slurried and disposed off by wet-disposal method in an ash

pond located close to the alumina refinery.

Smooth operation of the Cogeneration Plant is highly dependent on steady

consumption loads of steam and power mainly in the alumina refinery. However,

sporadic disturbances in the operation of the refinery are unavoidable and therefore a





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partial condensing system has been envisaged to provide greater flexibility in the co-

generation plant for taking care of any temporary imbalances in steam and power

demands. Additionally, suitable arrangements may be worked out with GRIDCO for

taking care of minor excesses and shortfalls in power. Further, it is proposed to

provide four nos. diesel generators (DGs), each of 4 MW capacity to take care of the

emergency power requirement in case of power failure. The DGs will mainly take

care of agitators and rakes for slurry application and also cater to the power

requirement for bringing the alumina refinery to safe shut-down.

The boilers will be provided with suitable arrangement for firing with furnace oil during

start-up. For meeting environmental regulations, electrostatic precipitators and a

common chimney of suitable height shall be provided with the boilers.

Compressed Air Supply

A centralized compressor house shall be provided to cater to the need of alumina

refinery as well as co-generation plant. It is envisaged to supply dry air for

instrumentation as well as for general-purpose usage.

Compressed Air Requirement

The centralized compressed air system considered for the proposed alumina refinery

shall also supply compressed air to various package items such as calciners, alumina

handling system and evaporation plant etc. The total compressed air requirement

including that of co-generation plant, utilities & off-sites and package items is

expected to be as follows:

Plant Air : 25,000 Nm3/hr.

Instrument Air : 5,000 Nm3/hr.

Total Compressed Air : 30,000 Nm3/hr.

Compressor House

The centralized compressor house shall supply the entire requirement of compressed

air. Based on the above requirement, seven nos. non-lubricating type compressors

each of 5000 Nm3/hr. capacity shall be provided. Normally, six nos. compressors

shall be in operation with one compressor as standby. The supply of compressed air

shall be at 7.0 kg/cm2 (g) pressure. In order to avoid to excessive pressure drop in

the distribution network, it is proposed to supply the compressed air in ring headers

on the main pipe rack.





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Fuel Oil Supply

Fuel oil shall be required mainly for the calcination plant. Additionally, some fuel oil

shall also be required as supporting fuel for initial firing of the boilers in the co-

generation plant. The fuel oil to the proposed alumina refinery shall be supplied by

railway tankers. An independent railway tanker unloading station for fuel oil shall be

provided. The unloading station shall be suitably designed to unload a rake of 28

wagons each of approximately 54 ton capacity in one shift. The unloaded fuel oil

from the railway wagons shall be directly pumped to four nos. of main storage tanks

each of 5000 KL capacity with the help of steam jacketed gear pumps.

From storage tanks the fuel oil shall be distributed up to the battery limits of

calcination and co-generation plants. The facilities required for internal distribution of

fuel oil including day tanks shall be a part of the respective packages of these units.

Caustic Soda Unloading & Distribution

It is envisaged that the entire requirement of caustic soda shall be met by importing

caustic lye having 47-50% NaOH. Necessary port facilities shall be provided at

Vishakhapatnam port to handle and transport the imported caustic lye by dedicated

rail tankers to the alumina refinery.

An independent caustic tanker unloading station shall be provided. The proposed

unloading station shall have adequate capacity for unloading tankers each of 54

tonnes capacity in five to six hours. The unloaded caustic from the railway tankers

shall be directly pumped to four nos, of main storage tanks of each of 5,000 m3

capacity,

Raw Water Intake and Treatment

The water requirement for Alumina Refinery is expected to be around 14.0 MGD

(approx. 53,000 m3/ day) for 3 million TPY Alumina production. The only source in

the vicinity of the plant site is Nagavalli river. The intake point for drawing water from

the river would be Kumaraguda which is approximately 3 km from the refinery site.

The raw water received at the plant will be stored in an over ground Raw Water

Reservoir equivalent to 10 days storage. This water will be sent to a water treatment

plant to yield industrial water, filtered water and drinking water. Industrial water will be

used for fire water system and for sprinkling at dust prone areas. Filtered water shall

be used as make-up water for cooling towers.





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Cooling Water System

General

In order to meet the cooling water requirement of various units of the alumina refinery

three nos. of independent closed circuit cooling towers are proposed as follows:

a. Alkaline Cooling Tower

b. Utilities Cooling Tower

c. Co-generation Plant Cooling Tower

Alkaline Cooling Tower

This cooling tower shall cater to the requirement of evaporation plant, plant heat

exchangers, disc filters in seed preparation area and horizontal pan filters in product

hydrate filtration area. For this service, two nos. industrial cooling tower each of

15,000 m3/hr capacity is envisaged. These cooling towers shall be located near the

evaporation plant. Keeping in view the possibility of alkaline contamination of cooling

water in the evaporation plant, these cooling towers shall be independent from the

cooling towers required for other cooling utility purposes. For the alkaline cooling

tower, alkaline condensate from evaporation plant shall be used as make-up water.

Utility Cooling Tower

This cooling tower shall supply cooling water to compressor house, calcinations plant

and other miscellaneous requirements line hydraulic coupling, air conditioning etc.

For this service, two nos. independent closed circuit type cooling tower each of 2000

m3/hr. capacity shall be provided.

Co-generation Plant Cooling Tower

As the turbine generators of the co-generation plant shall not be considering type, the

cooling water requirement of the co-generation plant shall be comparatively less. As

such two nos. independent cooling tower each of approximately 3000 m3/hr. capacity

will be required.

Fire Water System

Fire Water System shall include a fire water reservoir, pumping house along with fire

water piping network Fire hydrant shall be installed along the road side for fire

fighting in off-site areas while rising main shall be provided with landing valves inside

the plant buildings. Filtered water shall be supplied as make-up for the proposed fire

water system.





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Central Control Room

It is proposed to provide a centralized control room for the core plant of the Alumina

Refinery. In addition to this there shall be a separate control room for the co-

generation plant. For the process control of the alumina plant a state of the art

distributed control system (DCS) is envisaged. Process surveillance and control

actions shall be initiated from the proposed central control room through

computerized operator interface. The process instrumentation shall be based on

state of the art but industry proven of-the-shelf commercially available technology.

The field instruments with local transmitters shall provide analog 4-20 mA output to

the I/O rakes of the proposed distributed control system (DCS). Microprocessor

based controllers shall perform from end regulatory control algorithms. The digital

logic function shall be implemented by independent programmable logic controllers

(PLCs).

The central control room shall include operator’s interface terminals, data-loggers,

printers, alarm panels, etc. It shall be supported by various auxiliary equipment such

as UPS, special HVAC, MCC etc. The control room shall provide adequate facilities

for storage of record, documentation, data media and engineers consoles as well as

configuration terminals. The system software shall have sufficient protection features

including password based access control, diagnostic tools and system/data back-up.

Plant Laboratory

In addition to the proposed state of art Distributed Control System (DCS), the plant

laboratory shall play a complimentary role towards fulfillment of overall process

control objectives.

The proposed plant laboratory shall be equipped with the latest equipment and

necessary infrastructure facilities for carrying out the following process control

activities:

Analysis of raw materials viz. bauxite, lime coal, fuel oil etc.

Analysis of process samples such as process liquor, red mud, hydrate etc.

Environmental monitoring

Maintenance & Ware-House Complex

To ensure smooth and uninterrupted operation of the plant, it is extremely important

that adequate repair and maintenance facilities are provided within the plant. For this

purpose, a centralized maintenance & ware-house complex is envisaged which shall

mainly comprise of following sections:





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a. Valve Repair Shop

b. Pump Repair Shop

c. Electrical Repair Shop

d. Instrument Repair Shop

e. Mechanical Tool Room

f. Ware-house for mechanical, electrical and instrument spares

g. General Stores

h. Carpentry shop

i. Mechanical Workshop

Other Facilities

In addition to the various facilities mentioned in the above section, other essential

services such as canteen, first-aid, gate-house, fire station, etc. shall also be

provided within the plant.

3.7 Resource Optimization / Recycling and Reuse

Technology selection of the alumina refinery would be aimed at high process

efficiencies and recoveries in order to have optimum specific consumption of raw

materials and lower waste generation thereby minimum impact on environment. Over

the years Bayer process has undergone continuous improvement, refinement and

optimization both in the fields of process flow sheet and equipment design.

Consequently, optimized versions of the Bayer Process are now available from

various alumina technology and/or equipment suppliers. The technology selection is

done on the basis of their adaptability to the bauxite being processed, the quality of

alumina required and local considerations such as environmental impact and the cost

of energy and raw materials. Selection criteria for digestion technology included

acceptable design and proven track record in the areas of:

High liquor productivity

Low overall energy consumption

High overall gibbsite recovery

Low caustic loss

In general, extent possible recycling and reuse of various streams would be

considered for following areas:

a. Recycling and reuse of process streams like spent caustic liquor, various

process filtrates, red mud pond water etc.





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b. All process areas shall be provided with a 200-300 mm high curb wall to

minimize the possibility of any contaminated liquor overflowing into the storm

water drainage system. Plant drainage system shall incorporate alkaline water

drains running outside the curbed process areas. These drains shall be

directed to a collection pond. The effluent collected in this pond shall be

returned to process or pumped to the effluent treatment plant. The treated

effluent shall be used for the horticulture purpose.

c. Fuel Oil and Caustic soda shall be stored in dyked areas. Rainwater and

other run-off from oil storage shall pass through the settling chamber and oil

trap before discharging into the clean water drain. The run-off from caustic

storage shall be released to the dirty water drain if clean, otherwise will be

pumped into storage tanks and returned to tanks.

d. Alkaline effluents from various units would be recycled back / reused within

the battery limit. All the acidic effluents would be collected in an equalization

tank from where the equalized waste water is pumped to the reaction tank.

Lime is added in the reaction tank for neutralization and precipitation. The

waste water then flows to the clarifier where solids are separated and the

clarified overflow passes through a guard pond into the discharge drain. The

sludge flows under hydrostatic pressure to the sludge sump from where it is

pumped to the ash pond. The treatment effluent quality will conform to IS:

2490 (Industrial waste water discharged into inland waters).

Possibility of utilization of coal ash for the applications such as brick, paving stones,

cement plant, road carpeting, tree plantation, backfilling in mines etc. would be

explored. The water shall be reclaimed for reslurrying of ash, and the excess water, if

any shall be utilized for green belt development in the plant area.

3.8 Availability & Source of water and Electric Power

Water

It is estimated that the water requirement for mines, alumina refinery and the

township would be approximately 14 million gallons per day (MGD).

The only perennial water source in the vicinity of the plant site is the Nagavalli River.

However, various studies conducted on water sourcing indicate that the water flow

rate in the river is strongly influenced by monsoonal rains of the region. As a

consequence of this influence, drawal of water during hot summer months may be a

challenge. The intake point for drawing water from the river has been identified at

Kumharaguda which is approximately 3 Km from the refinery site. However, it is





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proposed to explore the possibility of identifying an alternate water intake point

further downstream the river where sufficient flow rate is available throughout the

year. Alternatively, it is proposed to go in for radial collection wells, as has been

practised by certain other industrial units in the vicinity.

The present scheme envisages that water shall be drawn from the Nagavalli River

from water intake point at Kumharaguda and pumped to a fresh water reservoir

located within the alumina refinery. It is proposed to construct three water reservoirs

namely fresh water reservoirs (2 nos.) and alkaline water reservoir (1 no.).

Water extracted from the river shall be treated in a silting pond to allow the turbidity in

the water to settle. This function shall be performed by the fresh water reservoir. This

reservoir would be clay lined to reduce seepage, and would be provided with suitable

devices to allow de-silting operation without disturbing the main water body.

Specific monitoring of the stored water shall be carried out to eliminate the possibility

of bacterial contamination due to stagnation.

In addition to the fresh water reservoirs, a low alkali reservoir shall be constructed to

facilitate recycling of process water as a part of the zero liquid discharge scheme.

This would also minimize the requirement of fresh water for the alumina refinery. This

reservoir shall be suitably lined to eliminate the possibility of water seepage.

Electric Power

Medium Pressure steam is a requirement in the alumina refinery. Hence, a co-

generation power plant has been proposed for this project such that the steam which

is produced at a higher pressure is expanded through back-pressure type turbo

generators to the pressure required for the alumina circuit. The byproduct electric

power is utilized for meeting the requirement of the process plant and associated

facilities.

The electric power produced in the co-generation plant shall be synchronized with

grid supply such that surplus power can be banked with GRIDCO (Odisha) while

minor temporary shortage will be met from the grid. For short durations, during

instability of the grid, it would be possible to operate the plant in “Islanding” mode

also.





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Manpower Requirement

Due to the remote location of the plant, there are many unfavourable factors and

constraints, such as very low level of education and professional skills, which would

mean that the normal labour productivity norms may not be easily realized in the

case of the proposed alumina refinery at Kusumshila. This would also call for

deployment of more number of supervisory staff at least until the general standard of

skills in the area are improved to an acceptable level.

Further, due to the remote location and poor development of the area, all the major

infrastructural facilities have to be provided internally which would further add up to

additional manpower requirement.

Considering the various factors and based on the experience of similar facilities in

India, particularly in this region, strength of approximately 1200 direct employees for

the alumina refinery is proposed. This shall consist of approximately 360 executives

and 840 non-executives.

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their

Management/ disposal

LIQUID WASTE

Liquid wastes in alumina production are generated from various sections of the plant.

There are three types of liquid wastes, namely

Process waste water

Oily waste water

Sanitary waste water

Process Waste Water

There are three types of effluents from various processing units:

a) Acidic waste water from heat exchangers and evaporators

b) Cooling tower blow-down comprising treatment chemicals

c) Laboratory effluents

Besides, there are alkaline effluents from various units, which are recycled back

within the battery limit. All the acidic effluents are collected in an equalization tank

from where the equalized waste water is pumped to the reaction tank. Lime is added

in the reaction tank for neutralization and precipitation. The waster water then flows to

the clarifier where solids are separated and the clarified overflow passes through a

guard pond into the discharge drain. The sludge flows under hydrostatic pressure to





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the sludge sump from where it is pumped to the ash pond. The treatment effluent

quality will conform to IS: 2490 (Industrial waste water discharged into inland waters).

Oily Waste Water

Oily waste water treatment plant is to treat only oily waste water from oil storage and

oil unloading area. Oily waste water is pumped to the collection tanks where oil water

separation takes place. The separated oil is collected in drums while the waste water

is allowed to flow by gravity to the API oil separator.

The remaining oil is recovered in the API separator and the treated waste water will

be discharged for final disposal. The sludge removed in API will flow by hydrostatic

pressure to sludge lagoons for drying and manual disposal.

Treated effluent characteristics are as follows:

pH : 5.5 to 9.0

BOD5 : 30 mg/l

Oil & Grease : 10 mg/l

Suspended solid : 100 mg/l

Sanitary Waste

Sanitary waste of the entire alumina plant would be treated in sanitary waste

treatment plant. Sanitary waste from the above sources is received in Sanitary

Sewage Sump and then pumped to compact unit consisting of digestion chamber,

stabilization chamber, clarifier and activated sludge process unit with facilities like

aeration, post chlorination, sludge removal, recirculation and scum removal. The

treated effluent after chlorination is collected in the treated effluent slump for final

disposal. The bio sludge generated is dried in sludge drying beds before final

disposal.

The treated effluent conforms to the following parameters:

pH : 5.5 to 9.0

BOD (20○C) : 20 mg/l


Expected liquid effluents from the alumina refinery are tabulated at Table 3.1





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TABLE 3.1

EXPECTED LIQUID EFFLUENTS

Area Stream Approximate

Quantity Periodicity Characteristics

Digestion,

Clarification

Precipitation,

Hydrate

Classification,

Seed Separation,

Evaporation etc

Alkaline

Effluent

- Upset rainy

season

Na2O = 0.5 gpl (max.)

Heat Exchanger Nitric

Acid

40 m3 per

batch

3

batch/month

HNO3 = 5 gpl

Al (M) = 13 gpl

NaNO3 = 5 gpl

Temp = 40-50 C

Evaporation Plant Sulphuric

Acid

240 m3 per

batch

30 batch./yr

H2SO4 = 30 gpl

Al2(SO4)3 = 100 gpl

Na2SO4 = 40 gpl

Temp = 40-50 C

Cooling Tower Blow

down

130 m3/hr Continuous pH = 8

TDS = 80 mg/l

TSS = 50 mg/l

Ca Hardness as

CaCO3 = 150 mg/l

Total hardness as

CaCO3 = 225 mg/l

Sulphate as SO4 = 400

mg/l

Chloride as Cl = 200 mg/l

Na Hexameta

Phosphate as PO4 = 6

mg/l

Oil storage Area Waste

Water

330 m3/day Continuous Oil = 200 mg/l

BOD = 150 mg/l

Suspended solid = 200

mg/l

Solid Waste

The major solid wastes discharged from the plant are Red Mud from the alumina

refinery and Coal Ash from the co-gen power plant.

Red Mud Disposal

Red mud is one of the most critical waste of alumina industry, both quantitatively and

qualitatively. Red mud is rendered alkaline by the adhering liquor. The proposed





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alumina refinery is expected to generate approximately 3.3 million TPY of red mud

(dry basis) which is required to be disposed of either through HCD or dry stacking

system. The storage area is lined with an impermeable layer to prevent ground water

contamination. Appropriate dust suppression system shall also be provided. Since

the red mud contains traces of caustic, it is extremely essential to dispose it off in the

most environment friendly manner and to allow proper rehabilitation of land filled up

with disposed mud such that it does not pollute the surrounding region.

Disposal of red mud from a thickening or dewatering device includes operations to

transport the material to its final resting location and operations to distribute over an

appropriate area at that location. There are various methods available for disposal of

red mud. However, there are several important factors that influence the final choice

of the scheme to be selected for efficient and safe disposal of mud. These are as

follows:

Thickening characteristics of red mud to achieve higher solid content

Rheological characteristics of red mud slurry with particular attention to

filterability & pumpability of the mud at increased solid concentration

Geographical location of the selected disposal site

Climatic conditions

Available Disposal Methods

There are a number of different mud disposal techniques available and being

practiced in alumina refineries all over the world. These disposal methods may be

broadly classified into the following three categories:

a) Conventional Wet Disposal

b) Thickened Slurry Disposal

c) Disposal as filter cake

a) Conventional Wet Disposal

In the conventional wet disposal system the red mud produced from the washing

circuit is directly pumped to a big settling pond at a solid content 30-40%. In this

pond, the solids settle while the supernatant caustic liquor is recycled back to the

alumina refinery. Such system typically consists of centrifugal pumps, pipes,

distribution header and water reclamation system.





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Though the conventional wet disposal system is comparatively easy to operate and

does not involve costly equipment, it suffers from inherent drawbacks. The major

disadvantages of this system are as follows:

Very high risk of ground water pollution due to seepage because of

large volume of alkaline water present in the mud pond.

Large pond area requirement due to high volume throughput and poor

settling rate

Unavoidable excessive ingress of rain water in the red mud pond

which can adversely affect the overall water balance of the alumina

refinery

Requirement of high dykes/dams, sometimes the dam height may

become a constraint due to excessive hydrostatic pressure.

b) Thickened Slurry Disposal

In this system, the mud slurry is thickened to a high solids consistency using specially

designed thickeners. The thickened mud slurry is pumped to the selected disposal

area where it is systematically discharged through permanent spigots from an

elevated position. Two types of methods are available for stacking of the red mud :

i) Thick layer deposition

ii) Thin layer deposition

i) Thick Layer Deposition

In thick layer deposition method, the thickened slurry released at one point comes to

rest at a slope governed by the viscosity or mobilized shearing strength of the

following mass. A low cone-shaped hill of the tailings developed below the discharge

point. To provide a good surface for reclamation, the slope of such hill is to be

controlled to less than 5%. The slope angle is controlled primarily by the degree of

thickening prior to discharge. Furthermore, because of the low water content,

segregation is inhibited and all solid particles are deposited without sorting,

regardless of distance from the discharge point. This effectively eliminates the need

for a conventional settling pond with its inherent polluting seepage problem.

ii) Thin Layer Deposition

In the thin layer deposition method, the mud slurry is stacked in various zones to

facilitate natural evaporation. At a time only one zone is under filling while the other

zones are exposed for natural evaporation. The zone widths are carefully selected in





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such a way that desired slopes are available for stacking as a sloped deposit. The

actual thickness of the deposited layer is decided based on climatic conditions and

the extent of thickening achieved.

There are many advantages with the use of this system compared with conventional

wet pond disposal system, which are as follows:

Mud disposal is at a slope of 2-5% which facilitates a self drainage

system

Provides increased mud storage capacity for the same storage area

because of sloped deposit and increased bulk density of the

consolidated mud

Eliminates the need for big dams/dyke walls

c) Disposal as Filter Cake

This scheme involves filtration of red mud and then transportation of the mud cake to

the mud disposal area by one of the following methods:

Transportation by dumpers

Pumping of mud cake by means of specially designed positive

displacement pump

Of the above two methods, transportation by dumpers is more problematic as well as

less environment friendly for obvious reasons. The modern method is to pump the

red mud cake with high solids content (55-60%) by means of specially designed

positive displacement pumps.

Out of the above methods, thickened slurry disposal with thin layer deposition method

will be adopted as it is proven system in India as well as in many places in the world.

However, ‘disposal as filter cake’ method will also be evaluated at an appropriate

time.

A sprinkler system shall be employed using water to wet the dry surface of the mud

for dust suppression. The final height of the dry stacks would be around 50 m. Red

Mud Cells would be provided with 500 mm of reworked and compacted clay and 800

micron thick PVC liner over the earthen base and outer embankment to prevent the

land pollution. This will help prevent the ground water pollution also.

Coal Ash Disposal

The proposed alumina refinery shall include a captive co-generation plant to produce

steam and power for its internal use. The coal earmarked for Thermal Power Plants

in India is mainly of grade “F” which has about 40 - 45% Ash content.





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The boilers shall consume approximately 1.8 million TPY coal and generate

approximately 0.75 million TPY coal ash.

Coal Ash shall be disposed off into conventional wet pond. The water shall be

reclaimed for reslurrying of ash, and the excess water, if any shall be utilized for

green belt development in the plant area. The disposal site shall be bounded and

garland drains shall be provided to isolate the surface run-off from the watershed

area of ash pond. Excess fly ash shall be utilized for land filling in low-lying areas and

for road construction etc. Further, it is proposed to be sold to briquette making plants.

It is recommended to employ the High Concentration Slurry Disposal system for the

ash generated in the power plant. The ash disposal area would be lined with

compacted clay layer to stop ingress of leachates of the ash.

Adequate green buffer all around the disposal site is also envisaged to serve as a

protecting barrier.

Expected solid wastes are Tabulated at Table 3.2

TABLE 3.2

EXPECTED SOLID WASTES

Area Stream Quantity Periodicity Characteristics

Mud Disposal Red Mud 690 T/hr Continuous Solids = 50 - 60 % (max.)

Steam

Generation

Plant

Coal Ash Slurry 180 T/hr Continuous Solids = 50-60%

of which :

Silica = 55%

Al2O3 = 30%

Fe2O3 = 8%

Lime Slaker Lime Grit 4.0 T/hr Continuous Un-dissolved part of lime

GASEOUS EMISSIONS

There are two main sources of gaseous pollution.

a) Steam Generation Plant

b) Calciner

Steam Generation Plant Flue Gas

About 1.8 million tonnes per annum of pulverized coal will be burnt for generating

steam in the high pressure steam boilers in steam/power plant. Electrostatic

precipitator will be provided to arrest particulate matter, other major pollutant being

sulphur dioxide. The flue gas is vented to atmosphere through a stack of adequate

height. This allows required dispersion of both particulate matters and SO2 to have





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ground level concentration as per the required environmental standards. It is

envisaged that Indian coal having low sulphur content shall be predominantly used.

Hence, FGD will not be required.

Calciner Flue Gas

In the calcinations unit, alumina is calcined using HV / LSHS grade fuel oil. The flue

gas discharged from this section is passed through cyclones and electrostatic

precipitators to restrict the solid content in the gas. The flue gas is vented to

atmosphere through a stack of sufficient height to permit dissipation of particulate

matter and SO2.

Expected gaseous emissions from the refinery are tabulated at Table 3.3.

TABLE 3.3

EXPECTED GASEOUS EMISSIONS

Unit Stream Quantity Periodicity Characteristics Stack

height

required

Calciner Flue Gas 150 m3/sec Continuous SO2 = 760 kg/hr

SPM = 135 kg/hr

120 m

Steam

Generation

Plant

Flue Gas 360 m3/sec Continuous SO2 = 2280 kg/hr

SPM = 260 kg/hr

150 m

3.10 Schematic representations of the feasibility drawing which give information of

EIA purpose

As per the Environment Impact Assessment (EIA) notification dated 14th Sept.

2006 and subsequent amendments, this project falls under category A. EIA/EMP

report shall be prepared to get the Environmental Clearance for this project from

the MoEFCC. The baseline studies will be undertaken as per schematic diagram

given in the following page:





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SCHEMATIC FIGURE SHOWING ACTIVITIES FOR EIA APPROVAL





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4 SITE ANALYSIS

4.1 Connectivity

The proposed plant site is at Kusumshila in Rayagada district in Odisha. This site is

well connected with Rayagada through a single lane metalled major district (MD)

Road upto JK Pur and then State Highway No. 4 to Rayagada.

This area is served by two railway lines of south eastern railway, viz. the Raipur-

Vizianagaram (R-V) double line in the east and the single lane Koraput-Raygada (K-

R) line in the south.

Although MD Road also provides approach to the red-mud disposal site in the north

of refinery and the township in the south of the alumina refinery, it is proposed to

provide separate sealed access roads for smooth movement between the following:

• Refinery and township

• Refinery and red-mud disposal area

• Refinery and intake well at Nagavalli river

• Township to MD Road

In addition to the above, a dedicated mine-plant link road of approximately 16 km is

proposed to provide access to Kutrumali Mine as well as to the long distance bauxite

conveyor. The final ascent of this road would require a 350 m rise in elevation within

a distance of 1.5 Km in difficult hilly terrain. A 11 Km road link from Sijjimali to the

loading station at Kutrumali is also being considered.

Transport of materials and equipment to the refinery and mine sites during

construction would require the strengthening and minor upgrade of 175 Km of road

access between Visakhapatnam and Sunger at the base of Kutrumali plateau.

4.2 Land Form, Land use and Land ownership

A) Land Form

The alumina refinery would be located near Kusumshila in the valley of Nagavalli

river, approximately 40 km north of district centre of Rayagada. The area around the

refinery is generally flat to undulating with a number of rocky outcrops with elevations

varying from 360 - 400 m above MSL. On the western side the Bijayanagar and

Ajaygarh hills are located with a general top elevation of 650 m.

The residue disposal area would be located approximately 4 km north of the refinery.

This area is generally flat to undulating at an elevation of 360-400 m. Rock outcrops

are common and there are two rocky hillocks in the immediate vicinity. One near





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Siripur, is located within the actual proposed residue disposal area. Another,

Debagiri, lies to the north of the area.

The proposed township would be located at about 7 km north-east of the refinery.

The area around the township is flat at an elevation of 360 - 370 m. Nagavalli river is

on the east.

B) Land use and Land ownership

The land in Kusumshila region generally consists of single crop low yield private

agricultural land and government land like Gauchar land, hutment area etc. The

distribution of different land uses in the area corresponding to the villages to be

acquired for plant, red mud pond, ash pond and township is as follows (all the areas

are in Hectares).

i) Core Plant

Sr. No.

Village Govt. Forest

(*)

Govt. Non-Forest

Private Agriculture

(#)

Private Non-

agriculture Total

1 Kusumshila 32.02 13.48 36.17 87.17 168.84

2 Petliguda 0 0 9.43 6.11 15.54

3 Krishnapatragura 8.19 7.05 8.26 18.51 42.01

4 Narayanpur 9.65 0 2.63 6.72 19.00

5 Karlima 2.02 3.23 0 4.88 10.13

6 Alanda 51.06 30.92 20.67 58.83 161.48

7 Chaujodi 48.78 0 0 2.62 51.40

8 Poduchuanpadar 78.82 0.81 0.68 4.44 84.75

9 Dhumuripadar 34.52 32.90 25.71 43.11 136.24

10 Karapa 0 8.11 40.49 51.99 100.59

TOTAL 265.06 96.50 144.04 284.38 789.98

ii) Residue Area

Sr. No.


(*)

Govt. Non-Forest

Private Agriculture

(#)

Private Non-

agriculture Total

1 Badatodra 3.06 22.05 20.68 66.21 112.00

2 Siripur 18.47 27.46 10.79 43.28 100.00

3 Dulduliguda 3.76 4.50 4.01 7.72 19.99

4 Dinatodra 0.21 3.21 11.13 10.44 24.99

5 Kenduguda 0.11 10.02 11.80 8.06 29.99

TOTAL 25.61 67.24 58.41 135.71 286.97

iii) Railway Corridor





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Sr. No.


(*)

Govt. Non-Forest

Private Agriculture

(#)

Private Non-

agriculture Total

1 Regdaguda 0 0.54 0 0.18 0.72

2 Ravalkana 0 0.03 0 0.16 0.19

3 Padaguda 2.05 1.25 2.02 3.79 9.11

4 Pitesi 0 0 0.23 0.62 0.85

5 Rampur 0 0.65 0 0.79 1.44

6 Laxmipur 0 1.89 0.37 2.13 4.39

7 Bheja 6.85 0.10 2.67 6.64 16.26

8 Belkana 4.98 4.16 0.34 2.36 11.84

9 Kirkelpadu 3.48 0.59 0 0.19 4.26

10 Dhamanima 0.11 0 0.66 1.05 1.82

11 Jamuguda 1.01 1.38 0 0.18 2.57

12 Lilibadi 0 0.25 0.26 1.45 1.96

13 Janibidhi 0 0.46 0.47 4.18 5.11

14 Sikarpai 0 0.30 3.47 0 3.77

15 Deulabadi 0.68 0.50 3.74 1.53 6.45

16 Dhapaguda 0 0.28 1.21 0 1.49

17 Badapadu 0.70 0 0 0 0.70

18 Chamarjodi 0.10 0.34 1.49 2.70 4.63

19 Gortoli 0 0 0.05 0 0.05

20 Alanda 1.70 0 0 0.49 2.19

TOTAL 21.66 12.72 16.98 28.44 79.80

iv) Mine Access & Conveyor Belt

Sr. No.


(*)

Govt. Non-Forest

Private Agriculture

(#)

Private Non-

agriculture Total

1 Karapa 0 0.12 0.28 1.00 1.40

2 Bijaynagar 1.18 1.76 1.18 2.31 6.43

3 Murkakona 1.08 1.57 0 1.13 3.78

4 Ajaygarh 4.25 2.75 0.67 0.05 7.72

5 Hechkona 9.45 0.10 0 0.25 9.80

6 Sadalasa 29.62 0 0.04 0 29.66

7 Ranipadar 15.40 0.11 0 0 15.51

TOTAL 60.98 6.41 2.17 4.74 74.30





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v) Mine Corridor

Sr. No.


(*)

Govt. Non-Forest

Private Agriculture

(#)

Private Non-

agriculture Total

1 Podapai 0 11.12 0 0 11.12

2 Mohanagiri PRF 8.91 0 0 0 8.91

3 Ranibali 0 0.02 0 0 0.02

4 Taijhola 0 7.37 0.10 0 7.47

5 Salabali 1.10 17.47 0.03 0.79 19.39

6 Saragipadar 0 1.13 0 0 1.13

7 Kerpai 0 6.04 0 0.38 6.42

8 Tadadei 0 8.65 0 0 8.65

9 Mahajal 0 2.56 0 0 2.56

TOTAL 10.01 54.36 0.13 1.17 65.67

vi) Township

Sr. No.


(*)

Govt. Non-Forest

Private Agriculture

(#)

Private Non-

agriculture Total

1 Kalyansinghpur 2.27 7.93 6.80 5.67 22.67

2 Lokagurha 2.60 5.20 5.20 4.33 17.33

TOTAL 4.87 13.13 12.00 10.00 40.00

vii) Rehabilitation Colony

Sr. No.


(*)

Govt. Non-Forest

Private Agriculture

(#)

Private Non-

agriculture Total

1 Baldia 9.00 18.00 15.00 18.00 60.00

TOTAL 9.00 18.00 15.00 18.00 60.00

(*) – Village Forest, having canopy density of less than 10%

(#) – Low yield, single crop

4.3 Topography (along with map)

The project site comprising the alumina refinery, residue area (viz. red mud disposal

area, ash disposal area and run off pond) and town ship have been overlaid on a

mosaic topo sheet generated from parts of Survey of India Toposheet Nos. 65 M/2

SE, 65 M/3 NE, 65 M/6 SW and 65 M/7 NW and is presented as Annexure 5

(Drawing No. A811-00-83-42-1101 C). This drawing also shows the two captive





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bauxite deposits of Kutrumali and Sijimali. The topography of the project area

described in earlier sections is repeated in the following paragraphs.

The area around the refinery is generally flat to undulating with a number of rocky

outcrops with elevations varying from 360 - 400 m above MSL. Bijayanagar and

Ajaygarh hills are located on the western side of the alumina refinery and have top

elevations ranging from 650 - 1000 m.

The residue disposal area would be located near Siripur village approximately 2 km

North of the refinery. Kalyanasinghapur is located to the north east. Mostly this is a

levelled land but part of this is barren land with open scrubs of slightly undulating

topography.

The proposed township would be located near the MD road about 7 km north-east of

the refinery. Kalyansinghapur is towards its North and Siripur village towards its

South.

4.4 Existing land use pattern

As already stated above, the land in Kusumshila region generally consists of private

agricultural land and government land like Gauchar land, hutment area etc. The

distribution of different land uses in the area corresponding to the villages to be

acquired for plant, red mud pond, ash pond and township has been detailed out

earlier in the Tables under section 4.2 (B). However, it may be noted that in majority

of the cases only part of the villages in the above mentioned table will need to be

acquired.

The project area is about 2 to 3 Kms from periphery of reserve forest areas of

Ajaynagar, Bijaynagar, Durpai and Alanda Reserve forests, as seen in Annexure 5

(Drawing No. A811-00-83-42-1101 Rev C) enclosed with the report. As already

stated the Nagavali River flows about 500 to 800 m on the east of the project area,

which is proposed to be the source of water during monsoon months.

The area falls under earthquake Zone-II (which is the mildest zone among all zones

in India) according to IS:1893 - Criteria For Earthquake Resistance For Design Of

Structures.

4.5 Existing Infrastructure

The area around the proposed project site is mostly barren Govt. land and single

seasonal crop agriculture land and is devoid of any infrastructure. As per the report

on Socio Economic profile Report prepared by Operations Research Group (ORG),





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majority (i.e about 87%) of the population is engaged in agricultural and agricultural

labour activities. There is no industrial infrastructure in the vicinity.

A major district road from JK Pur to Kalyanasinghapur passes through the area.

Further, the Koraput - Rayagada Railway line passes close by with Sikarpai as the

nearest Railway Station.

4.6 Soil classification

The soil profile mentioned below for the plant area and residue area is based on

Geotechnical Investigation Report prepared by M/s Vogue Construction and

Consultancy Services Limited. It is generally found that the top two metres is of clay

to sandy clay which becomes vey slushy during the rains and very hard during

summers.

In the plant area, soil layers comprise

silty clay,

clayey silt

lateritic clay

sandy silt

sand

disintegrated rock,

medium and hard rock.

Water Table stabilized in some bore holes at depths varying from 0.60 m to 5.9 m

below ground level at the time of exploration.

In the residue area, soil layers comprise

sandy silt,

silty clay,

sandy clay,

silty sand,

sand,

disintegrated rock,

medium and hard rock.



In the township area, soil layers comprise

clayey silt

silty sand,

sand,

sandy silt,





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cemented sand.

Hard rock is met with in some bore holes from 0.2 m to 8.5 m. Disintegrated rock

layer was observed in one bore hole. At one of the boreholes boulders of 1m

thickness were met with from 0.2 m to 1.2 m.



4.7 Climatic data from secondary sources

As per the meteorological data available for Rampur region which is adjacent to

Kusumshila area, the monsoon is rigorous during June to October and the summer

between April-July is very warm.

Maximum temperature recorded is around 42°C and minimum temperature is around

5°C. Maximum Relative Humidity is around 100% and averages 42%. Wind flow in

the region is generally distributed from all directions throughout the year.

Predominant wind direction is from South to South West from April onwards,

Average monthly rainfall of Rayagada District as observed during the year 2013 is as

follows:

Month Average Monthly Rainfall

January 3.6 mm

February 4.5 mm

March 1.2 mm

April 49.8 mm

May 47.5 mm

June 397.2 mm

July 263.3 mm

August 250.4 mm

September 181.7 mm

October 258.6 mm

November 1.7 mm

December 0.0 mm

Total 1459.5 mm

4.8 Social Infrastructure available

Access roads:

The access roads to the nearby villages and to Karpa are well connected. No

difficulties are there throughout the year even during the period from June to October

covering monsoon period and part of post-monsoon period.





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Water:

Villages tap the water mostly from the natural springs and the nalas and use it in

untreated form. Few hand tube wells have been set up in the study area.

Electricity:

All the villages are electrified under Rural Electrification Programme. Now Power is

available to most of the villages.

Education facilities:

Education facilities from primary level to High schools are available in the area. There

is no college in the area.

Health care:

Primary health care centre is available in Narayanpur village.

Fuels:

The fuels used by the villagers are forest wood, kerosene and cooking gas.

Trade and Commerce centre:

Kalyansinghpur is the sub-divisional headquarters located at a distance of 9.6 km

from Karpa. Basic infrastructural facilities like all-weather road to the District

headquarters Rayagada, Govt. Hospital, electricity, schools, post office,

communication, bank and police station are available at Kalyansinghpur, the main

trade commerce centre for almost all the villages in the study area.

Monuments/Buildings of archaeological significances:

There is as such no monument or public buildings of interest in the study area as

observed during field study.





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5 PLANNING BRIEF

5.1 Planning Concept

Project involves construction of Alumina Refinery and development of associated

facilities. This involves construction of township, rehabilitation colony, construction of

peripheral roads and railway linkage to the nearest rail head.

5.2 Population Projection, facilities, Country Planning / Development authority

Classification

The project will employ most of the workers from nearby villages. Only supervisory

staff will be hired from outside. There will not be any notable increase in population

due to the project. However, few people from other areas may migrate in this area for

business opportunities. Village wise population of the core zone is given in the table

below. However, it may be noted that in majority of the cases only part of the villages

in the below mentioned table will need to be acquired.

Village Name Population

Core Plant

Kusumsila 289

Petliguda 340

Krushnapatraguda 225

Narayanpur 626

Karlima 48

Alanda 476

Chaojodi 205

Poduchanpadar 115

Dumripadar 117

Karapa 300

Residue Area

Badatodra 556

Siripur 530

Dulduliguda 141

Dinatodra 347

Kenduguda 149





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5.3 Land use planning

The land use for the alumina refinery and its various associated facilities is as

follows:

Facility Approximate

Area (Ha)

Alumina Refinery



20 Km Rail Linkage to Kevatiguda Rly. Stn. 80


Mine corridor 66

Township 40


Total Area 1398

5.4 Assessment of Infrastructure Demand

The area around the project site is mostly Govt. Barren land with a few villages

dotting the area. The project site has sparse population. There is only one major

district road between JK Pur and Kalyanasinghapur which passes close to the project

area. Villages are connected to each other through either concrete roads or fair

weather roads. Sikarpai on K-R line is the nearest railway station.

5.5 Amenities/ Facilities

The following amenities / facilities which are proposed to be provided as a part of the

project infrastructure would benefit the local population as well and help in overall

development of the area:

Building of Access Road to Plant, Mine, Township and other facilities.

Peripheral Roads to different villages as part of community development.

Provide Electric power distribution network with the help of State agencies to

local people.

Provide Potable water to the nearby villages either through Bore well or through

the water storage reservoir created to cater to the plant.

The township will have school, hospital, market, sports facilities, communication

network, Police station, Post Office, Banks etc as necessary. All these facilities

so developed shall cater partly to the Local Community also under the company’s

Social welfare schemes.





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Diversion of roads and irrigation canals falling in project site

Specific programmes will be launched to benefit the Local People by undertaking the

following as per R&R Plan to be agreed to:

Mobile Medical services to cater to the population in the vicinity.

Primary schools in different villages with mid day meal scheme.

Vocational Training centre to cater to the locals, so that they can earn their

livelihood.

Local people will be encouraged by providing Loans to involve in local business,

undertake mini contracts, take up Transport business etc.

Local entrepreneurs will benefit from increased flow of outsiders and increased

purchasing power of the community, through sale of goods both consumables as well

as durables.

In general the overall purchasing power of people in the region will go up leading to

an overall spiraling effect of social development along with better health, education

and Infrastructure development.

6. PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

6.1.1 Roads

The proposed site of Alumina Refinery at Kusumshila is well connected with

Rayagada through the Main District Road (MD) of Rayagada. Although MD Road

also provides approach to the red-mud disposal site in the north of refinery and the

township in the north of the alumina refinery, it is proposed to provide separate

sealed access roads for smooth movement between the following:

Refinery and township

Refinery and red-mud disposal area

Refinery and intake well at Nagavalli river

Township to MD Road

In addition to the above as a related project, a dedicated mine-plant link road of

approximately 16 km to provide access to Kutrumali Mine and the mine to plant long

distance bauxite conveyor. The final ascent of this road would require a 350 m rise in

elevation within a distance of 1.5 Km in difficult hilly terrain. A separate 11 Km road

link from Sijjimali to the loading station at Kutrumali is also being considered.

Transport of materials and equipment to the mine sites during construction would





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require the strengthening and minor upgrade of 16 Km of road access between

Kashipur and Sunger at the base of Kutrumali plateau.

6.1.2 Railways

General

Railway system is one of the most important infrastructure for this project as it will be

used to deliver coal, caustic soda and furnace oil and transport the product alumina

to the port. The approximate quantities of materials to be transported by railways are

as follows:

Rail Traffic for Alumina Refinery (3.0 Million TPY)

Sl.

No. Material

Quantity

(Million TPY) From To

1 Coal 1.80 Ib Valley and

Vishakhapatnam Port Alumina Refinery

2 Caustic Soda

(as 50% NaOH) 0.36 Vishakhapatnam Port

Alumina Refinery

3 Fuel Oil 0.24 Vishakhapatnam Oil

Refinery

Alumina Refinery

4 Lime

(as 70% CaO) 0.13 Local suppliers

Alumina Refinery

5 Alumina 3.00 Alumina Refinery Vishakhapatnam Port

Total 5.53

The railway system for the project would comprise of the following main components:

Rail link to the main-line of Indian Railways

Wagon handling facilities at the Alumina Refinery and Port

Deployment and maintenance of Rolling Stock

Track maintenance

Rail traffic management

It is proposed that the traffic shall move in block rakes and that specialized rolling

stock shall be owned by the promoters.

Rail Link

It is proposed to install a private rail link for connecting to the main network of Indian

Railways as a part of the railway system of the project. The proposed refinery site at

Kusumshila which is near the Sikarpai station on Koraput-Raygada (K-R) Line and

Singapur Road station on the Raipur-Vijayanagaram (R-V) Line.

Based on the feasibility to the two lines, two options were evaluated for establishing

the railway link. Option-I is to install a siding beginning from the Y junction at





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Singapur Road for connecting to the R-V Line while the Option-II is to consider a

siding beginning from the Kevatiguda, another more feasible station, on the K-R Line.

In the option-I, if siding takes off from Y-junction, a loop would have to be provided

along the K-R line for reversal of locomotive. This was not found technically feasible

as the K-R line in that stretch is laid on 1 in 100 grade whereas the maximum grade

permissible for laying a loop is 1 in 400 and with special dispensation 1 in 260.

Hence, this proposal is not technically feasible.

Another possibility to work from Y-junction was by providing an additional chord

connecting the serving siding with the K-R line. This was found technically feasible,

but it requires provision of two block cabins involving not only capital expenditure but

also running cost of manning these cabins round-the-clock. The other drawback of

this layout was that a crossing station had to be provided on the serving siding

between Km 10 and Km 11 from the Y-junction where the trains could be controlled

and regulated for entry into the busy stream of K-R and R-V lines. The capital cost

and the annual recurring cost of manning the crossing station are an adverse feature.

Hence this option is also not feasible.

Since the plant is situated closer to K-R line, as compared to R-V line, the possibility

of taking off the siding from the K-R line was examined. Operationally, it would be

more convenient to handle the plant's traffic through a station on the K-R line, as

compared to Y-junction where the traffic is dealt from three directions.

Kevatiguda is a four-line crossing station on the K-R line. For reversing the loco

movement, adequate facility is available at Kevatiguda with three loops. Besides to

facilitate movement, one additional loop is proposed at Plant's cost. Hence, no

problem is envisaged in dealing with this traffic at Kevatiguda.

The chargeable distance for traffic inward and outward will be 5 km more in respect

of option-II as compared to option-I. The increase in the freight will be more than

compensated by the savings in the annual recurring cost by adopting option-II.

Thus it would be seen that both for operational convenience and cost-effectiveness,

the siding taking off from Kevatiguda is better.





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Part of the Coal supply to the refinery would be sourced from the Ib Valley mines and

transported to the alumina refinery via Jharsuguda - Titlagarh Line and then through

Titlagarh - Singapur Road section of the R-V Line and then on the K-R Line up to the

railway siding at Kevatiguda.

Wagon handling facilities at the Alumina Refinery

Specialized wagons used for transporting alumina and caustic soda would be

procured as a part of the project according to the specifications of Indian Railways.

Fuel Oil wagons would be sourced either from the fuel oil supplier or through the

Indian Railways while coal would be transported in general service box wagons

operated by the Indian Railways.

Trains carrying alumina would normally consist of a rake of 48 wagons. Caustic soda

would be transported in shorter rakes of 28 wagons or may be combined with

alumina wagons to make full length rakes. Fuel rakes would comprise of 28 wagons

lot with a maximum permissible load of 56 wagons. Coal would normally be hauled in

lots of 58 box ‘N’ type wagons.

Within the alumina refinery, all the shunting and placement operations shall be

performed by locomotives owned by the project. Two numbers of diesel locomotives

have been envisaged for this purpose.

It is proposed to install an electronic type railway weigh bridge of 100 T capacity for

weighment of all incoming and outgoing wagons.

A dedicated wagon tippler shall be provided for unloading coal wagons. The

unloaded coal shall be directly sent to the coal storage yard by means of a belt

conveyor.

In order to facilitate easy loading and unloading of material to and from the railway

wagons within the plat boundary, separate railway tracks shall be provided for

loading and unloading of the following materials:

Coal - 1 unloading track

Caustic Soda - 1 unloading track

Fuel Oil - 1 unloading track

Lime - 1 unloading track

Alumina - 2 loading tracks





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In addition to the above tracks, there shall be separate tracks for mainline and engine

escape. Space provision shall be kept for additional track for future requirement.

6.1.3 Port Facilities

It is proposed to export 3 million TPY alumina and import approximately 360,000 TPY

at 50% NaOH caustic soda lye through Vishakhapatnam port in the state of Andhra

Pradesh. It is also proposed to import about 50% of the coal from world market. The

facilities to be provided in the port shall include storage, handling and loading/

unloading facilities for alumina, coal and caustic soda.

The inner harbour of the port has sufficient draft to allow for ships up to 40,000 dwt to

the berth. Modifications are under implementation to allow ships up to 60,000 dwt.

Existing practice for transportation of alumina from India involves ships varying from

10,000 dwt to 45,000 dwt with most of them being within 25,000 to 40,000 dwt range.

To feed ships of this size, four silos of 40,000 T capacity shall be provided at the port.

Caustic soda lye would be delivered to the port in 10,000 dwt ships and unloaded by

ship unloading pumps. Four storage tanks of 10,000 T shall be provided for storing

the unloaded caustic soda.

Other facilities at the port would include separate loading/ unloading railway lines for

alumina and caustic with suitable loading/ unloading systems.

6.1.4 Communication

Three forms of telecommunication have been identified:

Communication within the project work area

Communication within India

Communication overseas

Within the process area (main Alumina Refinery), the following communication

systems have been envisaged:

An EPABX system would be used for the fixed site operations and mobile

telephones/ walkie-talkies shall be used for specific requirements.

All modern communication facilities included internet, email and video

conferencing shall be provided for communication within India as well as

overseas.

6.2 Residential Area (Non Processing Area)





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General

There will be approximately 1200 employees in the plant of which executives will be

360 and non executives will be 840. However to provide better amenities a full-

fledged combined township for plant, mines and security personnel and supporting

staff is proposed for the project near Budagurha.

Single and double storeyed flats are proposed in the township. The township will be

well planned and self contained. It will have all the infrastructure such as water

supply, underground sewerage, electricity, roads etc. Other amenities such as

school, community center, guest house, health center, hospital, shopping complex,

post office, bank, park, playground etc. will also be provided. Suitable provision shall

be kept for future expansion of the township.

Location

The township for alumina refinery and mines is proposed on the northen side of the

proposed alumina refinery. Approximately 40 hectares of area has been earmarked

for the township which is sufficient for the expansion also. The township shall be

developed near Siripur Village. The MD road is 1 km towards east;; Kalyansinghpur

on its North and Siripur on its South. Nagavalli river will be 1-2 km from the township.

The proposed township site is located on clayey soils to a depth of 2m, below which a

hard soil of soft rock is there. It is located in the mildest earthquake zone.

Dwelling Units

Apportionment of various types of accommodation shall be made as per entitlement

of the categories of the personnel as per standard norms. It is proposed to provide

100% housing requirements for executives and 70% requirement for non-executives.

The township shall be designed for 1100 employees and their families, with provision

for expansion.

Amenities

It is proposed to provide all basic amenities within the proposed township such as

Primary School, Higher Secondary, School, Community Centre, Guest House,

Hostel, Health Centre, Post Office, Bank etc.

Transport

The township will be connected with the Major District (MD) road which leads to

Kalyanasinghapur on one side and Sikarpai and Rayagada on the other side.





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Sikarpai Railway Station on K-R line is about 5 Km from the proposed township.

Temporary transport facilities will be provided during construction phase but

developed transport facilities will be made available to the people of colony &

residents of the area.

Industrial Activity

The activities will include service industries, transport and trading activities in the

area. Related auxiliary small and medium scale units will be encouraged in the

neighbouring areas.

Power, Water and other Services

The township shall be connected to the main district road and the refinery through

new approach roads. The main approach road shall be 6m wide, with 1.5m berms on

each side of the road. Local roads shall be 3m wide.

Power shall be supplied to the township from the captive co-generation plant located

in the alumina refinery. Treated water shall be supplied from the water treatment

plant located within the alumina refinery and pumped to an elevated storage tank in

the township area. In addition to these, following external services shall also be

provided:

Water Storage & Distribution network;

Sewage treatment & disposal;

Storm Water drainage System;

Power supply & Distribution Network;

Internal roads;

Telephone connections;

Cable T.V. connections;

Township maintenance department.

6.3 Green Belt

It is proposed to have Green Belt all along the periphery of the plant area. Green belt

development will depend upon:

a. Quality and quantity of pollution load

b. Meteorological factor

c. Soil & water quality

Selection of plants and vegetation will be based upon the following:

a. The plants should be fast growing





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b. The plants should have thick canopy cover

c. The plants should be preferably perennial and evergreen

d. The plants should have large leaf area index

e. The plants should match with the local ecological background

6.4 Social Infrastructure

Various Development Programme of the Govt. are there which are mostly routed

through BDO. The largest groups for such programmes are the families living Below

Poverty Line (BPL) which generally includes landless, marginal and small farmers,

SCs, STs, women, destitute, orphans, handicapped etc.

Since majority of the PAPs are Below Poverty Line they can avail the facilities/

benefits available under such programmes. There are basically four types of

programmes.

Asset endowments & Income Generation (AEIG)

Employment Generation

Training

Infrastructure Development

Most of the AEIG Programmes are based on subsidy loan combination and are

available under

Self Employment of Educated Unemployed Youth (SEEUY),

Forest Farming for Rural Poor (FFRP),

Development of Women and Child in Rural Area (DWCRA), etc.

Besides, there are various sectoral development programmes like fisheries,

sericulture, horticulture, floriculture, small scale and cottage industries etc. where

individual poor families are also assisted to establish their economic base with the

help of exclusive training programmes.

Training programmes are also organised by various govt. departments for their

different schemes. Employment generation and infrastructural development are

ensured through Jawahar Rozgar Yojana (JRY) under which required social and

other infrastructures are developed by employing local unemployed people. Project

also provides employment opportunities for some of the PAPs in its construction

activity.

For the PAPs, some of the development programmes discussed above can be

integrated for their economic rehabilitation. For the families headed by women and





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those who are supplementing their family income can be helped for self employment

under DWCRA. Depending upon skills, preference and managerial capabilities,

individual PAPs can be assisted to avail the benefits under such programmes through

Block Development Office (BDO). The NGO will have an important role to play in

ensuring the benefits along with the BDO. While NGO can motivate the PAPs and

help them from time to time in training,

BDO will help in processing the individual cases for assistance at block level. Based

on the detailed discussion with affected people, in several sittings, certain alternative

income generating activities will be identified by NGO for those families whose

income earning is likely to go down after Land Acquisition, a majority of them will be

the land owners. In order to improve the efficiency or to impart a new skill, training

programmes under TRYSEM will be organised and Self Employment thereafter under

income generating scheme will be ensured. Financial provision have been made for

the training of PAPs in different skills to help them in their economic rehabilitation

Artisans: The skill possessed is limited to rope making and carpentry. Apart from

these two major skills some PAPs also possess skill of khali stitching, broom stick

making, basket making and pottery.

These activities are basically carried out to meet the domestic needs and in case

there is any excess production, it is sold in the weekly markets. But there is good

scope of marketing the products of these activities not only within but also outside the

state. It requires organised marketing.

Therefore, there is a need to train and orient the people towards commercial

production of these items. Besides cash earning from such activities which may

substantially supplement the household income, these activities can provide

productive employment to women members on a long term basis.

Women Members: Apart from being helped in DWCRA women may be helped on an

individual basis, by providing them loan for petty business like small grocery shop,

tea shop, pan bidi shop etc . Other suitable activities such as bamboo basket making,

khali stitching etc. also can be promoted.

Educated Persons: Although the literacy level is extremely low in the area, still few

educated members are there. They can be covered under Self Employment schemes

for which necessary training programmes will be organised to impart skill I trade and

finally arranging the assistance required for their rehabilitation. Some of the important

self employment schemes could be cycle repairing, tailoring, welding, motor winding,

motor driving etc .





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Various economic activities may be taken up for the individual families based on

their socio-economic characteristics which includes

i) Education level

ii) Skill possession

iii) Main and subsidiary occupation

iv) Type of worker

v) Age

vi) Sex

vii) Suitability of economic activity to supplement the income

viii) Market potential and marketing facilities

Project affected Persons (PAP) whose main occupation is agriculture are suggested

allied agriculture activities which includes dairy, poultry, sheep rearing, goatery and

pig keeping etc., but the specific activities is not mentioned as it is upto the NGO to

discuss with the PAPs to know their preference. Some PAPs are having dairy and

poultry as subsidiary occupation, Therefore, those PAPs may take up the same as

main occupation after displacement. Although many PAPs are having skill but most

them are restricted to rope making and carpentry. For some of the PAPs household

industries have been suggested as an alternative economic activity. PAPs having

construction activity as subsidiary after agriculture will be given training in masonry

work for self employment. PAPs those who are educated (at least secondary level)

will be given loan for petty business.

Apart from the above, this project will improve their present economic conditions by

having direct and indirect employment opportunity as skilled/semi – skilled workers,

contractor’s labours etc. Thus the project will have significant beneficial impact on

the economic condition and life style of the local people.

In addition, the following benefits will accrue to the local people:

- Road facility

- Medical camps

- Social awareness camps

- Secondary employment opportunities





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6.5 Connectivity

The present connectivity in the project area has already been described earlier at

section 4.1. The project proponent would attempt to enhance the already existing

connectivity by providing suitable infrastructure like bus station, roads to reach to

Sikarpai railway station etc.

6.6 Drinking Water Management

It is estimated that the water requirement for alumina refinery and associated facilities

would be approximately 14 million gallons per day (MGD). To meet drinking,

sanitation and service water, the required treated water from the raw water system

will be utilized.

Raw Water Treatment Plant (RWTP)

Raw water from the fresh water reservoir would be properly treated in a RWTP by

flocculation, coagulation, filtration and chlorination to produce the desired quality of

water for process use and for drinking water circuit.

Treated water from the RWTP shall be stored in two underground reservoirs and one

overhead tanks to meet the requirement of the alumina refinery and the steam &

power plant. Water for the mines and township shall be pumped from the

underground reservoirs with the help of dedicated pumps. Sufficient storage

provisions for mines and township have been considered.

6.7 Sewerage System

The plant and township will have a well connected underground and above

ground sewerage network system with minimal discharge of effluents to the

surroundings.

6.8 Industrial Waste Management

LIQUID WASTE

Liquid wastes in alumina production are generated from various sections of the plant.

There are three types of liquid wastes, namely

Process waste water

Oily waste water

Sanitary waste water





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Process Waste Water

There are three types of effluents from various processing units :

a) Acidic waste water from heat exchangers and evaporators

b) Cooling tower blow-down comprising treatment chemicals

c) Laboratory effluents

Besides, there are alkaline effluents from various units, which are recycled back

within the battery limit. All the acidic effluents are collected in an equalization tank

from where the equalized waste water is pumped to the reaction tank. Lime is added

in the reaction tank for neutralization and precipitation. The waster water then flows to

the clarifier where solids are separated and the clarified overflow passes through a

guard pond into the discharge drain. The sludge flows under hydrostatic pressure to

the sludge sump from where it is pumped to the ash pond. The treatment effluent

quality will conform to IS: 2490 (Industrial waste water discharged into inland waters).

Oily Waste Water

Oily waste water treatment plant is to treat only oily waste water from oil storage and

oil unloading area. Oily waste water is pumped to the collection tanks where oil water

separation takes place. The separated oil is collected in drums while the waste water

is allowed to flow by gravity to the API oil separator.

The remaining oil is recovered in the API separator and the treated waste water will

be discharged for final disposal. The sludge removed in API will flow by hydrostatic

pressure to sludge lagoons for drying and manual disposal.

Treated effluent characteristics are as follows:

pH : 5.5 to 9.0

BOD5 : 30 mg/l

Oil & Grease : 10 mg/l


Sanitary Waste

Sanitary waste of the entire alumina plant would be treated in sanitary waste

treatment plant. Sanitary waste from the above sources is received in Sanitary





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Sewage Sump and then pumped to compact unit consisting of digestion chamber,

stabilization chamber, clarifier and activated sludge process unit with facilities like

aeration, post chlorination, sludge removal, recirculation and scum removal. The

treated effluent after chlorination is collected in the treated effluent slump for final

disposal. The bio sludge generated is dried in sludge drying beds before final

disposal.

The treated effluent conforms to the following parameters:

pH : 5.5 to 9.0

BOD (20○C) : 20 mg/l


6.9 Solid Waste Management

The major solid wastes discharged from the plant are red mud from the alumina

refinery and coal ash from the co-gen power plant. Red mud is rendered alkaline by

the adhering liquor. The mud is ‘dry’ stacked and the storage area is lined with an

impermeable layer to prevent ground water contamination. Appropriate dust

suppression system shall also be provided.

Coal Ash shall be disposed off into conventional wet pond. The water shall be

reclaimed for reslurrying of ash, and the excess water, if any shall be utilized for

green belt development in the plant area. The disposal site shall be bounded and

garland drains shall be provided to isolate the surface run-off from the watershed

area of ash pond. Excess fly ash shall be utilized for land filling in low-lying areas and

for road construction etc. Further, it is proposed to be sold to briquette making plants.

6.10 Power Requirement & Supply I source

Total electric power demand for the project including township and associated

facilities has been estimated at 150 MW which would be met from the Co-gen power

plant, with one unit as standby.

Medium Pressure steam is a requirement in the alumina refinery. Hence, a co-

generation power plant has been proposed for this project such that the steam which

is produced at a higher pressure is expanded through back-pressure type turbo

generators to the pressure required for the alumina circuit. The byproduct electric





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power is utilized for meeting the requirement of the process plant and associated

facilities.

The electric power produced in the co-generation plant shall be synchronized with

grid supply such that surplus power can be banked with GRIDCO (Odisha) while

minor temporary shortage will be met from the grid. For short durations, during

instability of the grid, it would be possible to operate the plant in “Islanding” mode

also.





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7. REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 Policy to be adopted (Central/State)

L&T proposes to follow the Odisha State policy on R&R and accordingly it will provide

benefits to the Project Affected Persons (PAP) which are estimated to be around

1040, as per the last socio-economic survey carried out for the project. Project

displaced households is around 800 (as per the definition of R&R policy and the

amended Land Acquisition Act, 2013).

8. PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

The proposed project comprises a 3 MTPY alumina refinery and its associated

facilities like co-gen power plant, residue area, township, R&R colony, road link to

major district road, rail link to Indian railways, water drawal from Nagavali river and

connectivity to state grid etc.

The major steps involved up to implementation of the proposed project are as

follows:

Selection and appointment of a Technology Supplier of international repute for Alumina Refinery

Conceptual Engineering by Technology Supplier

Detailed Feasibility Study (DFS)

Environmental Clearance

Forest Clearance

Other government approvals and statutory clearances

Land acquisition

Basic Engineering by the selected Technology Supplier

Detail Engineering by selected Engineering Consultant

Construction

Pre-commissioning and Commissioning

The overall project implementation schedule is presented in the form of a bar chart in

Annexure 3 (Document No. A811-00-1342-SCH-001). It is based on conventional

project implementation philosophy and experience of similar projects in India.

Date for commencement of construction of the Alumina Refinery is likely to be

January 2017 and completion date is expected to be December 2020.





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8.2 Estimated Project Cost

As informed by L&T, the capital cost of the project including facilities for

Core Plant

Red Mud Disposal

Coal Ash Disposal

Township

R&R Colony

Associated Road & Rail Infrastructure

would be Rs.13,468 crores including a foreign exchange component of Rs. 2385

crores.

8.2.1 Annual Operating Cost

Annual operating cost of Rs 2995 crores (Annexure 2) has been computed

considering following costs:-

a) Variable operating cost

i. Raw Material : Bauxite : Rs. 500/- per MT

: Caustic Soda : Rs. 26,000/-per MT

ii. Energy : Coal : Rs. 4,500/- per MT

: Power : only generation*

* Duty of Rs. 0.22/ Kwh has been considered. Power shall be evacuated from Co-gen Power Plant.

b) Fixed Operating Cost

Fixed Operating cost for Alumina Refinery is based on following assumptions:-

Salary & Wages

Executives :- Rs. 12,00,000/- per annum. (average) Non Executives :- Rs. 6,00,000/- per annum. (average)

Repair & Maintenance

@ 2.5% of Plant & Machinery and 0.5% of Building & Civil works.

Insurance

@ 0.1% of Capital cost.

8.2.2 Annual Sales Revenue

Annual Sales revenue of Rs. 5544 crores (Annexure 2) has been worked out

considering selling price of alumina @ USD 280/MT as advised by the L&T (at an

exchange rate of Rs.66.per USD).





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8.2.3 Financial Analysis

Based on capital cost, operating cost and sales revenue, financial analysis have been

carried out for calculating internal rate of return (IRR) with a view to establish

profitability of the project. The basis of financial analysis is as under:

Basis of Financial Analysis

Sl. No. Parameter Value

1 Construction Period 5 Years

2 Plant Life 20 years

3 Debt / Equity Ratio 70 : 30

4 Expenditure Pattern Simultaneous debt equity pattern

5 Loan Repayment period 10 years

6 Moratorium Period 2 Years

7 Interest on Long Term Debt 10% for indigenous and 5% for Foreign

8 Capital Phasing (Total Capital)

1 Year 15.0%

2 Year 25.0%

3 Year 35.0%

4 Year 20.0%

5 Year 5.0%

9 Capacity Build – up

1st year 66.66%

2nd year 83.33%

3rd year onwards 100%

10 Corporate Tax Rate @ 0%

11 MAT @ 20.96%

8.2.4 Results of Financial Analysis

Results of Financial Analysis for the plant are as follows:-





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9. ANALYSIS OF THE PROPOSAL

9.1 Financial and social benefits

Employment Generation Potential

The proposed project will generate significant employment in the economically

backward area of Rayagada district. The employment generation potential of the

project is estimated to be as follows:

6000 workers during Construction period.

1200 Employees directly employed for Operation phase.

4800 persons get indirect employment during Operation phase.

The population comprising of above-mentioned group will have high purchasing

power which will have a further effect on the economy of the region leading to

increase Revenue to State.

Development of Infrastructure around the Plant

The project is expected to help in overall development of the area as follows:

Building of Access Road to Plant, Mine Township and other facilities.

Peripheral Roads to different villages as part of community development.

Provide Electric power distribution network with the help of State agencies to

local people.

Provide Potable water to the nearby villages either through Bore well or through

the water storage reservoir created to cater to the plant.

ITEM DESCRIPTION Cost in Rs Crores

CAPEX 13450

ANNUAL OPERATING COST 2995

SALES – REVENUE 5544

ITEM DESCRIPTION Value in percent

IRR on Total Capital

Pre-Tax 14.31%

Post- Tax 14.31%

IRR on Equity

Pre-Tax 19.61%

Post- Tax 19.61%





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The township will have school, hospital, market, sports facilities, communication

network, Police station, Post Office, Banks etc as necessary. All these facilities

so developed shall cater partly to the Local Community also under the company’s

Social welfare schemes.

Specific programmes will be launched to benefit the Local People by undertaking the

following as per R&R Plan to be agreed to:

Mobile Medical services to cater to the population in the vicinity.

Primary schools in different villages with mid day meal scheme.

Vocational Training centre to cater to the locals, so that they can earn their

livelihood.

Local people will be encouraged by providing Loans to involve in local business,

undertake mini contracts, take up Transport business etc.

Local entrepreneurs will benefit from increased flow of outsiders and increased

purchasing power of the community, through sale of goods both consumables as well

as durables.

In general the overall purchasing power of people in the region will go up leading to

an overall spiraling effect of social development along with better health, education

and Infrastructure development.

9.2 Conclusions & Final Recommendations

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

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

well within the acceptable norms. 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 a Detailed Feasibility Studies before the financial

closure.

Annexure -1

Sl. No. Country Location CompanyPlant Capacity

(t/year)1 Argentina Puerto Madryn Aluar (Aluminio Argentino) 4,70,0002 Australia Bell Bay, Tasmania Rio Tinto Alcan (Bell Bay) Ltd. 1,80,0003 Australia Boyne Island Boyne Smelters Ltd. (BSL) 5,50,000

4 Australia Portland, VictoriaAlcoa World Alumina Australia Ltd. - Portland Aluminium 3,58,000

5 Australia Tomago Tomago Aluminium Company Pty. Ltd. 5,40,0006 Azerbaijan Ganja Ganja Aluminium 50,0007 Bahrain Askar Alba (Aluminium Bahrain) 9,12,000

8Bosnia and Herzegovina Mostar Aluminij d.d. Mostar 1,30,000

9 Brazil Vila dos Cabanos Albras (Alumínio Brasileiro S.A.) 4,60,00010 Brazil Poços de Caldas Alcominas (Alcoa Alumínio S.A.) 1,06,000

11 Brazil São LuísAlumar (Consórcio de Alumínio do Maranhão S.A.) 4,60,000

12 Brazil Santa Cruz Metalisul 95,00013 Brazil Saramenha Novelis do Brasil S.A. 51,000

14 Brazil Alumínio CBA (Companhia Brasileira de Aluminio) 4,75,000

15 Cameroon EdéaAlucam (Compagnie Camerounaise de l'Aluminium) 1,00,000

16 Canada Alma, Quebec Rio Tinto Alcan - Usine Alma 4,43,00017 Canada Arvida Rio Tinto Alcan - Usine Arvida 1,63,000

18 Canada BécancourA.B.I. (Aluminerie de Bécancour Incorporée) 4,20,000

19 Canada Baie Comeau Alcoa Aluminerie de Baie-Comeau 3,00,00020 Canada Deschambault Alcoa Aluminerie de Deschambault 2,60,00021 Canada Grande Baie Rio Tinto Alcan - Usine Grande-Baie 2,20,00022 Canada Kitimat Rio Tinto Alcan - Kitimat 2,10,00023 Canada Laterrière,_Quebec Rio Tinto Alcan - Usine Laterrière 2,35,00024 Canada Sept-Îles, Quebec Aluminerie Alouette Inc. 6,00,00025 Canada Shawinigan Falls Rio Tinto Alcan - Shawinigan Falls 1,00,000

26 Egypt Nag HammadiEgyptalum (Aluminium Company of Egypt) 3,20,000

27 France Dunkerque Aluminium Dunkerque SA 2,73,000

28 FranceSt. Jean de Maurienne Rio Tinto Alcan - St.-Jean-de-Maurienne 1,41,000

29 Germany EssenTrimet Aluminium AG - Niederlassung Essen 1,70,000

30 Germany HamburgTrimet Aluminium AG - Primary Products Hamburg 1,35,000

31 Germany NeussHydro Aluminium Deutschland GmbH -Neuss (Rheinwerk) 2,30,000

32 Germany Voerde Voerdal GmbH 96,00033 Ghana Tema Valco (Volta Aluminium Company) 2,00,00034 Greece St. Nicolas Aluminium de Grèce SA (AdG) 1,66,00035 Iceland Reyðarfjörður Alcoa Fjardaál 3,46,000

List of Aluminium smelters in the worldSource: Internet surfing

Page 1 of 6


(t/year)

36 IcelandGrundartangi, near Akranes Nordic Aluminum Co (Nordural) 2,85,000

37 IcelandStraumsvik, near Hafnarfjörður Alcan Iceland Co Ltd. (Isal) 1,90,000

38 India Angul National Aluminium Co. (Nalco) 4,75,000

39 India HirakudHindalco Industries Ltd. - Hirakud Smelter 2,13,000

40 India Haryana Century Metal Recycling Private Limited41 India Haryana Sumridhi Aluminum Private Limited 20,00042 India Jharsuguda Vedanta Resources 5,00,00043 India Korba Bharat Aluminium Co. (Balco) 9,00,000

44 India RenukootHindustan Aluminium Co. (Hindalco Industries Ltd)) 3,45,000

45 India LapangaAditya Aluminium (Hindalco Industries Ltd)) 3,60,000

46 India BargawanMahan Aluminium (Hindalco Industries Ltd)) 3,60,000

47 Indonesia Kuala TanjungPT Indonesia Asahan Aluminium (Inalum) 2,65,000

48 Iran Arak Iran Aluminium Co (Iralco) 90,00049 Iran Arak (2) Iran Aluminium Co (Iralco) 1,10,00050 Iran Bandar Abbas Al-Mahdi Aluminium Corp. (AAC) 1,10,00051 Iran Bandar Abbas (2) Hormozgan Aluminium (Hormozal) 1,47,00052 Japan Kambara Nippon Light Metals Co Ltd. 20,00053 Kazakhstan Pavlodar Kazakhstan Aluminium Works (KAZ) 2,50,00054 Malaysia Sarawak Press Metal Sarawak 1,20,000

55 Montenegro PodgoricaDP Kombinat Aluminijuma Podgorica (KAP) 1,20,000

56 Mozambique Maputo Mozal (Mozambique Aluminium Smelter) 5,65,00057 Netherlands Delfzijl Aluminium Delfzijl BV (Aldel) 1,70,000

58 New Zealand Tiwai PointNew Zealand Aluminium Smelters (NZAS) 3,51,000

59 Nigeria Ikot AbasiAlscon (Aluminium Smelter Co of Nigeria) 2,00,000

60 Norway Årdal Ardal Primary Production (Haas) 2,33,00061 Norway Hoyanger Hoyanger Primary Production (Haas) 60,00062 Norway Husnes Sor-Norge Aluminium AS (Soral) 1,85,00063 Norway Karmøy Karmoy Primary Production (Haas) 1,70,00064 Norway Lista Alcoa Norway - Lista Works 1,27,50065 Norway Mosjøen Alcoa Norway - Mosjoen Works 2,21,50066 Norway Sunndalsøra Sunndal Primary Production (Haas) 4,00,00067 Oman Sohar Sohar Aluminium Company 3,90,00068 China Aba Aba Aluminium Works 1,00,00069 China Baise Yinhai Baise Yinhai Aluminium Co 1,75,00070 China Baotou East Hope Baotou Oriental Hope Aluminium Co 4,00,00071 China Baotou Shi Baotou Aluminum Factory 6,10,000

72 ChinaChangjiang[disambiguation

needed ] Changjiang Aluminium Smelter 62,00073 China Chiping Xinfa Shandong Xinfa Aluminium Co. 5,50,000

74 ChinaChongqing Dongsheng Dongsheng Aluminium Works 50,000

Page 2 of 6


(t/year)75 China Chongqing Tiantai Chongqing Aluminium Co 55,00076 China Chuangyuan Changyuan Aluminum Works 1,00,000

77 China Danjiankou ShiDanjiangkou Water Conservancy Aluminium Factory 50,000

78 China Datong Xian Qinhai Aluminium Smelter 2,60,00079 China Dengfeng Dengfeng Aluminium Works 65,00080 China Dianneng Gejiu Dianneng Gejiu Aluminium Works 50,000

81 China Dongfang XiwangDongfang Xiwang Aluminium Smelter Innermongolia 7,80,000

82 China Donghai Shandong Donghai Aluminium Corp. 2,00,00083 China Emei Sichuan Emei Aluminium Pant 3,50,000

84 China EmeishanEmeishan Aluminium Industry Clique Co. Ltd. 3,55,000

85 China Faxiang Faxiang Aluminium Works 70,000

86 China FukangXinjian Tianlong Mineral Co. Aluminium Smelter 4,13,000

87 China Fushun Shi Fushun Aluminium Reduction Plant 3,50,00088 China Gansu Longxi Gansu Longxi Dongxing Smelter 2,40,00089 China Gongyi Gongyi Aluminium Plant 25,00090 China Guangxi Baise Guangxi Baise Xinghe Smelter 3,20,000

91 ChinaGuangyuan Qimingxing Qimingxing Aluminium Co. 1,14,000

92 China Guanlu (new) Shanxi Guanlu Co. Ltd. 2,20,00093 China Guanlu (old) Shanxi Guanlu Aluminium Plant 1,10,000

94 China Guanyuan AostarSichuan Aostar Guangyuan Aluminium Smelter 4,20,000

95 China Guiyang Shi Guiyang Aluminium Smelter 2,40,00096 China Guizhou Guizhou Aluminum Plant 4,10,00097 China Haizhou HaizhouAluminium Smelter 40,00098 China Hejin Xian Long Men Aluminum Plant 1,20,00099 China Henan Wanji Henan Wanji Aluminum Co. Ltd. 5,30,000100 China Hongjun Huomei Hongjun Aluminium Smelter 10,60,000101 China Honglu Aluminium Honglu Aluminium Co 1,50,000102 China Huadong Huadong Aluminium Works 70,000103 China Huanghe Huanghe Aluminum Co. 80,000104 China Huasheng Jiangquan Huasheng Jiangquan Aluminum Co. 1,12,000105 China Huaxin Huaxin Aluminum Industries 70,000106 China Huayu Huayu Aluminium Works 1,00,000107 China Jiaozuo Shi Jiaozuo Wanfang Aluminium Smelter 4,20,000108 China Jilin Jilin Aluminium Company 65,000109 China Jinneng Jinning Aluminium Smelter 80,000110 China Jinning Jinning Aluminium Co 3,50,000111 China Jinxi Xinfa Group 1,60,000112 China Ke'ao Shandong Yankuang Ke-au Aluminium 1,35,000113 China Laibin Yinhai Laibin Yinhai Aluminium Company 2,50,000114 China Lanjiang Shi Lanjiang Aluminium Works 30,000115 China Lanzhou Liancheng Lanzhou Liancheng Aluminium Plant 2,60,000116 China Lanzhou Shi Lanzhou Aluminium Smelter 7,00,000117 China Linfeng Linfeng Aluminium 1,60,000118 China Lintao Lintao Aluminium Plant 50,000119 China Linzhou Lifeng Aluminium Co. Ltd. 2,40,000120 China Longlin Longlin Aluminium Smelter 50,000

Page 3 of 6


(t/year)

121 ChinaLongquan Aluminium Longquan Aluminium Smelter 4,00,000

122 China Longxiang Longxiang Aluminium Works 55,000

123 ChinaMeishan Qimingxing

Sichuan Meishan Qimingxin Aluminium Co 1,30,000

124 China Mianchi Aluminium Mianchi Aluminium Plant 80,000125 China Nanping Shi Nanping Aluminium Group 73,000126 China Nanshan Shandong Nanshan Aluminum Co., Ltd. 4,06,000127 China Ningxia Ningxia St. Dehua 50,000128 China Ningxia Ningxia Jinjiang Group 3,70,000129 China Nongliushi Nongliushi Smelter Xinjiang 5,90,000130 China Panshi Xian Panshi Aluminium Works 25,000131 China Pingguo Xian Pingguo Aluminum Co. 1,40,000132 China Pingyin Shandong Pingyin Aluminium Plant 26,000133 China Qiaotou Qiatou Aluminium Works 3,50,000134 China Qinao Qinao Aluminium Smelter 90,000135 China Qinghai Qinghai Aluminium Plant 4,36,000136 China Qinghai Huanghe Qinghai Huanghe Aluminium Company 5,00,000137 China Qinghai Xinheng Qinghai Xinheng Aluminium Plant 5,00,000138 China Qinghai Xinye Qinghai Xinye Aluminium Smelter 5,75,000139 China Qingtongxia Shi Qingtongxia Aluminum Co. 6,85,000140 China Qinyang Henan Qinyang Aluminium Power 5,00,000141 China Qiya Qiya Group 4,00,000142 China Sanmenxia Shi Sanmenxia Tianyuan Aluminum Co. 1,20,000

143 ChinaShandong Aluminium Shandong Aluminium Smelter 78,000

144 China Shangdian Shangdian Aluminium Co. Ltd. 1,25,000145 China Shanxi-Huaze Shanxi-Huaze Aluminium & Power Co. 3,50,000146 China Shanxian Hengkang Shanxian Hengkang Smelter 2,20,000

147 China Shenhuo (new)Henan Shenhuo Orient Aluminium Company 4,20,000

148 China Shenhuo (old) Henan Shenhuo Aluminium Company 1,60,000149 China Sichuan Qiya Qiya Group 3,50,000150 China Taian Taian Aluminium Works 50,000151 China Taiyuan Shi Taiyuan Aluminium Works 1,00,000152 China Tianshan Tianshan Group 4,00,000153 China Tianyuan Tianyuan Aluminium Group 1,30,000154 China Tongshuan Tongshuan Aluminium Smelter 1,50,000

155 ChinaTongshuan Xinguang

Tongchuan Xinguang Aluminium Co. Ltd. 1,10,000

156 China Tongshun Tongshun Aluminium Plant 50,000157 China Wujiaqu Xinfa Group 7,40,000158 China Xichuan Xichuan Ferro-Alloy Works 90,000159 China Xiezhou Xiezhou Aluminium Works 3,30,000160 China Xinfa Xinfa Xiwang Al & Power 1,75,000161 China Xinjang Yihe Xinjiang Yihe Aluminium Smelter 4,00,000162 China Xinjiang Xinfa Group 3,70,000

163 China XinjinagXinjiang Easthope Coal Power & Aluminium 8,60,000

164 China Xinwang Henan Xinwang Aluminium Co. Ltd. 76,000165 China Yangquan Shanxi Yangquan Aluminium Co. Ltd. 68,000166 China Yangquan Shi Yangquan Aluminium Works 60,000

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(t/year)

167 China YichuanHenan Hong KongYugang Longquan Aluminium Co., Ltd. 4,00,000

168 China Yinhai Yinhai Aluminium Co. 1,00,000169 China Yongan Yongan Aluminum Co. 60,000170 China Yongchen City Yongchen Aluminium 5,00,000

171 China Yugang LongquanHenan Yugang Longquan Aluminium Co. Ltd. 6,00,000

172 China Yulian Power Henan Yulian Power Group. 1,20,000173 China Yuncheng Shi Shanxi Huasheng Aluminium Works 2,20,000174 China Yungcheng Shanhe Yungcheng Shanhe Aluminium Co. 65,000175 China Yunnan Yunnan Aluminium Co. Ltd. 5,00,000176 China Yunnan Dongyuan Yunnan Dongyuan Smelter 2,40,000177 China Yunnan Runxin Yunnan Runxin Aluminium Works 50,000178 China Yunnan Yongxin Yunnan Yongxin Metals Processing Co. 35,000179 China Zhaofeng Zhaofeng Aluminium Smelting Co 61,000180 China Zheijiang Huadong Zhejiang Huadong Aluminium Co. Ltd. 70,000181 China Zhengxing Zhenxing Aluminium Smelter 1,20,000182 China Zhengzhuo Shi Zhengzhuo Aluminium Smelter 58,000183 China Zhongfu Zhongfu Industry Group 3,08,000184 China Zhonghe Zhonghe Group 4,95,000185 China Zhongning Zhongning Aluminium Smelter 3,70,000186 China Zouping Zouping Aluminium Smelter 1,41,000187 China Zunyi Xian Zunyi Aluminium Works 2,42,000188 Qatar Mesaieed Qatalum (Qatar Aluminium Co) 6,25,000189 Romania Slatina SC Alro SA Slatina 2,88,000190 Russia Bratsk Bratsk Aluminium Works-BrAZ 10,10,000191 Russia Kamensk Ural Aluminium Works -UAZ 75,000192 Russia Kandalaksha Kandalaksha Aluminium Works -KAZ 75,000193 Russia Krasnoturinsk Bogoslovsk Aluminium Works-BAZ 1,90,000194 Russia Krasnoyarsk Krasnoyarsk Aluminium Works - KrAZ 10,08,000195 Russia Nadvoitsy Nadvoitsy Aluminium Works - NkAZ 80,000196 Russia Novokuznetsk Novokuznetsk Aluminim Works - NAZ 3,30,000197 Russia Sayanogorsk Sayan Aluminium Works - SaAZ 5,42,000198 Russia Sayanogorsk II Khakas Aluminium Works - KhAZ 3,00,000199 Russia Shelekhovo Irkutsk Aluminium Works -IrkAZ 4,15,000200 Russia Taishet Thaishet Aluminium Works - ThAZ 10,000201 Russia Volgograd Volgograd Aluminium Works - VgAZ 1,70,000202 Russia Volkhov Volkhov Aluminium Works - VAZ 24,000203 Saudi Arabia Ras Al Khair Ma’aden Aluminium 7,40,000204 Slovakia Ziar nad Hronom Slovak Aluminium Co - SLOVALCO 1,60,000205 Slovenia Kidricevo Talum dd Kidricevo 75,000

206 South AfricaRichards Bay, Hillside Hillside Aluminium 7,20,000

207 Spain Aviles Alcoa Inespal- Aviles Works 93,000208 Spain La Coruña Alcoa Inespal- La Coruna Works 87,000209 Spain San Ciprian Alcoa Inespal -San Ciprian Works 2,50,000210 Sweden Sundsvall Kubikenborg Aluminium AB (Kubal) 1,30,000211 Tajikistan Tursunzoda Tajikistan Aluminium Company (Talco) 4,50,000212 Turkey Seydisehir Eti Alüminyum Inc 65,000213 UAE Jebel Ali Dubal (Dubai Aluminium Co) 10,40,000

214 UAETaweelah, Abu Dhabi Emal (Emirates Aluminium) 8,00,000

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(t/year)215 Ukraine Zaporozhye Zaporizhsky Alyuminievy Kominat (Zalk) 1,20,000216 United Kingdom Fort William Rio Tinto Alcan - Lochaber Smelter 42,000217 USA Evansville Alcoa - Warrick Operations 2,70,000218 USA Hawesville Century Aluminum of Kentucky LLC 2,50,000219 USA Sebree Century Aluminum 2,00,000220 USA New Madrid Noranda Aluminum Inc. 2,80,000221 USA Massena Alcoa - Massena Operations 1,35,000222 USA Mount Holly Century Aluminum 2,24,000223 USA Ferndale Alcoa - Intalco Aluminum Corp. 2,80,000224 USA Wenatchee Alcoa - Wenatchee Works 1,84,000

225 USAState Metal Industries Camden

226 Venezuela Mantanzas CVG Venalum 4,48,000227 Venezuela Puerto Ordaz Alcasa - (Aluminios del Caroni C.A.) 1,70,000

Page 6 of 6

ANNEXURE-2

ALUMINA REFINERY OF L&T

ANNUAL OPERATING COST - ALUMINA

( For 3.0 MMTPY )

Job No. :A811 Estimate Validity Sept 2015 Production : 3 000 000 MT SL. NO. DESCRIPTION UNIT UNIT RATE ANNUAL ANNUAL COST RATE/MT

Rs. REQUIREMENT Rs. Rs.

A. VARIABLE

A.1 RAW MATERIALS

1 BAUXITE MT 500 9 000 000 4500 000 000 2 CAUSTIC SODA MT 26 000 180 000 4680 000 000 3 LIME MT 5 000 90 000 450 000 000 4 FLOCCULANT ( LIQUID ) Kg 210 734 880 154 324 800 5 FLOCCULANT ( POWDER ) Kg 210 1 286 000 270 060 000 6 SULPHURIC ACID Kg 4 1 125 000 4 500 000

OTHER MATERIALS LS 400 3 000 000 1200 000 000 A.2 ENERGY

1 COAL MT 4 500

1 800 000

8100 000 000

2 FUEL OIL

HFO - CALCINATION MT 30 000 241 100 7233 000 000

DIESEL MT 48 000 13 500 648 000 000 3 ELECTRICITY

GENERATION DUTY- For alumina KWh 22 600 000 000 132 000 000

GENERATION DUTY- For Others KWh 22 360 000 000 79 200 000

4 SELLING & DISTBN. ( PME ) MT 350 3 000 000 1050 000 000

TOTAL ANNUAL VRIABLE OPERATING COST

28 501 084 800

9500.36

B. FIXED

B.1 WAGES & SALARIES

1 EXECUTIVES PERSONS 12 00 000 360 432 000 000 2 NON - EXECUTIVES PERSONS 6 00 000 840 504 000 000

e.2 COMPANY OVERHEADS (

As 35 % of B1) 35% 327 600 000

B.3 REPAIR & MAINTENANCE

- @ 2.5% OF PLANT & MACHINERY LS 2.5% 158 649 806 - 0 5% OF BLDG. &CIVIL WORKS LS 0.5% 15 810 817

B.4 INSURANCE & TAXES

-@ 0.1% OF CAPITAL COST LS 0.1% 13 468 461

TOTAL ANNUAL FIXED COST 1 451 529 084 483.84

TOTAL OPERATING COST 29 952 613 884

9984.2

SALES REVENUE

UNIT RATE QTY TOTAL REVENUE

(RS. PER YEAR)

TOTAL SALES MT Rs. 18,480/MT

( $ 280 /MT ) 3 000 000 55440 000 000

Document No.: A811-6842-OC-001-01 Sheet 1 of 1

A-15 S-15 O-15 N-15 D-15 J-16 F-16 M-16 A-16 M-16 J-16 J-16 A-16 S-16 O-16 N-16 D-16 J-17 F-17 M-17 A-17 M-17 J-17 J-17 A-17 S-17 O-17 N-17 D-17 J-18 F-18 M-18 A-18 M-18 J-18 J-18 A-18 S-18 O-18 N-18 D-18 J-19 F-19 M-19 A-19 M-19 J-19 J-19 A-19 S-19 O-19 N-19 D-19 J-20 F-20 M-20 A-20 M-20 J-20 J-20 A-20 S-20 O-20 N-20 D-20

-16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

A Pre-Project Phase

1Appointment of Technology supplier by L&T

2 Conceptual Basic Engineering

3 Detailed Feasibility Study (DFS)

4 Financial Investment Decision

5Environmental & Other Stautory Clearances

6 Forest Clearance

S. N.

Activity Description

Project Zero Date

Land Possession

MECHANICAL COMPLETION(Streams 1 & 2)

COMMISSIONING(Streams 1 & 2)

MECHANICAL6 Forest Clearance

7 Land Acquisition and rehabilitation

B Project Execution Phase

1 Basic Engineering

2 Detailed Engineering

3 Construction

4Pre Commissioning & Commissioning

PROJECT : Odisha Alumina Project

LOCATION : Odisha, IndiaPROJECT SCHEDULE FOR ALUMINA REFINERY PROJECT A811 00 1342 SCH 001

Project Zero Date

Land Possession





LOCATION : Odisha, India

OWNER : L&T

JOB NO. : A811 No.

A

Chk.

28-09-2015 With Draft Report SKG

Date Issued for By

PROJECT SCHEDULE FOR ALUMINA REFINERY PROJECT

Rev./ Apv

VKLA811-00-1342-SCH-001

KGKP

Project Zero Date

Land Possession





[1]

ANNEXURE-4

Alumina Refinery project of L&T

Evaluation of Alternative Sites

The proposed industry being mineral based, involving transportation of as high as 9.0

MTPA of bauxite, it is of paramount consideration that the refinery should be located

as near the bauxite deposits as possible. Based on the techno-economic feasibility , it

is felt appropriate that the length of the conveyor meant for transporting bauxite

should not exceed 15 Km. Under this consideration, three potential sites were

identified, a comparative features of these alternative sites being provided below.

Parameters Site – I

(Kushumsila) Site - II

(Rampur) Site - III

(Majhiguda)

Latitude 19° 27’ 19° 28’ 19° 26’

Longitude 83° 17’ 82° 58’ 83° 20’

Village in the Vicinity

Kushumsila village is within the proposed

area

Badadarla village is within the proposed

area

Majhiguda village is within the proposed

area.

Distance from nearest city/ town

Kalyansinghpur, a small town is about 12 Km away

T. Rampur Block HQ is 10 Km away

Kayansinghpur is 15 Km away

Elevation of the site, above MSL

(avg)

380 m 720 m 340m

Land pattern Fairly flat land, mix of barren and agricultural land (single crop)

Mix of barren and agricultural land (single crop), with undulations

Fairly flat land, mix of barren and agricultural land (single crop)

Land availability (in acres)

Adequate land is available



Private / Government

55:45 60:40 80:20

Agriculture land Mostly single crop low yield type

Mostly single crop low yield type

Mostly single crop low yield type

Distance from mines

10 Km 20 Km. Conveyor routing poses a huge

challenge due to terrain constraints.

16 Km Conveyor has to cross a state high way and a

river

Displacement involved

800 650 1000

Water body and source of water

Nagavali river, 3 Km away

Indravati reservoir, 16 Km away

Nagavalli river, 1 Km away

Road connectivity Bounded by SH-45 T Rampur – Kashipur MDR in the vicinity. Road condition is not very good

SH-45 is 2 Km away

Rail connectivity Nearest railway station is Sikarpai, on K-R line

of ECoR, 5 Km from

plant site. However, take off point is from Keutiguda, 20 Km away from the site based on feasibility study.

Nearest rail head is at Junagarh, 30 Km

away. However, due

to terrain constraints, the rail connectivity is infeasible

Nearest railway station is Sikarpai, on K-R line of

ECoR, 8 Km from plant

site. However, take off point is envisaged from Keutiguda, 16 Km away from the site.

Religious, Archeological Monuments

Nil Nil Nil

[2]

Parameters Site – I (Kushumsila)

Site - II (Rampur)

Site - III (Majhiguda)

Forests No RF No RF No RF

National parks & Wildlife sanctuaries

None within 10 km None within 10 km None within 10 km

Rampur location is eliminated primarily due to two reasons viz,

1. Railway connectivity is not feasible

2. Conveyor will be too long and its route will pose challenges of adverse terrain

Although the factors relating to the other two sites viz, Kusumsila and Majhiguda are

generally comparable, Kushumsila is preferred due to the following reasons.

1. Proximity to bauxite deposits, being shorter by 6 Km than Majhiguda. This is likely

to reduce power consumption by about 3 MW as compared with Majhiguda and

avoid crossing of a state highway and a major river, which entails considerable

capital cost, noise pollution and additional land.

2. Lower capital cost of about Rs 220 Crore, as compared to Majhiguda, due to

difference in conveyor length.

3. Lower operating cost of Rs 9.0 crore per year on recurring basis, due to lower

power consumption of conveyor.

4. Avoidance of potential environmental impacts in form of noise and dust for the

increased length of conveyor.

5. Comparatively less acquisition of private land.

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