PRE- FEASIBILITY REPORT (In terms of provision of EIA Notification 2006)
For
Expansion of Maton Rock Phosphate Mine
from 0.18 Mtpa to 1.0 Mtpa with new
Beneficiation plant of 1.0 Mtpa
At
Maton Rock Phosphate Mine (Maton Mine),
Tehsil: Girwa District: – Udaipur- 313 004
(Rajasthan)
By
Hindustan Zinc Limited Rajasthan
Submitted to Ministry of Environment, Forest & Climate Change
(MoEF&CC) New Delhi
July – 2017
Contents 1.0 EXECUTIVE SUMMARY. 2.0 INTRODUCTION OF PROJECT
2.1 Identification of Project and Project Proponent 2.2 Brief Description of Nature of Project 2.3 Need for the Project and its importance to the country 2.4 Demand and Supply Gap. 2.5 Import Vs Indigenous Production 2.6 Export Possibility 2.7 Domestic and Export Market 2.8 Employment Generation.
3.0 PROJECT DESCRIPTION
3.1 Type of Project 3.2 Location 3.3 Alternate Sites Considered 3.4 Size or magnitude of Operation 3.5 Project description with Process details 3.6 Raw material required along with estimated quantity likely source,
marketing area of final product/s, Mode of transport of Raw material and finished.
3.7 Resource optimization / recycling and reuse envisaged in the project, if any
3.8 Water & Power Availability & Source 3.9 Waste Generation and its Management
4.0 SITE ANALYSIS
4.1 Connectivity 4.2 Land Form, Land use and land ownership 4.3 Topography 4.4 Existing Land Use Pattern 4.5 Existing Infrastructure 4.6 Soil Classification 4.7 Climatic data and secondary sources 4.8 Social Infrastructure available
5.0 PLANNING BRIEF
5.1 Planning Concept 5.2 Population Projection 5.3 Land use planning
5.4 Assessment of Infrastructure Demand. 5.5 Amenities and Facilities
6.0 PROPOSED INFRASTRUCTURE
6.1 Industrial Area 6.2 Residential area (Progressing 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 Water management 6.9 Solid Waste Management 6.10 Energy requirement
7.0 REHABILITATION AND RESETTLEMENT
Policy to be adopted (Central/State) in respect of the project affected persons including home out sees, land out sees and landless labourers.
8.0 PROJECT SCHEDULE AND COST ESTIMATES
8.1 Project Schedule 8.2 Capital Cost Estimates 8.3 Environment Protection Capital Cost estimates
9.0 ANALYSIS OF PROPOSAL (Final Recommendations)
9.1 Financial Benefit 9.2 Employment generation due to project 9.3 Social Benefits
Annexure 1- Layout Plan of Project Site
1.0 EXECUTIVE SUMMARY
Hindustan Zinc Limited (HZL) is Asia’s largest non-ferrous metal producer of Zinc and Lead and is Head office at Udaipur, Rajasthan. HZL is world's second largest integrated producer of Zinc with a global share of approximately 6.2%. HZL has its operations in exploration, mining, ore processing, smelting and refining of Zinc, Lead, Cadmium, Copper, Silver and Rock Phosphate. It is also a major producer of Sulphuric acid, as a by-product of Lead-Zinc metal processing. HZL also has interest in Solar, Wind and Thermal power generation. Hindustan Zinc Limited’s Rock Phosphate Mine at Maton Village in Udaipur, Rajasthan is presently operating at a capacity of 0.18 MTPA, for which an environmental clearance was granted by MoEF&CC vide letter No. J-11015/169/2009-IA.II (M) dated 17.03.2010. The project mine lease area is 143.13 Ha. The project is under possession of about 114.92 ha land within the Mine lease area and another 80.53 Ha area outside the mine lease area used for office, colony, OB dump and other non-mining activities, thus the total area being 195.46 Ha. The mine is operational since 1970, except for a brief stoppage during 2001-2009 due to poor economic viability & currently operating at reduced capacity. This proposal is for expansion of the Ore Production capacity from 0.18 Mtpa to 1.0 Mtpa and also for installation of a new Ore Beneficiation plant of capacity 1.0 Mtpa. The produce from this project is proposed to be used in the company’s captive Ammonium Phosphate Fertilizer Complex proposed to be installed at Biliya, Chittorgarh for which TOR has been granted by MoEF&CC on 29th May 2017 vide letter No. F.No.J-11011/350/2016-IA.II (I). The Maton mining expansion project requires an additional 165.0 ha land adjoining the present lease boundary for waste dumping & Ore Beneficiation and the tailing pond. No Forest Land is proposed to be acquired for the project. The total reserves and resources is 8.48 Mt, it is proposed to mine through open cast mining method. During the life of the project, it is expected that about 165 Mt of OB and 3.0 Mt of tailings shall be generated and stored over ground in the project area.
The proposed acquisition of land calls for Resettlement and Rehabilitation of the people and hence triggers the National / State R&R policy. An additional 3700 m3/d of water is required for proposed mine expansion & new mill requirement. Additional requirement will be met out from existing/new Udaipur Sewage Treatment Plant. Zero discharge is being maintained. Mine dewatering due to intersection will be consumed in the process. For this proposed expansion, power requirement is 8.0 MW after expansion which will be met through AVVNL.
The project envisages a direct employment to about 325 people and a substantial investment in the social sector through its CSR intervention.
2.0 INTRODUCTION OF PROJECT 2.1 Identification of Project and Project Proponent 2.1.1 Identification of Project
The Maton Rock Phosphate mine is an opencast mine located at Village Maton, Tehsil Girwa, District Udaipur, and Rajasthan. It is located at about 12 km southeast of Udaipur at a latitude 24°32’34’’ and longitude 73°47’30’’ and falls in the Survey of India toposheet No. 45H/14. The Phosphate deposit of Maton is located in a hill, which trends NE-SW. Site is well connected by asphalt road from Udaipur. The nearest airport is at Dabok about 12 Km NW of the project site. The nearest railway station is Rana Pratapnagar which is 8 km to the NW of Maton.
The deposit was discovered by the Geological Survey of India (GSI) in 1966-67. There after an exploration program for the assessment of the deposit was under taken. Based on the finding of GSI, HZL acquired the lease on 17.03.1970 for a period of 20 years with a view to develop the deposit as a captive mine for meeting the in-house requirement of Rock Phosphate for the production of Phosphoric Acid at its plant at Debari, Udaipur.
Maton Rock phosphate mine have been engaged in the mining of Phosphorite ore since inception at 0.06 Mtpa capacity. The initial lease area of 247.96 ha was granted on 17.03.1970. Subsequently the lease was renewed after the first approval period for ten years w.e.f. 16.03.1990. Thereafter the lease was granted an extension as second approval over a reduced area of 143.13 ha, after surrendering of forest land for a further period of ten years w.e.f 16.03.2000. The lease is valid upto 31.03.2030. The mine was non-operational during 2001-2009, due to unfavourable market conditions & currently operating at reduced capacity. This expansion project will supply phosphate for its proposed fertilizer plant at Biliya, Chittorgarh.
Clearance was granted by MoEF&CC for 0.18 million TPA ore production from Maton mechanized Opencast mine vide letter no. J-11015/169/2009-IA.II (M) dated 17.03.2010. Consent to operate presently granted by Rajasthan SPCB for its operation is vide letter no. F(Mines)/ Udaipur (Girwa) / 1828 (1) /2015-2016/ 2263-2267 dated 08.09.2015 valid till 31.03.2018. The instant proposal is for expansion of the Rock Phosphate mining capacity from 0.18 Mtpa to 1.0 Mtpa of ore production and installation of a beneficiation plant of capacity 1.0 Mtpa.
2.1.2 Project Proponent
Hindustan Zinc Limited (HZL) is the only integrated Lead & Zinc
manufacturer in India and owns captive lead and zinc mines at Rampura Agucha, Rajpura Dariba, Kayad, Sindesar Khurd and Zawar Mines that cater to the requirement of lead and zinc concentrate for its smelters located at Chanderiya, Dariba & Debari. It also has a Melting facility at Pantnagar.
HZL is also engaged in the mining of Rock phosphate, presently having annual production capacity of 0.18 Mtpa at its only mines at Maton village, district Udaipur. All the mining operations are based out of Rajasthan.
2.2 Brief Description of Nature of Project 2.2.1 Nature of the Project
The present proposal is for expansion of an existing mechanised open cast rock phosphate mine at Maton, Udaipur District, Rajasthan from the present capacity of 0.18 Mtpa to 1.0 Mtpa of ore and is classified as “Category-A” by Ministry of Environment, Forest & Climate Change, New Delhi as per the EIA notification dated on 14th September 2006 and further Amendments.
2.2.2 Size of the Project
The proposed rock phosphate deposit lies within the lease area of 143.13 ha with an estimated ore reserves and resource of approx. 8.48 Mt with average grade of 20.88% of P205. The target production capacity of mine proposed is 1.0 Mtpa. The Ore produced shall be beneficiated in 1.0 Mtpa Ore Beneficiation plant proposed to be installed in the project site to increase the grade above 31.5% P205.
2.2.3 Location of the Project/
Maton Mine is located at about 12 km Southeast of Udaipur, at a latitude 24032’34’’ and longitude 73047’30’’ and falls in the Survey of India toposheet No. 45H/14. The nearest railway station is Rana Pratapnagar on Udaipur - Chittorgarh broad gauge line of North - Western Railway at about 8 km away. The area is connected by airways with the airport being at Dabok which is at about 12 km. NW on Udaipur-Chittorgarh National Highway No. 76. The Mine is well connected by asphalt road from Udaipur city.
2.3 Need for the Project and its Importance to the Country
Indian Fertilizer industry is one of the vital industries for Indian economy, since it manufactures a very critical raw material for agriculture. The main objective of the Fertilizer industry is to ensure the supply of primary and secondary nutrients in the required quantities.
The Fertilizer industry in India has performed a vital role in enabling the necessary increase in the use of plant nutrients for achieving the objectives of self-sufficiency in food grains production and accelerated and continuous agricultural growth. Rock phosphate constitutes as a basic feed stock for manufacture of Phosphatic Fertiliser. In India the economy being predominantly based on agriculture, the Fertilizer application to the cultivable lands plays a pivotal role in getting desired crop production. To meet, the food requirements of ever increasing population, as per the Planning Commission, the utilization of NPK fertilizers is expected to increase at the rate of 4% till 2020.
India is net importer of its Phosphate requirements to the extent of 90%. Indigenous sources are able to cater only upto about 10% of the total requirement. The imports inter alia includes Rock Phosphate, Phosphoric acid which is an inter-mediatory for production of DAP and NPK fertilizers, Mono Ammonium Phosphate and Triple super phosphates. India is presently importing about 7.5 Mt of Rock Phosphate and the balance is met by indigenous resources to the extent of about 1.5 Mt (of different grades). Out of 1.5 Mt, HZL is contributing 0.18 Mt from Maton Mine. Considering the huge gap in Demand and Supply, HZL is proposing to increase / expand its capacity from 0.18 to 1.0 Mtpa.
2.4 Demand and supply Gap.
Against the annual demand of 10 Mt, India produces only 1.5 Mt of which 1.2 Mt coming from Rajasthan. Rock phosphate is a major ingredient for making SSP and DAP fertilizers and India imports almost 85% of it. According to the Geological Survey of India, has an estimated 250 Mt Rock Phosphate reserves with 150 Mt of it is expected to be in the Fertilizer grade.
2.5 Import Vs Indigenous Production
The present production of Rock phosphate in India is estimated at 1.5 Mt whereas the imports are estimated as 7.4 Mt. If we consider the likely increase in consumption @4.8% per year, the gap between Demand and supply is likely to increase further. Whereas, on accounts of limited resources available with Rajasthan State Mines and Minerals Limited (RSMML) (which is the main producer) and MP Mining Corp, the overall domestic production is going to remain stagnant.
2.6 Export Possibility
As India is already having scarcity of Rock phosphate for its domestic consumption, the chances of export do not exists in near future.
2.7 Domestic and Export Market
India has very limited resources of Rock Phosphate as against the Demand. The major use of Rock Phosphate in India is for manufacture of SSP, DAP, MAP, TSP, Phosphoric acid, Di-calcium Phosphate and elemental phosphorus. The Rock Phosphate from proposed expansion is proposed to be supplied as a feed stock to SSP, Phosphoric Acid manufacturing either for standalone use or for blending purpose. There is no export market for rock Phosphate in India as per the reasons given above.
2.8 Employment Generation.
The proposed expansion would provide direct employment opportunity for about 325 persons (50 Executives and supervisors and 275 skilled and unskilled manpower) besides indirect employment for maintenance of mining equipments, service providers and transportation etc.
3.0 PROJECT DESCRIPTION 3.1 Type of Project
The proposed project is for an expansion of the mechanized Open Cast mining of Rock phosphate from 0.18 Mtpa to 1.0 Mtpa along with a new 1.0 Mtpa Beneficiation plant for up gradation of mineral. The detail of Beneficiation is described in Section 5.1.
3.2 Location
Maton Mine is located at about 12 km southeast of Udaipur, at a latitude 24°32’34’’ North and longitude 73°47’30’’ East and falls in the Survey of India toposheet No. 45H/14. The phosphate deposit of Maton is located in a hill, which trends NE-SW, rising nearly 100 m above valley level. The climate is semi-arid with an average annual rainfall of 600 mm. The temperature varies from 43.1°C in summer to as low as 2.2 °C in winter. The area is drained by a nallah, which is a tributary of non-perennial Ahar River which feeds Udai Sagar Lake. Maton mine receives power at 33 KV from Aklingpura substation of AVVNL. The nearest railway station is Rana Pratapnagar on Udaipur - Chittorgarh broad gauge line of North - Western Railway at about 7.1 km away in NW direction and Umra R.S is located at about 1.9 km in SSW direction. The area is connected by airways with the airport being at Dabok which is at about 11 km in NW direction. NH 76 (Udaipur – Chittorgarh) is passing at distance of 6.1 km in NNE direction, NH-8 (Mumbai – New Delhi) passing at a distance of 9.5 km in NW direction and SH-32 (Sadri - Banswara) passing at a distance of 6.4 km in SW direction. The Mine is well connected by asphalt road from Udaipur city.
The Ahar River is flowing in the buffer zone of the mine at a distance of 0.7km towards Northeast from the mine lease boundary. In addition, the Udaisagar lake and the Bagdara Talav are located in buffer zone of the mine at a distance of 1.4km (NE) and 2.9km (S) respectively from the mine lease boundary. The Project site and surrounding area of 10 km radius from the mining lease boundary does not have any protected areas such as National Parks/ Wildlife Sanctuaries/ biosphere reserve/ Tiger Reserve/ Elephant Reserves etc. 13 reserve forests (RFs) namely Segara RF (0.1 km, E), Umara RF (0.1 km, S), Hinlashia RF (1.4 km, NNE), R.F near Duniamata village (1.9 km, NNE), Bagdara RF (2.1 km, ESE), Hora RF (2.5 km, W), RF near Lakarwa (3.7 km, NE), Panwari RF (4.5 km, NNE), Amarbir RF (4.6 km, ESE), RF near Dhauji ki Bawari (4.8 km, NNW), Bara Magra RF (6.0 km, NNE), RF near Ambua village (6.2 km, SSW) and Kantia RF (7.5 km, NNE) located in the buffer zone of the mine. The general location map is as shown below-
3.3 Alternate Sites Considered
No alternate site is applicable since ore deposit is present at operating Maton mine. The beneficiation plant shall be located in the proposed land to be acquired.
Maton
Mines
3.4 Size of Operation
The proposed project is to produce 1.0 Mtpa Rock phosphate Ore from the mechanized opencast mine by expanding from the present 0.18 MTPA along with a new Ore Beneficiation plant of 1.0 Mtpa. The salient features of the proposed project are given in Table 3.2
TABLE-3.2
SALIENT FEATURES OF THE PROJECT
S. No. Description Details
1 Name of Mine Hindustan Zinc Limited Maton Rock phosphate Mine
2 Mine lease area 143.13 ha
3 Mine Lease No ML-6/89
4 Ore mineral Rock Phosphate
5 Area under possession 195.46 Ha
6 Area to be acquired 165.0 Ha
7 Reserves & Resources 8.48 Million Tonnes
8 Average Grade 20.88 % P205
9 Ore body Width 3 m to 10 m.
10 Overall Strike Length & Direction 1.20 kms , N40ºE- S40ºW
11 Ore body Dip 50º - 80º towards N50ºW
12 Mineable Reserves 5.1 million Tonnes
13 Established Depth Upto 100 mRL (590 mtrs)
14 Mode of Entry Haul Road
15 Method of Mining Open Cast Mechanized Mine
16 Ore Production 1.0 Mtpa
17 Ore Beneficiation 1.0 Mtpa
18 Transportation of Concentrate By Truck/ Dumpers
19 Total Waste Rock Generation 165 Mt
20 Total Waste Dump area 170 Ha (including existing 40 ha waste dump area)
21 Tailing Generation 3.0 Million Tonnes
22 Tailing pond area 10 Ha
23 Power requirement & Source 8.0 MW From AVVNL & 1500 KVA DG set for emergency purpose
24 Water requirement & Source 3700 KLD from existing/new STP Udaipur
25 Manpower requirement (Nos) About 325 persons
26 Project Cost 404 Crores
27 Environment Protection Cost 44 Crores
3.5 Project description with Process details 3.5.1 Geology
The Rock of Maton area belongs to Aravalli Super group of Proterozoic age, strikes N 40°E-S40°W and dips at 50-80° degree’s towards N50° W and display a synformal structure plunging moderately due NE. Dolomite and argillaceous dolomite is the oldest formation. Next in the stratigraphic column is ortho-quartzite and jaspery-quartzite, which hosts stromatolitic rock phosphate. The rocks overlying rock phosphate are phyllite, which grid into mica-schist at places. Rock Phosphate in general is unconsolidated, soft to medium hard in nature, except in few patches where it is compact and cherty. The ore forming mineral is mainly Fluor-apatite (Ca5 (P04)3F).
The phosphorite horizon in the Maton area extends over a strike length of 1.2 km. Thickening and thinning of the horizon is quite common. The thickness of the horizon varies from 3.0 m to as high as 15.0 m.
3.5.2 Exploration
In 1970 Geological survey of India initiated the exploration and carried out drilling of 2868.86 m in 28 boreholes (designated as MPBH). Hindustan Zinc Limited drilled 100.67m in two surface boreholes (HZM-1 & HZM-2) at the time of taking over of the prospect from GSI, to validate the orebody configuration at 600 mRL. HZL conducted an exploratory drilling program in 1991 to establish the orebody geometry and spatial correlation of the ore zones. A total 1540 m of surface drilling in 18 holes was carried out. The drilling was completed in March 1994. Initially it was thought that the phosphorite ore body was faulted & tabular in shape. On detailed exploration it was observed that the ore body is of lensoidal shape. The lenses were named as W1, E1, E2, & B-Block. The second phase of surface exploratory drilling programme commenced in 2011. Total 1.93 sq. km. area was covered in this phase from section S2 in South to N63 in North. During this phase 22220.55 meters of diamond drilling comprising of 127 boreholes was carried out, which concluded in Jan-2014. The previous exploration revealed that the orebody is open at depth, hence deeper level exploration program has been initiated in Jun-2017, it is planned to drill 17450 m in 47 boreholes for resource enhancement and 2500 m in 9 boreholes for geotechnical studies which will help in deriving the mining parameters. The exploration is in progress and a total of 3350m have been completed as on 31-Jul-2017.
3.5.3 Ore Reserves
The reserve has been estimated by Datamine Software using geo-statistical
method and statistical analysis. Reserves are taken to the ultimate planned pit limit. The mine recovery factors have been applied, to the resource numbers to derive the reserves. The factors used are 95% recovery and 5 % dilution. The combined Mineral Resources and Ore Reserves of Maton Mines of M/s Hindustan Zinc Limited as on 31 March 2017 were estimated to be 8.48 Mt with average grade of 20.88 % of P2O5.
3.5.4 Depletion of reserves:
During the plan period of 2015-16 to 2016-17, 0.056 Mt of ore reserves have been depleted.
The ore reserves at Maton Rock phosphate mine is as under –
CATEGORY Mt %P2O5
A) Reserves Proved 1.59
26.87
Probable 3.47 22.24
Total 5.06 23.69
B) Resources Measured (M) - -
Indicated (I) 1.07 16.18
Total M & I 1.07 16.18
Total Inferred 2.35 18.33
Total Reserves & Resources 8.48 20.88
The in-situ geological reserves/resource as on 01.04.17 is shown in the table below.
Lens PROVED PROBABLE Reserve INDICATED INFFERED RESOURCE
Mt % P2O5
Mt % P2O5
Mt % P2O5
Mt % P2O5
Mt % P2O5
Mt % P2O5
W1 0.15 26.82 0.40 24.12 0.55 24.84 0.65 17.47 0.80 16.16 1.45 16.75
E1 1.23 28.30 0.16 25.93 1.39 28.02 0.19 9.74 1.00 18.20 1.19 16.84
E2 0.16 16.32 1.37 22.37 1.53 21.75 0.23 17.91 0.44 22.71 0.67 21.06
BB 0.06 24.68 1.53 21.24 1.59 21.37 0.11 17.73
Total 1.59 26.87 3.47 22.24 5.06 23.69 1.07 16.19 2.35 18.33 3.42 17.66
As per United Nation framework of Classification (U.N.F.C), Reserve and Resources position as on 01.04.17 is as follows: (in Mt)
Lens Mineral Reserves (111) Mt
Mineral Reserves (121 & 122) Mt
Mineral Resources (332) Mt
Mineral Resources (333) Mt
W1 0.15 0.40 0.65 0.80
E1 1.23 0.16 0.19 1.00
E2 0.16 1.37 0.23 0.44
BB 0.06 1.53 0.11
Total 1.59 3.47 1.07 2.35
3.5.5 RESERVES AND ANTICIPATED LIFE OF MINE
A total of 5.1 Mt of ore Reserve and Resources, (1.59 Mt Proved & 3.47 Mt probable reserves) and 3.42 Mt of resources have been estimated upto 100 mRL with average grade of 20.88 %. At a production rate of 0.18 Mtpa in the first year and then 0.4 Mtpa in second year and then targeting @1.0 Mtpa in the subsequent years, the present life of the mine upto 450 mRL will be about 7 years considering limits of practical mining open pit of reserves and resources. As explained previously, exploratory drilling done will further augment the reserves and resources which would increase the life of the mine beyond 10 years.
3.5.6 Mining 3.5.6.1 Method of Mining:
The deposit is being worked by mechanised open cast mining method with benches of 10 m minimum width and 10 m height. The bench height and width parameters have been optimized after studies on geo-technical slope stability were carried out by CIMFR. Dhanbad. The study recommended a slope of 45˚ in footwall ortho-quartzite upto a depth of 100 m from highest point. Beyond 100 m the overall pit angle along footwall has to be revised according to local conditions. The mining of the deposit is intended to continue with the same method. The present working is confined in E1, E2, B1 & W1 lens only. For extracting the ore, hangwall overburden is removed first, then ore is mined out and then waste of Foot Wall is removed on the bench to reduce the dilution to the maximum possible extent and thus the bench is formed. The heavy earth moving machineries deployed for mining are diesel operated. With expansion, there would be increase in the size of the machines viz. excavators and dumpers to cope up the excavation requirements. The crusher capacity would also be increased to meet out the crushing requirements of expanded ore production.
Drilling and Blasting:
At Maton Mine the bench height in waste (Over Burden) and ore is 10 mtrs. The hole dia. for both ore and waste benches is 115/165 mm. The drilling is carried out with the help of track mounted diesel engine powered DTH (Down the Hole) drill machines of 115/165mm button bit. Drill machine with dust extractor system is being used for controlling Air Borne Dust. ANFO (Ammonium Nitrate Fuel Oil) is used as the column charge along with Primary charge in the form of PETN cast booster or cartridge slurry explosive. The initiation of the explosive is being done by down the hole
delay Non Electric shock tubes (NONEL). For interhole delay the trunk line delay detonators are used on surface tie up for improved blast performance, reduced ground vibration and noise level. The max. charge is kept within limit to minimize environmental impact of blasting. The no. of blasts required in ore and waste clubbed together are approx. 20-25 per month. However by increasing the size of the blast, number of blasts would be reduced to 14 to 15 per month. Depending upon the strata condition, bench height and rock type, spacing and burden is being varied. Typical Drill & Blast design parameters are as under.
Description Details
Spacing 4 to 5 m
Burden 3 to 4 m
Depth of holes 10.5 to 11m
Sub grade drilling 0.5 to 1.0 m
Primary charge/Booster charge 250 gm PETN Booster / Cap sensitive slurry cartridge of 83/125 mm dia (12.5 to 25 Kgs)
Column charge SME/SMS (Side Mixed Emulsion/slurry)
Charge Length 50-60% of hole depth
Powder factor 4 to 5 T/Kg of explosive
Pattern of holes Staggered or Square Pattern
Detonators Millisecond delay detonators.
Avg. No. of holes in a blast 140 to 150 nos.
Avg. Quantity of explosive/hole 100 Kg. (Approx.)
Quantity of explosive/Blast. 14-15 T (Approx.)
Safe storage of explosive Explosive will continue to be sourced from licensed magazines.
Secondary breaking: Oversize boulder’s (Boulder of size more than 1 mtr.) size reduction is done by Hydraulic Rock Breaker. Secondary Blasting i.e. Pop Shooting or Plaster shooting is avoided. With proposed expansion, additional rock breaker would be put in to use to cope up the breaking of boulder. Efforts would be made with improved blasting techniques as described above to keep generation of boulders below 1% of total blasted volume. Pre-splitting: To achieve stable slopes and control the blast damage to walls, pre-splitting techniques would be adopted at final pit limits. The technique would involve, drilling small dia holes (100-115 mm) at a close spacing of 1.0 to 1.2 mtrs. along the final bench profile line at an angle of 70 to 80 degrees as per the recommended slopes. These holes would be then charged lightly with 25-32 mm cartridges which are suspended in to holes axially tied with a detonating fuse. A charge factor of 0.40 to 0.60 Kg / sq meter would be maintained depending upon
the strata conditions. The holes are then fired instantaneously and are normally fired prior to the production blast in front of limit line. The final production blast is called “Trim Blast”. In Trim blast in front of Pre-Split, one or two small dia production hole line is drilled at a standoff of 1.0 to 1.5 mtrs to reduce the charge concentration near final wall. The trim blast is fired with inter hole delay of 42 ms or 65 ms with inter row delays of 100 ms so as to have proper burden relief for holes and reduced vibrations on wall. The excavation is then done maintaining the slope. However exact parameters of pre-splitting can only be established after a number of trial blasts with varying spacing and/or explosive charge and the most appropriate pattern would be adopted. The machinery to be deployed for expanded capacity would be as tabulated below.
TABLE 3.6
DETAILS OF MACHINERIES
Equipment Capacity Existing (Nos.) Proposed (Nos.)
Excavator 2.0 cum 5 2
9-11cum - 4
Rock Breaker 1 1
Dumper
20 MT 24 -
35 MT - 5
100 MT - 20
Drill 165 mm 1 6
115 mm 1 1
Water Sprinkler 10 KL 2 -
40 KL - 2
Track Dozer D65 E 2 -
D375 A - 3
Front End Loder 4 cum 1
Crane 50T 1
Tyre Dozer - 1
Motor Grader 2
Tyre Handler - 1
The expanded production (ore and overburden) requirement is 75,000 to 80,000 Tonnes of rock per day. The capacity of machinery has been arrived at after considering the availability and utilization of the equipments. Six Excavators (4 of 9 -11 m3 & 2 of 2.0 m3 for ore and miscellaneous jobs) and twenty no. of dumpers of 100 T & 5 Dumpers of 35 MT are proposed. 3.5.6.2 Mineral Beneficiation
The ROM ore from the mine after primary crushing transported to coarse ore stock pile by belt conveyor.
Tentative Beneficiation process flow sheet
3.5.6.3 Conceptual Mine Plan
The present working is confined to E1-W1 & E2 lens only. The present entry is through a ramp along the hill on Footwall (FW) side. Hangwall (HW) overburden is being removed first, then ore is mined and then FW is excavated thereby forming the bench and reduced dilution. The ore body is proven up to 100 mRL and the pit will be economical up to this depth of approx 240 meters from the top (450 mRL). It is proposed to keep a pit slope of 40˚ in footwall and 45˚ in Hangwall. A detailed Geotechnical study would also be conducted to arrive at optimal bench slopes and overall angles and depth of pit so as to achieve optimum depth and mineral extraction.
The mine operation is planned on three shifts per day of 8 hours duration basis. The mine is scheduled to work for 365 days/ year. Ore Production Schedule for Mining Plan period five years after grant of EC would be as follows.
Year Ore Production
1 1,80,000
2 4,00,000
3 8,00,000
4 10,00,000
5 10,00,000
3.5.6.3 Selection of Dumping Site
The overburden generated from mines will be stacked at earmarked Dump locations which are at North east of strike direction and East of the strike direction. In addition to that it is proposed to acquire about 165.0 ha of land on the hang wall and south east side of the pit for dump stack, tailing pond and Beneficiation plant. These sites have been selected as the area doesn’t bear any mineralization.
3.6 Raw material required along with estimated quantity likely source, marketing area of final product/s, Mode of transport of Raw material and finished product.
The major raw materials to be consumed for the proposed mines expansion and Ore beneficiation include the following. All material transport shall be through trucks, except water through pipelines.
S. No Description Source Remarks
1 Fresh Water 3700 cum/day from existing/new STP Udaipur
2 HSD 40 KL/Day – Open market Sourcing
Mining operations
3 Explosives 7250 MT/Annum Mining operations
4 Lubricating oil 8 KL/Month – Open market Sourcing
Mining operations
5 Electricity 8.0 MW from AVVNL. Ore Beneficiation process and mining lighting
6 Sodium oleate 1000 TPA – Open market sourcing
Ore Beneficiation process chemicals
7 Sodium Silicate 6000 TPA – Open market Ore Beneficiation
sourcing process chemicals
8 Sodium Carbonate 1500 TPA – Open market sourcing
Ore Beneficiation process chemicals
9 Sodium Hydroxide 1500 TPA – Open market sourcing
Ore Beneficiation process chemicals
10 LDO/Kerosene 500 tons– Open market sourcing
Ore Beneficiation process chemicals
11 H2SO4 acid 1500 tons – Open market sourcing
Ore Beneficiation process chemicals
12 Flocculent 15 tons – Open market sourcing
Ore Beneficiation process chemicals
13 Grinding media 1800 tons – Open market sourcing
Ore Beneficiation process chemicals
14 Liner- screen wear 800 tons – Open market sourcing
Ore Beneficiation process chemicals
3.7 Resource optimization / recycling and reuse envisaged in the project, if any
The following Resource Optimization opportunities are envisaged in the project,
· The HSD consumption shall be optimised by deploying high capacity
high efficiency HEMM. · The waste lubricating oil generated from the HEMM’s shall be
recycled through registered recyclers.
· Ground water intersection and Rainwater collected in the mine pit shall be completely reused for mining operations like dust suppression, crusher operation and Ground water recharge.
· The Ore Beneficiation tailing shall be slurry disposed to tailing dam.
The supernatant liquid shall be reused for mining and beneficiation operations.
· The top soil excavated from the land proposed to be acquired shall
be separately stored and conserved for use in rehabilitation and vegetation of OB dumps.
· The tailings disposed to tailing dam shall have unrecovered P2O5 of
about 6%. Efforts will be made for suitable utilization of the same.
· The OB generated from the mining operations shall be utilized for tailing dam embankment construction and OB stack retainer wall construction.
3.8 Water & Power Availability & Source 3.8.1 Water Availability & its Sources
An additional 3700 m3/d of water is required for proposed mine expansion & new mill requirement. Additional requirement will be met out from existing/new Udaipur Sewage Treatment Plant. Zero discharge is being maintained. Mine dewatering due to intersection will be consumed in the process.
3.8.2 Power Availability & its Sources
For this proposed expansion, power requirement is 8.0 MW after expansion which will be met through AVVNL grid. New power transmission line with a substation to meet the requirement of 8.0 MW for Beneficiation plant is proposed.
3.8.3 Emergency Power DG set of 1500 KVA capacity having acoustic enclosures for emergency power is introduced as a part of 1.0 Mtpa ore production & new 1.0 Mtpa Beneficiation plant.
3.9 Waste Generation and its Management 3.9.1 Solid Waste
The waste rock generated from the mining will be systematically dumped at earmarked overburden dumps with proper stabilization and plantation. The physico-chemical analysis of the waste rock indicates that the waste is non-hazardous in nature and not likely to cause any adverse impacts. Waste generated by mining will be dumped at pre decided sites in ultimate dump configuration of 10 x 10 meters or 5 x 20 m lifts after obtaining necessary approval. Each lift would have slope angle of 400 and overall final slope of 270. There is no sub grade mineral available as such there would not be need for stacking of sub grade mineral separately. The proposed excavation of overburden for five year is as follows.
Year Quantity (T)
1 9000000
2 1700000
3 2500000
4 3000000
5 2800000
Total 10,90,00,000
The other major solid waste to be generated is the Ore Beneficiation
Tailings. During the life of the mine, about 3.0 Mt of tailing is estimated to be generated. The tailing will be stored in a specially constructed Tailing dam (Impoundment Area). The bottom of the tailing pond shall be lined with impervious layer (HDPE lining) to avoid any seepage in ground water. The embankments shall also be impervious with suitable core and cap material of construction to avoid any seepage through embankment. The material for construction of the tailing dam would primarily consist of mine waste. Thickened tailing will be pumped for discharge into the tailing dam. A pumping station will be built in the downstream corner of the dam and water will be recycled through closed circuit piping system and reused in process.
3.9.1 Liquid Waste, effluents
There are different sources of Liquid effluent likely to be generated in the proposed project,
· The rain water runoff from the OB dumps shall carry high suspended
solids due to siltation. The same shall be diverted through garland drain to the desilt pit and stored in rainwater harvesting structures for ground water recharge.
· The mine drain water accumulated in the mine pit includes the
groundwater intersected and the rain water accumulated. This shall be used for mining operations like dust suppression, crushing and further used for ground water recharge.
· Effluents are likely to be generated from the Ore beneficiation plant
during any process upsets of power failures. The same shall be collected in the dyke area of the plant and recycled back to the froth floatation tanks. Any excess spills coming into the garland drain around the Beneficiation plant shall be pumped into reclaim water reservoir and reused back into process.
· The tailing dam effluents shall be reclaimed through decantation and
used back into process through reclaim water reservoir.
· A garage shall be constructed for vehicle maintenance. Effluents are likely to be generated from this area due to washing and maintenance activities. The effluents collected shall be oil skimmed and reused in process or other application as suitable.
· There shall be sewage effluent generation from the sanitation and
canteen facility to be provided to workforce. The sewage shall be treated in an STP and utilized back in process, dust suppression or afforestation.
4.1 Site Analysis 4.1.1 Connectivity
Maton Mine is located at about 12 km Southeast of Udaipur, at a latitude 24°32’34’’ North and longitude 73°47’30’’ East and falls in the Survey of India toposheet No. 45H/14. The nearest railway station is Rana Pratapnagar on Udaipur - Chittorgarh broad gauge line of North - Western Railway at about 7.1 km away in NW direction and Umra R.S is located at about 1.9 km in SSW direction. The area is connected by airways with the airport being at Dabok which is at about 11 km in NW direction. NH 76 (Udaipur – Chittorgarh) is passing at distance of 6.1 km in NNE direction, NH-8 (Mumbai – New Delhi) passing at a distance of 9.5 km in NW direction and SH-32 (Sadri - Banswara) passing at a distance of 6.4 km in SW direction. The Mine is well connected by asphalt road from Udaipur city.
4.2 Land Form, Land use and land ownership 4.2.1 Land Form
The general topography of the Mining Lease area is flat to undulate with a hillock of about 100 mtr height having the mineralization/Ore deposit. HZL has the surface rights over the land where mining and related activities are being carried out.
4.2.2 Land Use
Total Mine lease area is of 143.13 ha. The project is under possession of about 114.92 ha land within the Mine lease area and another 80.53 Ha area outside the mine lease area used for office, colony, OB dump and other non-mining activities, thus the total area being 195.46 Ha.
The pre operational land use pattern of mining lease is as follows:
The pre-operational land ownership within the MLA was Govt. land and the area outside the MLA was private land. The primary land use pattern was Grazing land, Agricultural land and Barren Land.
The present land use detail of acquired land is as per following table.
Land Use Area (ha.)
Built up 4.42
Mine pit 19.84
Waste Dump 40.0
Vegetative Cover 62.83
Others 68.37
Total 195.46
Additional land of about 165.0 Ha is proposed to be acquired for the project for installation of Ore Beneficiation plant, Tailing Dam and Overburden storage. This includes the land within the MLA (about 28 Ha.) and outside (137 Ha.). The land proposed to be acquired is contiguous with the present acquired land.
4.2.3 Land Ownership
For the present land acquired, Village wise details of total land acquired from within the mine lease and outside the mine lease area is as below.
Village Govt Land Private Land Total
Maton 133.1450 49.8378 182.9828
Umra 10.3750 1.2540 11.0290
Lakadwas 0.8216 NIL 0.8216
Kharbadia NIL 0.0260 0.0260
Total 144.3416 51.1178 195.4594
The primary land use of the proposed acquisition is agricultural and residential area. No forest land is proposed to be acquired.
4.3 Topography
Topography of the area is shown in following page.
TOPOGRAPHICAL FEATURES OF THE AREA 4.4 Land Use Pattern of Mining Lease
Details of the land is as given in sec 4.2.2 and 4.2.3 above 4.5 Existing Infrastructure and Amenities
The project site presently has the basic infrastructure viz. Office building, Crusher, electrical transmission line, all weather access road and quarters for the security personnel. Infrastructure for fuel supply, explosives supply, water supply, vehicle maintenance, etc as required for the mining operations are available from the city of Udaipur located within 10 kms form the project site. All basic amenities like residential facility, school, hospital, recreational facilities, are available at Udaipur.
4.6 Soil Classification
The texture of soil is mostly sand and silty sand in the study area. The PH of the soil in the study area ranged from 7.0-7.7. The soil is neutral to slightly alkaline.
4.7 Climatic data and secondary sources
The meteorological data recorded during the monitoring period is very useful for proper interpretation of the baseline information as well as for input prediction models for air quality dispersion. Historical data on meteorological parameters will also play an important role in identifying the general meteorological regime of the region.
The year may broadly be divided into four seasons:
Winter season December to February
Pre-monsoon season March to May
Monsoon season June to September
Post-monsoon season October to November
The generated data then compared with the meteorological data generated by nearest Indian meteorological Department (IMD) station located at Dabok civil airport, Udaipur at a distance of (11 km NE).
ENVIRONMENTAL SETTING OF THE SITE
S. No. Particulars Details
1 Location Maton Village, Girwa Tehsil, Udaipur District, Rajasthan State.
2 Topo sheet No. 45H/14
3 Geometric Coordinates
ML Area
Corner Latitude Longitude
A 24°32’34’’ N 73°47’30’’ E
B 240 33'25.79" 730 47' 42.38''
C 24032’41.82” 730 47' 45.95''
C1 24032' 20.74" 730 47' 28.18''
E1 24032' 15.65" 730 46' 39.99''
F 24032' 50.91" 730 47' 24.57''
O 24032' 26.85" 730 47' 16.77''
4 Climatic conditions (Based on IMD - Dabok) Source: Atlas of windroses -IMD (1971-2000)
Annual Maximum Temp: 43.1° C Annual Minimum Temp: 2.2°C Annual Average Rainfall: 654.3 mm Predominant Wind direction – SW, W and NE
S. No. Particulars Details
5 Present land use of mine site
Agriculture, grazing, and barren land
6 Nearest Highway NH-76 (Udaipur – Chittorgarh) – 6.1 km, NNE)
SH-32 (Sadri - Banswara) – 6.4 km, SW
NH-8 (Mumbai – New Delhi) – 9.5, NW
7 Nearest Railway Station
Umra RS – 1.9 km, SSW
Rana Pratap nagar - 7.1 km, NW
8 Nearest Airport Dabok - 11 km, NE
9 Nearest Village Maton - 0.4 km, N
Khardadia – 0.6 km, NNW
Lakarwas – 1.0 km, E
10 Nearest Town/City City and District HQ - Udaipur (10 km, NW)
11 Hills/Valleys There are few mountain peaks ranging about 100 to 150 mtrs in the buffer zone
12 Reserved/Protected forest
13 Reserved Forests 1. Segara RF – 0.1 km, E 2. Umara RF – 0.1 km, S 3. Hinlashia – 1.4 km, NNE 4. R.F near Duniamata village- 1.9 km, NNE 5. Bagdara RF – 2.1 km, ESE 6. Hora RF- 2.5 km, W 7. RF near Lakarwa – 3.7 km, NE 8. Panwari RF – 4.5 km, NNE 9. Amarbir RF – 4.6 km, ESE 10. RF near Dhauji ki Bawari- 4.8 km, NNW 11. Bara Magra RF – 6.0 km, NNE 12. RF near Ambua village – 6.2 km, SSW 13. Kantia RF – 7.5 km, NNE
13 Protected areas as per Wildlife Protection Act, 1972 (Tiger reserve, Elephant reserve, Biospheres, National parks, Wildlife sanctuaries, community reserves and conservation reserves)
Nil
14 Defence Installations The Udaipur Cantonment area is located at an aerial distance of 13 km from the lease area.
15 List of Industries Major Mines RSMML at distance of 5 km and HZL’s Debari Zinc Smelter at 8 km. There are 6 nos. of SSP plants and two RIICO industrial
S. No. Particulars Details
estate within 5 km from the project boundary
16 Socio-economic factors The area is well connected to Udaipur city and the community is primarily dependent on agriculture and urban labour. About 165 Ha land is proposed to be acquired and National/State R&R policy will be adopted.
17 Seismicity Seismic zone-II IS:1893(Part 1) 2000
4.8 Social Infrastructure available
The location is very near to the city of Udaipur and all the basic social infrastructure as listed below are available.
Hospitals
Bank
Post Office
School
Police Station
Shopping Market
Sports Infrastructure
Cinema Hall
Club House
5.0 PLANNING BRIEF 5.1 Planning Concept
It is proposed for expansion of mine from 0.18 Mtpa to 1.0 Mtpa of ore production. The mining will be through open cast method by conventional Shovel Dumper combination and Drilling and Blasting. The operations will be fully mechanised. The ore excavated will be stacked at ore yard from where will be loaded in dumpers and will be crushed to <12 mm size. Separate stock yards of crushed ore will be maintained as per the grade. It is proposed to establish the crushed ore to be beneficiated in a new Ore Beneficiation plant proposed to be installed. The beneficiated ore shall be sent to phosphoric acid plant.
The details of beneficiation plant are described as:-
The mine is planned for 3 shifts of 8 hours basis for 365 days / year for a minimum 85% availability basis. The specifications of acid grade phosphorite concentrate is as below,
S. No Constituent Normal Value Mean Value
1 P2O5 >30% >32%
2 SiO2 <10% <7%
3 CO2 <3% <2%
4 Iron and Aluminium oxides <3.5% <3%
5 MgO <0.75% <0.5%
6 CaO <45% <47%
7 Fluoride <4% <2%
8 Chloride <0.05% 0.02%
9 Organic Matter <2% <1.5%
10 Moisture <16% <10%
The typical Ore quality would be,
S. No Constituent Concentration (%)
1 P2O5 22
2 SiO2 38
3 CaO 28
4 MgO 4
5 Fe2O3 3
6 Al2O3 2
7 LOI 3
The sample consists of yellowish brown to gray coloured hard and compact lumps. The ore contains mainly d cryptocrystalline apatite [50-55%] as phosphate mineral finely associated with major amounts of very fine grained ferruginous cherty quartz [30-35%]. Hydrated iron oxides [5-7%], clay [3-5%], carbonates [5-7%] and mica [traces] occur in minor amounts. The ROM [~ 1000mm] is crushed to mill feed size of ~ 10 mm in minimum 3 stages at 600 tph. The crushing circuit comprises of single stage open circuit primary crushing [either jaw or gyratory crushers] followed by two stages of secondary crushing [cone / reduction gyratory crushers] and tertiary crushing [cone/ High pressure grinding rolls] in closed circuit with screens. The tertiary crusher- screen under size is mill feed. A provision of scrubbing – spiral classification of mill feed before grinding is also placed in the circuit to treat clayey friable ores. The mill feed is ground in ball mills in closed circuit with hydro cyclones to – 200 mesh size at 150 tph. The cyclone over flow and re-circulating middling [scavenger float and cleaner tails] are thickened in feed thickener. The thickened feed is conditioned in conditioner 1 and 2 with depressants [Sodium silicate and sodium carbonate/ sodium hydroxide] and collector mix [sodium oleate and LDO/kerosene]. The intensively conditioned pulp is floated in rougher flotation battery [mechanical] at slightly high pulp density of 35%S. The rougher tails are further subjected intensive scavenger flotation [mechanical] using collector mix in stages. The scavenger flotation tails are thickened in tailing paste thickener and disposed to tailing pond/dam. The rougher float is cleaned thrice at moderate to dilute pulp density [25-15] after conditioning with depressant with/ without sodium oleate collector booster dosage either in [mechanical] flotation battery or flotation columns. The cleaner tails and scavenger float is re circulated back to feed thickener. The III
cleaner float [preferably column cell] is fed to concentrate thickener and then dewatered using either disc filter [capillary ceramic] or pressure filter [with cake air blow facility]. The reclaimed water from concentrate thickener, filter, tails thickener and feed thickener are re circulated. The plant is designed to treat a minimum of 1.0 million tons per year ore and to produce acid grade concentrate of 0.5 million tons per year. The crushing circuit is designed for 1 shift- 8 hours operation for 350 days / year while the rest grinding, concentration, dewatering and other accessories are designed for 3 shift – 8 hours operation for 350 days/ year. The mean plant availability is fixed at 85%. The plant is designed to treat a min 20% P2O5 grade ore, producing acid grade concentrates >30%P2O5 with minimum weight percent yield of 50%. Table 1; Conditions and results of scaled down open cycle test of old HZL Maton rock phosphate plant Grind: 500 gms of -10# sample stage ground to -200# in 175 x 350 mm rod mill, 6.5Kg rod charge, 67%S, in 5 stages with stage grind time of 5 minutes each. The processing of the Rock Phosphate in Ore Beneficiation and the resultant beneficiated ore expected is as given below. Details Pilot plant test on Froth Flotation Process :
Stage Cell gms RPM pH Reagent Kg/t CT min FT min
RF 250 1500 10 Na silicate 2 5
RF 250 1500 10 Na Oleate+oil mix 0.8 5 2
SF 250 1500 10 Na silicate 1 5
SF 250 1500 10 Na Oleate+oil mix 0.4 5 2
IClF 500 1500 10 Na silicate 0.5 5
IClF 500 1200 10 Na Oleate+oil mix 0.2 5 2
IIClF 500 1500 10 Na silicate 0.3 5
IIClF 500 1200 10 Na Oleate+oil mix 0.1 5 2
IIIClF 500 1200 10 Na silicate 0.2 5 2
Beneficiated Ore Expected quality:
Products % S Wt% P2O5 % grade P2O5 % Distn
Concentrate 17 50.1 33.22 78.2
IIICl T 2 4.9 22.8 5.3
IICl T 4 12.1 16.31 9.3
I ClT 7 17.6 5.69 4.7
SF 3 3.6 7.08 1.2
ST 5 1 2.35 1.3
Feed Cal 33 100 21.27 100
SF+RF 15 88.3 23.77 98.7
RF 17 84.7 24.48 97.5
ICL F 12 67.1 29.41 92.8
II CL F 11 55 32.29 83.5
RT 6 15.3 3.46 2.5
RT+ICLT 6 32.9 4.65 7.2
RT+ICLT+IICLT 5 45 7.79 16.5
RT+ICLT+IICLT+IICLT 5 49.9 9.26 21.7
ICLT+IICLT+IIICLT+SF [Rec middling]
4 38.2 11.38 20.5
Reagent consumption
Reagent Dosage kg/t
Sodium silicate 4
Sodium carbonate for pH adjustment 1
Sodium hydroxide for pH adjustment 0.5
Sodium oleate as collector 1.2
Kerosene as collector supplement 0.3
Table 2 Tentative material and metallurgical balance of scaled down lab test [ref Table1]
S. No
Stream TPH M3/h TPH %S %P2O5 %P2O5
Product Ore Water pulp Grade Assay
1 Condioner 1 & 2 feed 100 100 200 50 21.27 100
2 Water to R cell 100 0
3 Rougher cell feed 100 200 300 33 21.27 100
4 Rougher tails 15.3 239.7 255.5 6 3.46 2.5
5 Rougher float water 453
6 I cleaner feed [RF] 84.7 414.3 498 17 24.48 97.5
7 I cleaner tails 17.6 233.8 251.4 7 5.69 4.7
8 I cleaner float water 312.6
9 II cleaner feed[IClF] 67.1 492.1 559.2 12 29.41 92.8
10 II cleaner float water 243.3
11 III cleaner feed[IIClF] 55 445 500 11 32.29 83.5
12 III cleaner float water 39.7
13 Conc. Thickener feed[IIIClF] 50.1 244.6 294.7 17 33.22 78.2
14 Dewatered Conc cake 50.1 4.9 55 91 33.22 78.2
15 Water reclaim by Conc dewater 239.7
16 Final tails[RT,I,II&III Cl T] 49.9 1053.9 1004 5 9.29 21.8
17 Final tails to tail pond 49.9 50.1 100 50 9.29 21.8
18 Water reclaimed by Tail Thick 1003.8
19 Theoretical water req 55
20 % water reclaimed 95%
Table 3 Tentative data utilities, supplies, product and other plant data for 1 million tons / year treatment
Supplies and Utilities Rate Yearly consumption
Ore > 22% P2O5 Av 24%P2O5 125-150 [Av 137tph] 1000000 tons[1mt/y]
Fresh water/ton of ore 1.0-1.5m3[Av1.25m3/t] 1250000 m3
Total water/ton of ore 3 -5m3/t [Av3m3/t] 5000000 m3
Sodium oleate kg/t of ore 0.6-1 kg/t[ 0.8 kg/t] 1000 tons
Sodium silicate kg/t of ore 4-6 kg/t[ 5 kg/t] 6000 tons
Sodium carbonate kg/t of ore 1-2 kg/t[ 1.5 kg/t] 1500 tons
Sodium hydroxide kg/t of ore 1-2 kg/t[ 1.5 kg/t] 1500 tons
LDO/Kerosene kg/t of ore 0.3-0.5 kg/t[ 0.4 kg/t] 500 tons
pH neutralizing H2SO4 acid 1-2 kg/t[ 1.5 kg/t] 1500 tons
Flocculent 0.01-0.02 kg/t[ 0.015 kg/t] 15 tons
Grinding media kg/t 0.8-1.8 kg/t[ 1.5 kg/t] 1800 tons
Liner- screen wear kg/t 0.6-1 kg/t[ 0.8 kg/t] 800 tons
Power kwh/t 55 -65 kwh/t [60 kwh/t] 600000 MW
Conc > 30% P2O5 Av 32%P2O5 63-90 [Av 77 tph] >0.5 mt/y [Av 0.56mt/y]
Tails 50-80[Av 60tph] <0.56mt/y
Total Plant area m2 400,000 m2
Minimum tail pond area 400,000 m2 [ Min]
5.2 Population Projection
As per 2001 census, 25646 persons inhabited in 10 villages around Maton Mine. The distribution of population in the study area is as per the table below.
TABLE 5.1 DISTRIBUTION OF POPULATION IN STUDY AREA
S. No. Village Total Family Population
1 Maton 229 807
2 Kharbadia 218 1195
3 Lakadwas 1171 5855
4 Kaladwas 601 3650
5 Eklingpura 338 1860
6 Umra 809 5779
7 DhuniMata 57 245
8 Boiki Pancholi 240 1200
9 Kanpur 897 4485
10 Kamlod 114 570
Grand Total 4674 25646
5.3 Land use planning
Proposed land planning details in ha. area as under-
Particulars Area required (ha)
Pit Area 70
Waste Dump Site1 70
Waste Dump Site 2 20
Waste Dump Site 3 80
Plant 16
Tailing dam 10
Office 5
Green Belt around periphery 20.25
Others/Open spaces 69.21
Total 360.46
5.4 Assessment of Infrastructure demand.
The additional infrastructure requirements for the proposed project are as follows,
S. No Description Requirement Status
1 Road for inward and outward movement of material and goods
6 mtr road Exists
2 Garage for vehicle maintenance
25 dumpers and 25 mining machineries
Shall be constructed
3 Office 50 Personnel Existing shall be upgraded
4 Canteen and sanitation facility for mine workers
325 personnel Shall be constructed
5 STP for domestic effluents
325 personnel Shall be installed
6 Change room/Rest room for mine workers
325 personnel Shall be constructed
7 Electrical infrastructure 8 MW power supply Shall be installed
8 Weigh bridge 0.5 Mtpa product dispatch
Shall be installed
9 Emergency power supply
1500 KVA DG shall be installed
0 Vehicle parking area 30 vehicles Shall be provided within the project area
11 Residential colony for mine workers
325 personnel
No residential infrastructure will be constructed as the nearby villages and Udaipur city provides
adequate facility
12 HSD storage 100 KL Shall be installed
5.5 Amenities and Facilities
Education: There exists Primary, Secondary and Senior Secondary Schools and colleges at Udaipur.
i) Social Infrastructure like Hospitals, Post Office, Bank, Police Station,
Bus Station, Facility Exists at Udaipur and neighbouring villages ii) Telecommunication, LPG services, Marketing stalls, Sports
infrastructure – exists at Udaipur and neighbouring villages. iii) Recreation- Existing Recreation facilities such as cinema hall, Sports
infrastructure at Udaipur.
6.0 PROPOSED INFRASTRUCTURE
6.1 Industrial Area Infrastructure is already available for 0.18 Mtpa capacity. The same infrastructure will be upgraded to cater to the expansion.
Road Network – two way road along the mine.
Power transmission – 4 kms of 33 KV transmission line installed through AVVNL.
Internal roads within mine boundary.
Office buildings, workshops, ware house etc
The following would be developed as part of the proposed expansion in premises
Truck parking facility
Beneficiation Plant and Tailing dam
Workshops, buildings and warehouses
Fuel storage facility and DG set
Canteen, Rest rooms, Sanitation facility and Sewage Treatment facility
6.2 Residential Area:
No residential Area shall be developed as the neighbouring villages and Udaipur city already has adequate residential facility available to cater to requirement of the project.
6.2.1 Social Infrastructure
The Maton Mines is very near to the city of Udaipur and its suburbs and all the social infrastructures as listed below are available as detailed in section 5.5 above. Looking to above, company doesn’t propose for creation / construction of any Social Infrastructure. However the company would continue its CSR activities in surrounding villages of the project site.
6.3 Green Belt
HZL has planted 28000 plants saplings till date in an approx. area of 20.25 ha. Thick vegetation will be developed along acquired land boundary to attenuate the noise and Dust. The plantation will be carried out along the roads within the boundary to arrest dust. The plantation will also be carried out on the waste dumps slopes as and when they mature i.e. reach to final limits after their stabilization. Plantation will also be done on the top of waste dump benches. Around 33% acquired area shall be developed with plantation.
6.4 Connectivity
The project site is located 12 Km South East of Udaipur city and is well connected by Jhamarkotra road from Udaipur. The nearest Airport is Dabok about 12 Km NW of the Maton Mine. The nearest railway station Rana Pratapnagar is 8 Km NW of Maton Mine. NH 76 is at 6 km NW from the ML area. As site is well connected, there is no requirement for any additional infrastructure except strengthening of internal roads.
6.5 Drinking water management
25 cum/day of drinking water would be required during the operations. Same shall be purchased from external sources in the same way as being done at present.
6.6 Sewerage System
As there will be no township facility developed within the boundary so no major sewerage waste would be generated. However, the sewage generated from the canteen facility, rest room and offices shall be treated in a proposed onsite STP and reused.
6.7 Industrial Waste Water management
The source of industrial effluents are the tailing pond water and garage effluent which shall be collected in the reclamation pit and recycled back to mining and Ore beneficiation operations. An oil trap system/skimmer shall be installed at the garage to strip off the oil from the garage effluents before reusing the effluents generated due to washing and maintenance.
The rain water runoff collected in the mine pit and the desilt pit around the OB dumps shall be suitably used for mining operations like drilling, dust suppression and excess for ground water recharge. Zero discharge shall be maintained at all times during operation.
6.8 Solid Waste Management
About 109.00 Mt of waste rock (Over Burden) would be generated from the mine proposed Mining Plan period of five year and total 165 Mt at conceptual stage. Waste rock would consist of quartzite, phyllite, Jaspery quartzite, etc. Mine waste from development areas shall be transported and dumped in a specifically assigned area i.e. waste dump area. The waste is non-hazardous in nature and not likely to cause any adverse impacts. The dumps will be stabilized by plantation of trees.
Tailing shall be generated from the Ore Beneficiation process. About 3.0 Mt of tailing is expected to be generated during the life of the mine. Tailing shall be stored in tailing pond specially constructed for the purpose.
The following mitigation measures for solid waste management shall be adopted:
· Adequate slope will be maintained to give proper stability to the
dump.
· Waste will be stacked & levelled systematically in layers.
· After reaching the benches to their ultimate height and location, plantation shall be done on slopes and top.
· Construction of garland drains around the Waste dump so that
surface run off from the dump is collected in a sump.
· Regular maintenance of the garland drains constructed around the solid waste dump to collect the surface run off.
6.9 Energy requirement
Presently Maton mine receives Power at 33 KV from Aklingpura substation of AVVNL located at 7 kms from the project site. Energy requirement post expansion shall be approx 8.0 MW. Power will be wheeled from AVVNL grid. The existing grid shall be upgraded by AVVNL for the wheeling of power and a suitable capacity substation shall be constructed within the project site.
7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN
It is proposed that about 165.0 Ha. of land shall be acquired for the proposed expansion of the mines, around the existing acquired lease area. The land proposed to be acquired is primarily government land. There would be no Forest land acquired for the project. The land acquisition process would be done as per Land Acquisition Act 1895 & State/National R&R Policy.
8.0 PROJECT SCHEDULE AND COST ESTIMATES 8.1 Project Schedule
The current production of rock phosphate ore of Maton mine is 0.18 Mtpa. It is proposed to increase its production of ore from 0.18 to 1.0 Mtpa. The mine will reach to the expanded capacity of 1.0 Mt in Year 3 / year 4. The Ore Beneficiation plant is expected to be operational within 24 months from the grant of EC by MoEF&CC.
8.2 Capital Cost Estimates
As the mining operation is going to be completely outsourced, there will be no capital cost on machineries. The only cost comprise of, office infrastructure, shifting of power line, small warehouse and beneficiation plant etc. The total Capital cost has been estimated at INR 404 crores. The cost of P2O5 (above 30%) concentrate will be 7500 per MT compare to imported concentrate of 6250 per MT. Considering the national interest the higher price of indigenous high grade P2O5 will not be a matter of concern as the company objective is to boost the agriculture sector by producing fertilizer indigenously.
8.3 Environment Protection Capital Cost Estim
Particulars Capital Cost in cr.
Excavation & installation of Dust control/suppression systems for crushers
5.0
Tailing Dam management (Land, HDPE lining, pumping system and water recycle line)
15.0
Tailing thickener for water conservation 20.0
Water recycling system 1.0
Plantation/Green belt development and drip irrigation system 0.5
Different Environmental Monitoring equipment & automation in Environment Monitoring & Safety
0.5
Construction of Garland drain and silt settling tank and recycle system for waste dump management
1.0
Installation of Sewage treatment plant and Oil grease trap system 0.5
Water tanker with pumps & Water hydrant system 0.5
Grand Total (Rs. in cr.) 44.0
9.0 ANALYSIS OF PROPOSAL (Final Recommendations) 9.1 Financial Benefit
The proposed project will reduce import of Rock phosphate and phosphoric acid thus saving in foreign exchange. It will supplement to bridge the gap in fertilizer demand v/s supply. This will also generate revenue to the state Government as well as Central government. The people around the region will get direct and indirect employment thus improves the financial and socio-economic status.
9.2 Employment generation due to project
The proposed expansion project will provide direct employment opportunities to around 325 employees. The existing project has already provided huge opportunity for development of the area and the proposed expansion Project is also anticipated to provide additional indirect employment opportunities to number of people from the Girwa tehsil and its surrounding area. The proposed expansion project will also bring in people for secondary employment like transporters, vendors, local canteen and tea stall operators etc. Sourcing of consumable will be carried out from local region which will also provide considerable opportunity for local economy.
9.3 Social Benefits
The proposed project shall proactively participate in the upliftment of socio economic index of the communities around the project site by way of financial and administrative support. The project will open up employment opportunities, directly and indirectly. There shall be opportunities for entrepreneurs to engage in many service sectors directly or indirectly associated with the project. The CSR approach of the company shall be towards sustainable livelihood management of the community around. There shall be focus on education, health, sanitation, drinking water, agriculture, water shed management, culture identity preservation, tribal welfare, welfare of socially weaker sections and marginalized people.
Annexure 1 Layout Plan of Project Site
