PRE-FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY Name of the Project Kaliapani Chromite Mineenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0... · 2015-08-21 · Kaliapani Chromite

Kaliapani Chromite Mine (ML area – 64.463 Ha.) with Production Capacity of 1.692 MTPA At Village Kaliapani, Tehsil Sukinda, District Jajpur, Odisha State

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M/s. Balasore Alloys Limited. 31

PRE-FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

S. No. Particulars Details

A. Name of the Project Kaliapani Chromite Mine

1. Chromite Ore Production

Capacity 1.692 MTPA

B. Location Details

2. Village Kaliapani

3. Tehsil Sukinda

4. District Jajpur

5. State Odisha

6. Coordinates Latitude N21002’9.82’’ to N21001’33.05’’ and

Longitude E85045’29.24’’ to E85046’28.24’’

7. Topo sheet No. F4516(73 G/16)

C. Lease Area Details

8. Mining Lease area 64.463 ha

9. Green Belt Development 14.25 ha

D. Cost Details

10. Project Cost Rs.1500.00 Crore

11. Cost of EMP(Capital) Rs.150.00 Crore

12. Recurring Cost/Annum Rs.85.00 Lakh

E. Others

13. Water Requirement Present water requirement is 347.2 KLD. This

is met from mine water & bore-well present

at mine. After expansion of project activities,

water demand & abstraction of ground water

shall be increased. The detail study regarding

same is going on and action shall be taken as

per findings. 14. Man power Requirement 1050

15. Extent of mechanization Dumper, Excavator, Drilling machine etc.

2.0 Introduction of the Project / Background Information

2.1 Identification of Project & Project Proponent

M/s. Balasore Alloys Limited (BAL) formerly Ispat Alloys Limited, has registered

office at Balgopalpur, District Balasore, Odisha. BAL, is an ISO 9001:2008, ISO

14001:2004 certified company having their Ferro Alloy plant at Balgopalpur,

District Balasore, Odisha.

Underground Mining is proposed over mine lease area of 64.463 Ha for

production of 1.692 MTPA chromite ore along with ongoing opencast mining which

is continued since Sept’2000.

Screening Category: As per EIA Notification dated 14.09.2006, as

amended on 1st December, 2009, the project falls under S. No. ‘1’ (Mining of

Minerals), Project or Activity ‘1(a) - (3)’, Category “A”.


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(B) Mining Lease Status

The Govt. of Odisha has issued Terms & Conditions that would govern the grant

of mining lease of 100.063 Ha vide their letter no VI-SM-108/99-3927/SM dated

24/5/1999. Further Govt. of Odisha has split up the total area of 100.063Ha into

two leases viz 64.463Ha (Non-Forest area), 35.6Ha (forest area) vide letter No

1864/SM BBSR Dt 16/02/2000. The Mining Lease Deed of 64.463Ha was

executed vide Lease Deed dated 17.07.2000 (Annexure-I). Lease Deed was

further modified on 01.01.2008 for change of name from Ispat Alloys Ltd. to

Balasore Alloys Ltd. Mining operation started from September’2000 in 64.463 ha

ML area in non-forest Govt. land as per all valid statutory documents available

since inception.

The Scheme of Mining along with progressive mine closure plan of Kaliapani

Chromite mine over 64.463 Ha has been approved by IBM vide letter no.

MS/FM/27-ORI/BHU/2014-15/4853 dated 27.03.2015 and the copy of letter is

enclosed as Annexure-II.

However, as per MoEF guideline dated 10.3.2015 as well as the subsequent

circular dated 30.3.2015 issued by Govt. of Odisha and land detail available from

DFO, Cuttack basing on certified land schedule as per Sabik settlement received

from concerned Tahsildar, the M.L. Area of 64.463 ha includes, 64.119 ha Forest

Land and 0.344 ha road.

Accordingly DFO, Cuttack Division has issued order for payment of NPV

(Annexure-II) and joint verification (Annexure-III) for forest land

involved/broken up area in the existing ML area of 64.463 ha. The lessee has also

initiated process to obtain approval of FDP within stipulated time.

2.2 Brief Description of the Nature of Project

The applicant intends to mine 1.692 MTPA of Chromite Ore from the allocated

mining lease area of 64.463 ha.

The mining lease over 64.463 Ha in village Kaliapani for chrome ore was executed

in favor of M/s Ispat Alloys Ltd (Now known as Balasore Alloys Limited) for 30

years. The same was executed w.e.f 17.07.2000. Consent to operate for the

mine has been obtained from Odisha State Pollution Control Board (OSPCB).

Environmental clearance for the project has been received from Ministry of

Environment, Forests & Climate Change (MoEF&CC), New Delhi with an annual

production capacity of 0.6 MTPA of Chrome ore by opencast and underground

including mining of blocked pillars in open pit mines by Drift and Fill mechanized

mining method vide Letter No J-11015/139/2012-IA.II (M) Dated 22nd August

2014.

As per EIA notification 14th September 2006, and subsequent amendments, the

proposed mine expansion falls under S. No. ‘1’ (Mining of Minerals), Project or

Activity ‘1(a) - (3)’, Category “A” and needs Environmental Clearance (EC)

from MOEF&CC, New Delhi.


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Kaliapani Chromite Mine is under active operation since 2000 by opencast mining

method. Chrome ore (>10%) is produced from this mine along with overburden.

Machines deployed are Wagon Drill Machine, Excavator, Dumper and Dozer etc.

Mine development and production of ore is done with the help of Excavator and

Dumper combination. However Drilling and blasting for development/production

overburden/ore is carried out in opencast pit for 8-10% of the total volume being

excavated due to strata being highly weathered.

It has been proposed to develop the mine in order to produce chrome ore by

adopting following methods of mining within the lease area.

a) Opencast Mining

Mining towards dip direction of ore body

Common boundary mining (Joint mining with adjacent lessee JSL)

b) Underground Mining

Boundary Pillar Mining (BPM)

Conventional Underground Mining

It is proposed to adopt the above methods of mining for winning ore to desired

level during proposed 5 years scheme period. There is a proposal in the scheme

period mining of chrome ore shall be executed with both opencast a well as

underground mining along with boundary pillar mining of blocked ore.

Chrome ore of this lease area is of fine-grained, brownish black colour to black

color friable ore. The associated gangue minerals are Magnesite, serpentine,

magnetite and limonite. Grain size of Chrome crystals varies between 0.1mm to

1.5mm. Hardness 2 to 4, sp gravity 1.6 to 3.0 and non-magnetic to feebly

magnetic in nature.

The cut-off grade of Chrome ore production is fixed at 10% Cr2O3. The usable

grade of chrome ore in Ferro Alloys Industry of the company is +40% Cr2O3

minimum with Cr/Fe ratio >2.0. These are produced from the mines, being

consumed in the captive plant of the lessee situated at Balasore, Odisha for

production of Ferro Chrome. Whatever ore having less than 40% Cr2O3 produced

is being kept as sub grade mineral stock for beneficiation and regularly fed to

Chrome ore Beneficiation Plant (COBP) of the company located in the lease hold

area.

There is no topsoil which will require handling. The other waste materials are

consisting of dark brown coloured lateritic soil and yellow to brownish limonite

etc. Three waste dumps are earmarked inside the lease areas which are active at

the start of scheme period for disposal of waste material being/to be generated in

the process of mining. However part of the waste material being/to be generated

will be utilized for strengthening of haul road, terraces and plantation areas.

Detailed studies were conducted and shall be conducted in future also for

optimization of waste dump capacity. Details of the same are included in

approved Scheme of Mining by IBM. Accordingly the additional waste (over

burden) from mines shall be accommodated in these 3 existing dumps.

Beneficiation of mineral rejects (-40% grade Cr2O3) is being continued in the

company’s own facility inside the lease, which has a capacity to beneficiate 20


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TPH. A detailed study has been made on different sub-grade chrome ore at

National Metallurgical Laboratory, Jamshedpur; for construction of full-fledged

chrome ore beneficiation plant consisting of screening, two stage grinding,

cyclone and spirals. It was observed that part of tailings of about 13% Cr2O3

grade are also generated during beneficiation process in addition to same for

<10% grade, which are being dumped in earmarked place, considered as rejects.

To reduce Cr2O3 content in the part of the tailings( >10% grade) and increase the

recovery of chrome content a detailed study has been made by IMMT

Bhubaneswar and a new process-flow sheet developed and incorporated for

further processing of the lot.

The tailing of the COB plant are being collected in 2 numbers ponds of size 20m x

20m x 4m made up of RCC floor and walls. The tailings are removed from the

pond by hydraulic excavator and kept outside for drying. After drying, the tailings

are being shifted through tipper and excavator combination to the earmarked

tailing disposal area within the lease area.

No reclamation of mined out land is proposed during the proposed scheme period.

Efforts are being taken to restrict/ reduce the degradation of land in the coming

years by limiting the activities by depth ward extension of mining. However,

during the coming years of mining in the lease hold area, it has been projected

that an additional area of 4.142 hectares of land will be utilized for systematic

development of the quarry during the period 2015-2016 to 2019-20 and by end

of conceptual period, a total area of 26.164 Ha of land will be utilized.

The plantation program during the coming years is shown in the Conceptual Plan.

Continuous plantation or similar plantation will be done at the waste dumps and

mined out areas. Environmental monitoring with respect to air, water, noise, etc

will be continued as per norms and guidelines. The existing land use shall be

changed during the scheme period and conceptual period since the mining

activity shall be extended and some fresh areas shall be utilized for mining and

other activities.

2.3 Need for the Project & Its Importance To The Country/ Region

More than 80% of the chrome ore mined in the country and the world is utilized

for the downstream processes of Ferro Chrome/ Charge Chrome Alloy production,

which in turn is utilized for the production of stainless steel and other high quality

alloy steels.

M/s Balasore Alloys Ltd has its Ferro Alloys plant located at Balgopalpur,

Balasore, Odisha. BAL is planning for expansion in its existing capacity. It is also

in the process of acquiring two more Ferro Alloys Plants in Odisha. Therefore the

total Ferro Chrome production capacity of Balasore Alloys Ltd will become

approximately 6,75,000 TPA. The chrome ore requirement for production of total

Ferro chrome quantity will be around 17, 00,000 TPA. BAL will meet this quantity

from its captive mine “Kaliapani Chromite Mine”. Hence in order to meet the

increased demand of chrome ore, it is proposed to enhance the capacity of mine

from 0.6 MTPA to 1.692 MTPA.


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Underground mining is environmental friendly. Dust pollution will be negligible

due to less excavation of OB/waste as compared to opencast mining. There will

not be any affect to quality of water and the air quality, except marginally for the

allied activity at the surface. Surface features shall not be disturbed. Mining will

be totally mechanized.

Considering above mentioned facts the proponent now has taken a decision to

start underground development for ore Band – I & II, so that by the end of the

opencast conceptual period there will be full-fledged ore production from friable

and hard zone of Chromite ore by underground mining.

2.4 Demand-Supply Gap

Demand

Chromite ore will be dispatched to company’s own Ferro chrome plants present at

various places, where the same will be used as raw material for making Ferro

chrome. The ore raised from the mine will be for captive use only.

Presently global Chrome alloy production (Ferro and Charge Chrome) is

estimated at 11.0 MTPA with India contributing at about 0.9 MTPA (8%) on

the wake of steady growth in Carbon (1380 MTPA), Stainless Steel (31 MTPA)

and Alloy Steel (20 MTPA).

Stainless Steel has grown at a CAGR of over 4% during the last 10 years and

is expected to grow @ 5% over next ten years. This will trigger similar growth

rate (6%) of demand for Ferro Chrome and hence Chrome Ore after factoring

scrap availability

36% of the worlds Chrome Alloys (4.25MTPA) are currently consumed in

China and the country imports – 9.4 MTPA of Chrome Ore/concentrate

However, in India the Stainless Steel has grown at the rate CAGR 12% over

the last 10 years and expected to grow @ 6-8% for the next years

Indian Ferro Chrome Industry has registered a significant growth @15% over

the last decade and expected to grow @ 5-6% in the next decade driven by

both domestic and export demand.

The Chrome Ore requirement in India is expected to grow @ 5%.

Supply

China is the largest producer of Ferrochrome (4.28MTPA , 36% of world

production) , South Africa is second largest (3.98MTPA, 34%) followed by

Kazakhastan (1.18MTPA) and India (0.9MTPA). 70% of total Chromite ore

reserves in the world are in South Africa followed Kazakhstan (17%),

Zimbabwe (5%),India (4%) and rest from others. Specially for India,

expedited exploration program will help to augment the country’s chrome ore

reserve.

Capacity utilization of Ferro-Chrome industry hovers around 80-85%.


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2.5 Imports Vs Indigenous Production

As the raw material for manufacturing of Ferro Alloys is available locally, there is

no requirement of import of Chromite ore. The ore raised from the mine will be

for captive use only for the production of Ferro Chrome Alloys.

The production of chrome ore during the last 5 years is given in the Table-1

TABLE-1

YEAR WISE CHROME ORE PRODUCTION

Year Production Quantity (tonnes)

2010-11 244260

2011-12 166507

2012-13 142962

2013-14 207989

2014-15 341051

2.6 Export Possibility

The ore raised from the mine will be for captive use only for the production of

Ferro Chrome alloys in the company's own plants. As such there is no scope to

export chrome ore from the mine.

2.7 Domestic/Export Markets

The major demand for Stainless Steel in our country had been traditionally for the

production of utensils. With the increasing pace of infrastructure development of

our country as well as increase in the production in the white goods and

automobile sectors, it is likely that there shall be substantial growth in the

domestic markets in the near future.

The produced ore will be used by the proponent for captive use only for

production of Ferro Chrome. The generated 1.692 MTPA of Chromite ore will be

fully utilized at the company’s own Ferro Chrome plant and hence no possibility of

export of chrome ore.

2.8 Employment Generation (Direct & Indirect) Due to the Project

During Construction- Direct 300, Indirect 600

During Operation- Direct 1050, Indirect 1500

3.0 Project Description

3.1 Type of Project Including Interlinked and Interdependent Projects, If any

Present proposal is for opencast & Underground mining over Kaliapani Chromite

Mine (ML area 64.463 ha) with production of 1.692 MTPA chrome ore production.

M/s Balasore Alloys Ltd has its Ferro Alloys plant located at Balgopalpur,

Balasore, Odisha. BAL is planning for expansion in its existing capacity. It is also


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in the process of acquiring two more Ferro Alloys Plants in Odisha. Therefore the

total Ferro Chrome production capacity of Balasore Alloys Ltd will become

approximately 6,75,000 TPA. The chrome ore requirement for production of total

Ferro chrome quantity will be around 17, 00,000 TPA. BAL will meet this quantity

from its captive mine “Kaliapani Chromite Mine”. Hence in order to meet the

increased demand of chrome ore, it is proposed to enhance the capacity of mine

from 0.6 MTPA to 1.692 MTPA.

3.2 Location (Map Showing General Location, Specific Location, And Project

Boundary & Project Site Layout) With Coordinates

The study area map is given in Figure-1.


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FIGURE-1

LOCATION MAP SHOWING LOCATION OF THE MINE SITE


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3.3 Details of Alternate Sites Considered

No alternative site is considered as the proposed project is being the

enhancement of production of Chromite ore from 0.6 MTPA to 1.692 MTPA within

the existing ML area 64.463 Ha.

3.4 Size & Magnitude of Operation

The mining project is proposed for expansion of Chromite ore from 0.60 MTPA to

1.692 MTPA which will be achieved by fully mechanized opencast and

underground mine.

3.5 Project Description With Process Detail

3.5.1 Geology

a) Topography

The area lies in the South-Western quadrant of the survey of India topo sheet No.

73 G/16. The Tomka-Mangalpur all weather road passes almost along the

northern lease boundary. This road connects the area with Jajpur- Keonjhar

Road, the nearest rail head on the South- Eastern Railways via-Mangalpur as well

as Tomka. At Tomka it joins with the Express Highway (Daitari -Paradeep) and

via-Duburi to Jajpur Road the total distance is 57 Km. The distance via-

Mangalpur where it joins NH 53 to Jajpur Road is 53 Km.

The Damsal Nala flowing towards south-west is the main drainage system of the

area and is 2 Km away from the lease area in N-W direction. This is the only

perennial stream adds as tributary to Brahmani river.

Systematic evaluation of the deposit commenced since 1960 in the chrome valley

and the reappraisal of chromite resources was carried out by G.S.I. during 1974-

76. Since 2000 after grant and execution of the lease Balasore Alloys Ltd started

detailed geological mapping and core drilling in order to assess the resources. The

area exhibits a pene plained topography marked by linearly disposed mounds of

low relief. The line of subsequent and obsequent slopes are not very well defined.

Waxing faces are more prominent than the winning faces. The maximum

elevation in the area is 182 mRL whereas the minimum elevation is 121 mRL. The

overall slope is from South-East to North-West.

b) Regional Geology

The sukinda ultramafic complex forms a part of the unfossilliferous

metamorphosed pre-cambrians of peninsular India. It is associated with the

sedimentary sequences in parts of Keonjhar, Cuttack and Dhenkanal districts of

Orissa studied by G.H.S.V. Prasad Rao et al. six sequences separated by

unconformities have been deciphered in this region. The Sukinda ultramafites

come in the second sequence of the succession and occur as intrusive. The

succession is given in the following:


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Sixth Sequence

Granite Intrusive Contact Shale, Carbonaceous shale, lava & tuff, Conglomerate, Sandstones

-------------------- Unconformity -------------------- Fifth Sequence Gabbro, Ultrabasic and Dyke swarms, Quartzite, Conglomerate

-------------------- Unconformity -------------------- Fourth Sequence Manganese bearing Shale

Banded Hematite Jasper, Shale

-------------------- Unconformity --------------------

Third Sequence Gabbro and ultrabasic (intrusive), Lava and Interbedded Grits, Conglomerate, Grit, Sandstone

-------------------- Unconformity -------------------- Second Sequence

Granit & Granit Gneiss Granophyre, Gabbro and Ultrabasic with Chrome Load Banded Hematite Quartzite, Banded Hematite Jasper, Conglomerate,

Ferruginous Shale and Phyllite

-------------------- Unconformity -------------------- First Sequence Metavolcanics, Chlorite Schist, Quartzite, BHQ, Mica Schist, Fuchsite Quartzite

The stratigraphic succession given by K.L. Chakrabarty, T.L. Chakrabarty and Tapan

Mazumdar (1980).

Stratigraphic Succession (K.L.Chakraborty, et. al.)

Alluvium

Laterite (Nickeliferous at places)

Dolerite

Granite and Granite gneiss

Orthopyroxenite (enstatites)

Ultramafic with chromite lode

Sandstone (Quartzarenite) Kolhan Group (?)

Conglomerate

-------------------- Unconformity --------------------

Iron ore group Banded iron formation with inter banded

volcanic tuff and alternation product

quartzite with intraformational Conglomerate

Basement Not Exposed


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The host rocks of ultramafites include contrasted types of metamorphic

associations. North of latitude 21000’ in topo sheet 73 G/12 and 16 the

ultramafites occur either as concordant emplacements within green schist facies

quartzites (e.g. Sukinda mass) or as disjointed pendants floating in biotite

hornblende granite (e.g. Kathpal mass). In contrast the ultramafites occurring

south of latitude 20056’ are sporadically distributed within granulite facies

assemblages (P.K. Banerjee, 1972). Systematic geological mapping has

established that the granulite facies rocks immediately south of latitude 20056’

mark the northern fringe of the Mahanadi valley charnochite-khondalite

association in this area while the low grade metamorphites north of latitude

21000’ are the southern outposts of iron ore stage of Bihar and Orissa. Thus the

ultramafic cluster is located near the contact between two different stratigraphy-

tectonic provinces.

c) Lithology

The ultramafic rocks along with the associated chromite ore bodies are intrusive

into the lower sequence of rocks. In Sukinda area these rocks are extensively

lateritised and except for the main pyroxenite band all the rock types lie under a

thick cover of lateritic soil.

The ultimafic body is a layered complex composed of alternate bands of chromite.

Chromite, dunite, peridotite and orthopyroxenite repeated in a rhvthmic manner.

The dunite and peridotite rocks are almost wholly serpentinised. In dunite skeletal

crystal of olivine lies within the ground mass of serpentine variety. In peridotite

both skeletal crystal of olivine and pyroxene are present. The orthopyroxene is

almost monominerallic and composed mostly of enstatite (P.K. Banerjee) with

miner olivine (R.N. Pattanaik)

The presence of numerous chert vein close to the chromite body and the cross

cut relations it bear with chromite band and ultramafics is a distinctive feature.

The ultramafics are intruded by dolerite dykes which after weathering altered to

montmorillonits. Small exposure of granite- granophyres are seen at southern

base of Mahagiri intruding in to quartzites.

The hornblende granite exposed to the west of Sukinda ultramafic body is

medium grained and shows a granophyric texture at places. This also contains

innumerable pods and pocket shaped inclusions of ultramafic rocks associated

with chromite.

d) Local Geology

Geology of Kaliapani Chromite Mine Area

The Kaliapani Chromite Mine is situated in the south eastern part of Sukinda

Valley. The area falls in Survey of India toposheet No.73 G/16, having total lease

hold area of 64.463 ha.


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Lithology

The local stratigraphic sequence of different litho units at established from field

observation of the lease and neighboring areas is given below:

Alluvium and Laterite

Pyroxenite

Yellow limonite with Goethite

Limonite with Chromite disseminations

Friable Chromite

Cherty Limonite

Sand stone and quartzite

A brief description of important litho units encountered in & around the area is

given below

Quartzite

The milky white colored massive quartzites are exposed in the south outside the

lease area along Mahagiri range. The quartzite is characterized by fine to medium

grained mosaic texture.

Limonite:

The ultramafics with pyroxenite – Dunite suite of rocks have been completely

altered into limonite. These are soft, yellow to brownish in color with low specific

gravity.

Chert

The chert veins cuts across the ultramafics and the ore body in all possible

directions. They are hard, compact and brownish in colour. They might have

originated during the process of serpentinisation.

Laterite :

The chromiferrous dark brown coloured laterite occurs as a capping over a major

part of the lease hold.

Based on the field observations in and around the area, it can be said that the

chrome ore mineralization is mainly controlled by litho stratigraphy. The chrome

ore bands are confined to the older ultramafics of dunite and peridotite. The

ultramafic formations comprising both the hanging wall and the ore band have

been completely limonitised by metasomatism and stand in site viz. limonitised

ultramafics or cherty limonite. Both the hanging wall and the ore bands are

occupied by limonite, which are derived from ultramafics.

There are two parallel running, NE-SW trending Chromite bands (called as Band-I

& II) that are chemically ferruginous in nature and physically friable. The bands

are generally sub-vertical dipping at an angle of about 70-85o North-west.


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The ultramafics of this area are extensively lateralized and except for the main

pyroxenite band, all the rock types lie under a thick cover of lateralized soil. The

placement of pyroxenite – Dunite suite (now altered to limonite) is still genetically

debatable.

Structure

The structural imprint of deformation is almost no discernible due to extensive

(weathering and hydro-thermal action) primary and secondary metasomatism

followed by weathering in the area. The ultramafics are confined to the south-

western part of the doubly plunging synform. Inclination of the lodes is almost

vertical. The friable zone dips slightly towards the north.

3.5.2 Reserves

Calculation is based on the reserves as 01.04.2013 (-) reserves depleted during

2013-14 and 2014-15. Total depletion is 0.552 MT from opencast working within

proved limitations. So, resource available as on 01.04.2015 is as below.

Category of Reserves Band-I Band-

II Total UNFC Code

A Mineral Reserve in million tons

1 Proved Mineral Reserve 18.188 4.790 22.978 111

2 Probable Mineral Reserve 0.970 0.270 1.240 122

Total Mineral Reserves A 19.158 5.06 24.218 111 + 122

B Remaining Resources in million tons

1 Feasibility Mineral Resource 6.350 1.760 8.11 211

2 Prefeasibility Mineral Resource 0.480 0.400 0.88 222

3 Measured Mineral Resource 0 0 0 331

7 Indicated Mineral Resource 0 0 0 332

5 Inferred Mineral Resource 0 0 0 333

6 Reconnaissance Mineral Resource 0 0 0 334

Total Remaining Resources B 6.830 2.160 8.990 221+222

Total of A + B 25.988 7.22 32.208 111 + 122

+ 221 + 222

3.5.3 Mining Method

The mining methodology will comprise of open cast as well as underground

method.

In the scheme of mining that has been last approved by IBM it was proposed to

work ore Bank-I only by open cast mining along with some development work in

underground mining. There was no proposal for mining in Band-II. It has been

established that good quality of Chromite Ore continues below 15 mRL (opencast

UPL) up to a greater depth in Band-I and Band-II, which can only be mined by

adopting suitable technology of mining from opencast to underground in Band-I

and directly by underground in Band-II. In the above scenario, the lessee now

has taken a decision to start underground development for ore Band-I & II from

the 1st year of scheme period (2015-16). Ore production by opencast mining in

band-I has been proposed from 1st to 5th year along with ore production by BPM


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from 1st year of scheme period as well as conventional underground mining from

the 2nd year (Band- I & II) from development heading and from stope blocks

from 5th year of scheme period. Ore production from Band-II by underground

mining will start from the 2nd year.

By Opencast Method

In opencast mining operation drilling & blasting is adopted in the mine for

loosening of the hard rocks. Drilling is performed by 100 mm dia DTH drills

associated with compatible size compressors. Non cap sensitive slurry of 83 mm

dia cartridge like Aqua dyne, as column charge and for secondary blasting Aqua

dyne – 25 explosive cartride of 25 mm dia are adopted. Two numbers or

excavators of 2.1 - 2.7 CuM bucket capacity is used for excavation & loading of

ore as well as waste materials. Ore from Mining pit to COB plant is being/will be

transported via tippers (20 tons & 10 tons).

By Underground Method

The underground mining operation shall be carried out as below:

Mode of Entry

Shaft stations (Shaft Insets)

Production shaft (PS) 7.6 m finished dia

There will be 7 insets connected to PS. Access level each of 15m length

The PS connections to the main production levels will be as follows:

Skip unloading: +209m RL;

Collar: +182m RL;

Band I: -240m RL, -370m RL, -500m RL;

Mining car loading: -515m RL;

Crushing chamber: -545m RL; Crusher Station level as per design having

power substation and crusher chamber to accommodate the crusher and

related feeding equipment chutes and EOT crane

Skip loading: -580m RL;

Spillage treatment: -630m RL; a shaft bottom spillage facility with a horizontal

drive and water collection sump.

Shaft Bottom: -660m RL.

Return Air Raise1 (RAR1) 5 m finished dia

A return air raise (RAR1) will be required for ventilation. The RAR1 is to be located

at the footwall of Band I on the north-eastern part of the lease-1. The diameter of

the RAR1 depends on the total quantity of air required for ventilation. The total

quantity of air will be of 210m³/s as per the power of diesel equipment to be used

underground, a finished diameter of 5m was defined as per the comments of BAL,

the air velocity will be 10.70m/s, this caters Indian regulation of ventilation

(Maximum Velocity of Air 15m/s) and it will be a economical air velocity for air

return.


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There will be six insets connect to RAR1:

-60m RL, -120m RL, -144m RL, -192m RL, -240m RL.

Bottom: -240m RL.

Return air raise from +77m RL to -240m RL will be of 317m long & it shall be

equipped through fan evasee as per design.

Return Air Raise2 (RAR2) 4 m finished dia

A circular vertical shaft is designed as the return air raise (RAR2) to provide air to

both Band-I and Band-II operations. This will also be the second access for both

the bands as well will provide emergency egress.

The finished diameter of RAR2 depends only on ventilation, required quantity of

return air will be of 103.21m³/s, as per Indian regulation of ventilation, Maximum

Velocity of Air will be 15m/s, a minimum section area of RAR2 required for

ventilation should be 7.32m2. The designed section area of RAR2 will be of 12.56

m2, i.e. diameter will be of 4.0m, and velocity of air will be 8.22m/s as per

ventilation solution, and it will be an economical air velocity for air return.

The mining limit of Band II will be up to -120m RL in phase1, the RAR2 will be

down to -120m RL, and can be deepened further in phase 2.

There will be 6 insets connect to RAR2:

+112m RL, +76m RL, +40m RL, +4m RL, -60m RL, -120m RL.

Bottom: -120m RL.

RAR2 from +182m RL to -120m RL will be of 302m long & it shall be equipped with

through fan evasee as per design

Main level drives

(1) Level distribution

There will be 9 levels to be developed during development period in project

phase1.

six levels: +112m RL,+76m RL, -60m RL, -120m RL, -160m RL, -240m RL will be

in friable zones;

Three levels, -240m RL, -370m RL and -500m RL will be in hard zones.

Every main level drive will be connected to declines.

(2) Dimension of drives

Drives at two levels in strong weathered zone, +112m RL and +76m RL will serve

for LHD and mine trucks, with a size of 4×4m. Drives at five levels -60m RL, -

120m RL, -160m RL will serve for Explosive Truck, Mine truck MT2010, Boomer281

and LHD moving, of which will be Explosive Truck with the largest dimension of

2.5m (width) ×2.6m (height), the size of drives is designed as 4m (width) ×4m

(height). Drives at three levels -240m RL, -370m RL, -500m RL will serve for


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Explosive Truck, Mine truck MT2010, Boomer281, Simba1354, Head Roader and

LHD moving, of which will be Simba1354 with the largest dimension of

2.43m(width)×3.075m(height), air intake, the size of drives is designed as

4.5m(width)×4.5m(height).

(3) Drives support

All drivages / excavation shall be supported as per the rock mass rating &

classification jointly made after the face mapping as per the approved systematic

support rule approved by DGMS.

Stepped Intake Air Raise and Return Air Raise

Finished intake air raises and return air raise diameter depends on the quantity of

air passing through, they will be equipped with ladders as second exits between

two level drives, refer to Table-2, a return raise for air return of waste rock loading

level, crushing level, skip loading level, spillage level is included in.

TABLE-2

DIAMETER OF INTAKE AIR RAISES AND RETURN AIR RAISES

S. No. Level Band I Band II

1 Intake Return Intake Return

2 +76~+112m RL 3.0m

3 -120~-60m RL 3.0m 3.0m 3.0m 3.0m

4 -150~120 m RL 3.0m 3.0m

5 -240~-156 m RL 3.5m 3.0m

6 -370~-240 m RL 3.5m 5.0m

7 -500~-370 m RL 4.0m 3.0m

8 -630~-500m RL 3.0m

Ore and Waste Rock Passes

Ore & waste Rock passes shall be constructed as per the site requirement &

approved design.

Inspect raise

Inspect raise will be for coarse ore bin inspect with a height of 20m from -545mRL

to -525mRL

Chambers

(1) Coarse ore bin

Coarse ore bin will be located near production shaft, it will be 35m long vertically

between -500m RL and -535m RL as per approved design.


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(2) Crushing chamber

2 (two) crushing chambers for high grade and low grade ore, the biggest chamber,

will be at -545m RL as per approved design.

(3) Loading chamber

Loading chamber will be at -580m RL.

(4) Pump house / substation / sump

Pump house / substation / sump will be at -500m RL.

(5) Stope substation chamber

There are 5 stope substation chambers at +76m RL, -60m RL, -156m RL, -240m

RL, - 370m RL, -500m RL respectively.

(6) Store / infirmary / rest room

There are 3 store / infirmary / rest rooms at - 240 RL m, -370m RL, -500m RL

respectively.

(7) Ventilator / substation chamber

There are 4 ventilator substation chambers at - 60m RL, -240 RL m, -370m RL, -

500m RL respectively, and 4 substation chambers at - 60m RL, -240 RL m, -370m

RL, -500m RL respectively as per approved design.

Shafts and Stepped Air Raise Equipment

PS below -580m RL and RAR2 will be equipped with ladders as second or third exits

out of mine, stepped air raises at the footwall of BandⅠwill be equipped with

ladders between -60m RL and -500m RL, as second exits out of stopes.

Decline

The Chromite deposit planned for underground mining will be accessed by Declines

(herein referred as Decline-1 and Decline-2) with a common portal. Decline-1,

which will serve Band – I will initiate from the surface from the common portal in

the open pit at 100mRL.

(1) Parameters of declines

A size of 4.5 m (height) × 4.5 m (width) will be applied for both decline1 and

decline 2.

The decline will be driven at an average gradient of 1 in 8 in friable zones (here

defined as above -240mRL), and 1 in 7 in hard zones.


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A curve radius of 20m will be for both decline1 and decline2 with the same

gradient.

(2) Declines support

All decline / excavation shall be supported as per the rock mass rating &

classification jointly made after the face mapping as per the approved systematic

support rule approved by DGMS. The portal of decline1 will be located in very

friable zone and will be heavily supported with RCC as per the approved design.

(3) Passing bay

There will be passing bays in decline1 and decline2 at a space of 300m.

(4) Manhole

As per regulation MMR 1961, manhole will be at each ramp portion of decline.

(5) Cross cuts

There will be 8 cross cuts to decline1 and 5 cross cuts to decline 2.

The declines connections to the main production levels will be as follows:

Decline1: +76m RL, -60m RL, -120m RL, -156m RL, -240m RL, -370m RL, -500m

RL;

Decline2: +112m RL, +76m RL, -60m RL, -120m RL.

(6) Parameters of decline

Decline1 from +100m RL to -500m RL Decline 2 from +112m RL to -120m RL

The decline sinking and equipping will also be in Contractor’s scope along with

other ancillary work like the pass bay and man holes

Development and equipping.

The level at -515 mRL will have a bin for feeding to the crusher with a grizzly at

top. The scope covers excavation, supporting and excavation of Ore dumping point

and related drive and furnishing with a grizzly. All civil & structural works are

included. The roof and walls for the crusher chamber shall be shotcreted and

supported as per its mentioned support class. The development of all box fronts

civil as well as supply and equipping of all structural and mechanical and

commissioning. Lining & reinforcement of all bins shall be done to sustain the

impact and abrasion because of rock movement.

Development of loading station and related civil will be by the Contractor as well

as supply and the equipping of all structural steelwork, liners, chute work,

fabricated measuring flask, mechanicals, electrical and commissioning thereof.


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The loading station is to be supplied and equipped and conveyor to be

installed by the Contractor as well as commissioned. Conveyors shall be completes

and have drives, having fire suppression system, magnetic separator, safety

system, brakes on drive coupling and associated automation.

Development of shift I/c & First-aid room, crusher chamber, bins etc as per the

drawing.

There shall be surface facilities like winder house, substation building, compressor

house, shift I/c room, change room, battery room, first aid station, rope storage,

Heavy winch room, surface area development near shaft, storm water drain,

drain water storage, banks man room, reserve station etc.

Setup a pumping facility at both the stages to maintain water pumping in u/g.

Installation of pipes and pipe fittings, pumps, valves, in the shaft as specified in

the design and commissioning of dewatering pumps

Supply fabrication & installation of buntons, guides Head frame structure, arrester

system of conveyances at top and bottom, inset structure etc.

Permanent winders will be supplied by BAL / OEM & will be installed by

Contractor. Contractor shall assist the winder supplier during Installation &

commissioning by providing crane and labour etc Winder supplier / OEM shall

provide technical support services

Contractor will construct winder foundation and winder house and will assist in

installation of winches. Installation of sheaves, EOT, cage, skip, rope and its

attachment for permanent winders, elevator and all signaling and safety devices

and system hookup will be Contractor’s responsibility.

Development and equipping of all main rock transfer stations, crusher station, skip

loading station, belt conveyor drive station. With compatible EOT cranes will be

responsibility of Contractor. Crusher station includes 2 (two) jaw crushers with

vibrating grizzly feeder and apron feeder and associated electrical and

instrumentation system.

The pipes along with various fitting will be installed in shaft and at shaft bottom.

No excavation other than designed will be paid even if Contractor requires it for

conducting off shaft as well as off decline development. That sum is assumed to be

included in their price.

Notwithstanding the above any other item, work, services required for completion

of the work shall be provided by Contractor unless explicitly excluded.

ROM Ore Evacuation system

In the first phase of mining the ROM ore shall be hoisted through cage system.

Underground mining in locked up ore in opencast shall be extracted by using 2.5

m3 LHD.


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Whereas in underground mining to meet the substantial quantity of production in

later years, Load Haul Dump (LHD) of 2.5 m3 capacity and will be deployed to

muck ore in stope and same will be loaded in Low Profile dump trucks (LPDT) of

20 T/25 T capacity. LPDT will carry the ore into the bin of 800 T capacity

constructed at (-) 500 to 535 mRL. Skip loading system will be arranged at (-)

580 mRL below. This system is broadly consisting as under.

(a) Ore Bin of 800 T capacity

(b) Ore will be crushed to -75 mm by 200 TPH crusher installed in underground at

(-) 545 mRL

(c) Ore received from crusher will be accumulated in a Fine (Crushed) ore bind or

surge ore bin (400T cap) and carried by belt conveyor to a measuring bin.

(d) From this surge bin, ore will be carried by conveyor to a measuring bin

(e) From measuring bin, the exact quantity (10 MT) ore will be loaded into skip

(f) Skip will be hoisted to surface and ore will be dumped into 100 T capacity

surface bunkers fitted with loading chute to load

(g) From surface bunker, ROM ore will be transported by means of stack conveyor

to surface stock piles.

4.0 Mining

4.1 Scope of Mining and Mining Blocks

(1) Scope of mining

The mine has two chromite bands namely Band I and Band II. At present the

mining of Band I ore body is being carried out since Sept’2000, by open pit

method and underground mining is planned to be established beneath the open

pit at Band-I as well as at Band-II.

Underground mining will consist of two phases, ore body of Band1 and Band 2

above -500m RL will be mined in phase-1 and in Phase-2, ore body of Band1 and

Band2 below -500m~-1000m RL will be mined. As per the requirement of design

contact, the scope of design work falls in phase-1, and all fixed facilities

arrangement for mining in phase-1 shall cater production capacity of 2.0MTPA in

Phase-2.

According to production capacity requirement in design contact, scope of

exploration, and the meeting on discussion DPR (Draft) by SRK held on

25.04.2014 at Jajpur, Odisha the mining scope in phase-1 is defined in this

design report as follows:

Band II: +120m~-120m RL;

Band I: -60m~-500m.

Refer to Drawing 14-0011-01-02, 11 in 11

(2) Blocks

To achieve a production capacity of 1.4MTPA, the scope of mining will be divided

in 15 blocks. Out of this 15 blocks, 6 Blocks in Phase-I and another 9 Blocks for

Phase-II. Details are as under


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Block 1 +120m~0mRL in Band II

Block 2 0m~-120mRL in Band II

Block 3: -60m~-156mRL in Band I




Block 7 -130m~-230mRL in Band II

Block 8： -510m~-630mRL in Band I






Block 14 -640m~760mRL in Band II

Block 14 --770m~890mRL in Band II

(3) Sub-block

To keep intake or return air raises stability and easy maintenance in weathered

zones, blocks will be divided into sub-blocks. There will be 3 sub-blocks in Block1,

2 sub-blocks in Block2, 2 sub-blocks in Block3, 2 sub-blocks in Block4.

(4) Slice

A slice will be defined in friable ore, meaning a plate of ore with a vertical height

of 3m in Block1 and 4m in Block2~Block4.

(5) Sublevel

A sublevel will be 3 slices in Block1, 4 slices in Block2~Block4 and 20m in

Block5~Block6.

(6) Stope

A stope means part of a slice with a horizontal length of 30m, 24m or 15m along

with ore body strike.

4.2 Production Capacity and Distribution

The design contract stipulated Basis of Design and Engineering would be to

achieve production of 1.692MTPA from Band-I and II,.

The mining blocks and a peak production capacity of 1.692MTPA are presented in

Table-3, and life time of each block in Table-4, the total ore to be mined by

underground will be 20.59M tonnage after deduction of boundary pillar (7.5m

from each boundary).


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TABLE-3

MINING BLOCKS AND PRODUCTION CAPACITY

Block Ore

body Scope Mining method

Expected production

capacity

1 Band-II +120m~0m RL Underhand D&F 0.05MTPA

2 Band-II 0m~-120m RL Overhand D&F 0.15MTPA

3 Band-I -60m~-160m RL Overhand D&F 0.15MTPA

4 Band-I -160m~-240m RL Overhand D&F 0.15MTPA

5 Band-I -240m~-370m RL SLOS& Filling 0.45MTPA

6 Band-I -370m~-500m RL SLOS& Filling 0.45MTPA

7 Band-II -130 m to -230m RL SLOS& Filling 0.20MTPA

8 Band-I -510 m to -630m RL SLOS& Filling 0.45MTPA








TABLE-4

LIFE TIME OF EACH BLOCK

Exploration during mine construction or production period will be done; a

potential extra production capacity of 0.3 MTPA may be expected.

The production capacity at -240m RL and above will be 0.5 MTPA, ore extracted

will be transferred by trucks via declines.

The production capacity at -240m~-500m RL will be 0.9 MTPA, ore extracted will

be transferred by trucks via decline1 to crushers, and then will be hoisted by a

skip via the production shaft.

However, all fixed facilities are designed to meet the requirement of production

capacity of 1.692 MTPA.


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Mineral Processing and Beneficiation

Ore being mines is subjected to sizing/sorting for the +40% grade Cr2O3 Chrome

ore for direct use for Ferro chrome making in company’s own plant and less than

40% grade ore is fed to company’s own COB plant (20 TPH capacity), situated in

lease hold area. The ore of this lease area is of fine-grained, brownish black

colour to black color lumpy/friable ore. The associated gangue minerals are

magnesite, serpentine, magnetite and limonite. Grain size of Chrome crystals

varies between 0.1mm to 1.5mm. Hardness 2 to 4, sp gravity 1.6 to 3.0 and non-

magnetic to feebly magnetic in nature.

A detailed study has been made on different sub-grade chrome ore at National

Metallurgical Laboratory, Jamshedpur; for construction of full-fledged chrome ore

beneficiation plant consisting of screening, two stage grinding, cyclone and

spirals. It was observed that about 13% Cr2O3 middling are generated during

beneficiation process.

To reduce Cr2O3 content in the part of the tailing (about 13% Cr2O3 against cut off

grade 10%) and increase the recovery of chrome content a detailed study has

been made by IMMT Bhubaneswar and a new process-flow sheet developed for

middling processing.

4.3 Raw Material Requirement

Raw material requirement for the Chrome Ore Beneficiation plant essentially

consists of the low grade chrome ore. Mineral Rejects with 10 to 40% Cr2O3 is

subjected to beneficiation in the 20 TPH capacity COBP of the company inside the

lease. The COB Plant recovery for useable grade ore is about 39% by volume of

chrome concentrate with the grade range of 48% to 51% Cr2O3. The rest tailing,

generated in the process of beneficiation and out of the total tailings, the -10

grade products are considered as waste and disposed off as the same is below

threshold limit. However the part of the tailings which are of +10% grades are

kept separately to recover useable grade of chrome ore concentrate.

4.4 Resource Optimization/ recycling and reuse envisaged in the project

The following measures are being adopted

The used lubricant oils from the Heavy Earth Moving Equipment is collected

through a centralized collection system in the workshop premises and stored

in an impervious underground tank. Oil and grease separation pits are

provided for separating oil from the vehicle wash water. Such oil is collected

and sold to authorized recyclers approved by Pollution Control Board. The

water from the oil separation pit is again recycled back and reused for vehicle

washing.

The old lead acid batteries are also being sold to authorized recyclers

approved by Pollution Control Board.

The water from the tailings ponds is also being recycled and reused for the

beneficiation process.

Energy efficient lighting system is being used extensively for lowering power

consumption.


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The overhead tanks are provided with float valves to arrest overflow and

wastage of drinking water.

The sewerage from the colony Admin building, canteen etc( no colony exists

in lease area) shall be treated in the Sewage Treatment Plant under

construction. The waste collected shall be used as manure in the gardens. The

treated water is also reused for gardening and plantation.

Rain water harvesting system is proposed to be taken up in future.

4.5 Availability of Water & Energy

The present water requirement of the 0.6 MTPA is 347.2 KLD, out of which 220

KLD is required for COB plant, 115 KLD for mining purpose and 12.2 KLD for

Domestic /drinking purpose. The requirement is being met from mine discharge

water and bore-well (only for drinking). The water requirement after expansion

will be 1539.8 KLD and will be met from mine water and Borewell. However a

comprehensive hydrogeological study is under progress to ascertain the

discharge/requirement to various purposes and fresh application shall be made

for NOC from CGWA.

Waste water & sanitary sewage from domestic use being discharged through soak

pit at present and to be treated through Sewage Treatment plant (STP) under

construction. As estimated, the source of water for futuristic operations of the

project shall be mostly from quarry accumulated water and dug well.

4.6 Quantity of Waste to be Generated

Recovery of waste from mines (OC & UG) during proposed scheme period and

their place of dumping are as below.

The waste materials are consisting of dark brown colored lateritic soil & yellow to

brownish limonite etc. During proposed scheme period of five years (2015-16 to

2019-20) about 56.15 LCuM waste have been calculated to be generated from

OC and UG. Summary of waste development proposed during the scheme period

of 2015-16 to 2019-20 is tabulated below.

Year Opencast

Mining in CuM

Under Ground Mining

in CuM

Total in CuM

2015-16 1716031 154583 1870614

2016-17 1108750 120785 1229535

2017-18 837281 156136 993417

2018-19 900844 75813 976657

2019-20 458750 86937 545687

Total 5021656 594254 5615910

15% of the waste to be generated i.e. 842387 CuM (5625910 CuM x 15%) shall

be utilized for strengthening of haul road, terraces, filling in voids created by rain

on side walls of dumps, berm on the sides of road and terraces and plantation

areas, leaving a balance of 4773523 CuM for which space is available in the

existing 3 active dumps.


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The following table shows details about, waste and Mineral Rejects (MR) available

in the lease area, proposed generation in proposed scheme period, their

utilization and storage etc.

WASTE UTILIZATION & STORAGE

Year OB/SB/IB dump (CuM)

Total waste generated

Back filling

Utilized for strength. of haul road, berms,

plantation areas and

terraces etc

Balance stored in diff.

locations

2015-16 1870614 0 280592 1590022

2016-17 1229535 0 184430 1045105

2017-18 993417 0 149013 844404

2018-19 976657 0 146499 830158

2019-20 545687 0 81853 463834

Total 5615910 0 842387 4773523

MINERAL REJECT

Year MR Stack

at present (CuM)

Generation (CuM)

Total (CuM)

To be utilized in COBP (CuM)

To be utilized in COBP (CuM) of M/s Rohit

Balance stored (CuM)

2015-16 69943 40106 110049 46000 0 64049

2016-17 64049 53574 117623 46000 46000 25623

2017-18 25623 85815 111437 46000 46000 19437

2018-19 19437 121479 140916 46000 46000 48916

2019-20 48916 117373 166290 46000 46000 74290

Total 418347 702082 230000 184000 230000

(b) The proposed dumping ground within the lease area proved absence

of mineral

(i) Waste dump – 1

Waste dump-1 covers an area of 11.892 Ha and has been heighten to 182 mRL

as on date. Size of a part of the dump at present is 432 m Long x 212 m wide x

60 m in average and the other part is 385 m x 71 m x 12 m. As on date the

dump has accommodated about 2556845 CuM waste, with 3 number of terraces.

Considering following suggestions space for 2033465 CuM can be created.

(ii) Waste dump – 2

Waste dump – 2 covers an area of 4.875 Ha and has been heighten to 180 mRL

as on date. Size of the dump at present is 250 m Long x 195 m wide x 40 High.

As on date the dump has accommodated about 812005 CuM waste, with 2

number of terraces. For extending the periphery of the quarry on Band-I towards

north about 275000 CuM from 1.0 Ha area from the toe of the dump shall be

shifted and will be re-located on waste dump -2 to join with vacant area towards

IMFA dump. The vacant area can accommodate additional quantum of 353613

CuM waste. Thus wastes dump – 2 of BAL and dump of IMFA merges. This is

under an agreement between both lessee’s.


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At this time size of the dump will be 411 m long x 126 m wide x 37 High (in

average). It has been calculated that the ultimate capacity of the dump after

extending towards common boundary to join with wastes of IMFA will cater

about 1165618 CuM waste. MoU with IMFA along with approval of DMS, has been

accorded. Dump slope also be stabilized with plantation, Coir matting & grass

turfing. Overall slope will be kept at 28O. Existing statutory provisions like

retaining wall, and garland drain, check dams, terraces and settling tanks those

exist at site will be reconstructed.

(iii) Waste dump – 3

Waste dump – 3 covers an area of 13.28 Ha and has been heighten to 227 mRL

as on date. Size of the dump at present is 366 m Long x 380 m wide x 60 High.

As on date the dump has accommodated about 5096484 CuM waste, with 3

number of terraces.

To heighten the dump – 3 (for next 10 m thus dump height will be 70 m) from

227 mRL to 235 mRL study was undertaken by IIT Kharagpur. But, now the

lessee proposes to keep the dump height at 227 mRL. Instead of 4 terraces at

different heights, proposal is there to convert the dump with 3 terraces of 20 m

height each. The dumping will with catch drain in the inward slope to connect

with the garland drain at the toe of the dump.

Western side of waste dump – 3 is proposed to join eastern side dump of JSL

upto a height of 225 mRL.

A Gabion wall from the toe of the waste dump – 3 towards east and south shall

be constructed to find more area for accommodating wastes.

Final conclusion – Considering above technical studies a dump plan and section

has been prepared which shows that a quantum of 2394185 CuM waste can

further be accommodated in waste dump – 3. Finally the waste dump will be

having 7490669 CuM waste. Dump slope also be stabilized with plantation, Coir

matting & grass turfing. Overall slope will be kept at 28O. Existing statutory

provisions like retaining wall, and garland drain, check dams, terraces and

settling tanks those exist at site will be modified.

Summary of waste dumping locations

Dump No Existing Volume Final volume Additional Volume

Initial waste dump - 1 2556845 4590310 2033465

Office & other infrastructure area

0

Common dumping with IMFA

0



Gabbion wall 0

Terrace heightening 0

Common dumping with JSL 0

Total 8465334 13246597 4781263


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Liquid Waste: Mine Discharge Water

The primary sources of water infiltration into the mining pit are direct rainfall and

groundwater seepage. It is essential that the mining operation be properly

dewatered to minimize the impact on the operation.

(ii) Dewatering in the Mine Area

By the open cast mining process, it was observed that during the rainy seasons

and for the next few months in the post monsoon season, very negligible amount

of seepage was occurring in the mine pit. This amount was however, hardly

perceptible, even on a local scale. In the pre monsoon season, there was no

visible or perceptible seepage at all. However, detailed study on slope stability of

pits suggested that a considerable amount of water pressure is building up inside

the pits due to which the chances of pit walls collapse was imminent. In order to

prevent these precarious emergencies, it was suggested by experts to go for

horizontal boring in the pit walls to drain out the water present in the pores /

fractures and thereby reducing the pore pressure buildup in them. This was the

only measure available for ensuring safety and stability of the mine pit.

On expert advice, six numbers of horizontal bore wells of approximately 40 – 50

m length with perforated casings were constructed in the bottom most part of the

pits to drain out the water. The discharge from all these horizontal bores is

drained to the pit sumps from where they are being pumped to the effluent

treatment plant at mine, after treatment used for reuse in COB plant and for dust

suppression purpose only.

4.7 Schematic Representations of Feasibility Drawing

The process flow sheet mining process for open cast and Underground mining

given below


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PROCESS FLOW OPENCAST

MINING


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PROCESS FLOW U/G MINING

The low grade ore (-40 Cr2O3) is subjected to beneficiation through wet gravity

separation method within ML area for production of usable ore.


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FLOW SHEET OF BENEFICIATION PROCESS


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5.0 Site Analysis

5.1 Connectivity

Kaliapani Chromite Mine is located at village Kaliapani, Tehsil Sukinda, Jajpur

District, Odisha. The nearest railway station is JK Road Railway station at a

distance of 53 km towards ESE direction. The nearest airport is Bhubaneshwar,

which is 150 km in south direction from the mine site. The site is easy accessible

via roads due to proximity of a number if National & State Highways. Besides this

the site is also connected with communication facilities like telephone, fax etc,

5.2 Land Form & Land Use Pattern

At about 64.463 ha is Government Land including 64.119 ha as Forest land and

0.344 ha as roads, for which Surface Right has been granted by Collector.

The existing land use shall be changed during the scheme period and conceptual

period since the quarries are to be extended and some fresh areas shall be utilized

for mining and other activities. The present land use pattern vis a vis that in scheme

period and conceptual period are tabulated below:

Land use at the start and end of conceptual period

Sr. No.

Head Area put on use at start of

Scheme of Mining (Ha)

land use at the end of the proposed

scheme period (Ha)

land use at the end of

the conceptual period (Ha

1 Area under mining 17.880 22.022 26.164

2 Storage for top soil 0 0 0

3 Waste dump site 33.178 35.173 31.309

4 Mineral storage 2.210 2.249 2.249

5 Infrastructure (workshop, admin building, colony etc.

1.219 1.071 0.801

6 Roads 1.738 0.686 0.678

7 Railways 0 0 0

8 Tailing pond 0.020 0.020 0.020

9 Effluent Treatment Plant 0.240 0.240 0.240

10 Mineral Separation Plant 0.800 0.702 0.702

11 Township area 0 0 0

12 Others (to specify) - Area towards south east side of dump – 3 and areas where green belt has already been developed.

0 2.300 2.300

Grand Total 57.285 64.463 64.463

5.3 Topography

The area exhibits a peneplained topography marked by linearly disposed mounds

of low relief. The line of subsequent and obsequent slopes are not very well

defined. Waxing faces are more prominent than the winning faces.

The altitude within the lease area ranges between 120 m to 182 m above mean

sea level. The area represents an undulating topography, sloping towards the

west. The bottom and top RL of the hillock in the central portion of the lease area

are 135 m and 182 m respectively. There are no streams, perennial Nalas or


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Report


seasonal nalas observed within the lease area. The land within the lease area is

mostly covered with lateritic and wasteland with no settlements. The nearest

habitation is the mine colony of TISCO on the west and Chirigunia camp of OMC

on the north. Both are approximately 1.0 km away from the lease boundary. The

major drainage system of the region is located NNW of lease area named as

Damsal nalah which originates from Eastern part of Tungaisuri hill range, flows

towards West in Sukinda Valley and then turns towards South and finally joins

with Brahmani river. There is another seasonal major nalah named as

Kurchamula nalah flows towards South from Daitari hill range and ultimately joins

with Damsal nalah through Kharkari Reservoir. Besides few more seasonal nalahs

named as Nadiabaroa nalah, Langalakanta nalah and Petapeti nalah flows from

North to South and ultimately joins with Damsal nalah. There are so many

seasonal nalahs originating from Daitari hills and flow towards South and those

seasonal nalahs originated from Mahagiri hills flow towards North and ultimately

join with Damsal nalah. There are 2nos. perennial nalahs in the South Western

part of buffer zone and known as Pandara nalah and Dharainalah originated from

Mahagiri hills and flow towards South. Due to very gentle slope, there is no

perennial or seasonal nalah in the lease hold area. Damsal nalah is the nearest

water body at 1.0 km in NNW direction from the mining lease area. The working

RL of the mine lease area being considered at 139 m AMSL.

5.4 Existing Land use Pattern Buffer zone

The total area of the core and buffer zone within 10km radius is 314.285 sq.km.

The present land use pattern comprises 7.84% of Built up Land, 41.1%

agricultural land, 40.54% forest cover, 2.76% waste land, 3.76% water bodies

and 4% mining area. The details of land use pattern are as follows.

LAND USE / LAND COVER DETAILS OF STUDY AREA

S.

No. Level – I S. No Level – II Area in Ha Area in

Sq. Km %

Geographical Area

1 Built up Land

1.1 Built Up-Built Up (rural) 1201.7081 12.1 3.64

1.2 Built Up-Built Up (urban)-mixed Built Up area

55.7511 0.55 0.17

1.3 Built Up-Built Up (urban)-transportation

5.0402 0.05 0.02

1.4 Built Up-mining / industrial area industrial/mine dump

114.4055 1.1 0.46

1.5 Built Up-mining / industrial area-abandoned main pit

51.4913 0.51 0.15

1.6 Built Up-mining / industrial area-mine/quarry

1201.788 12.1 3.4

2 Agricultural Land

2.1 Agricultural land-crop land-kharif crop

11056.331 110.56 37.4

2.2 Agricultural land-crop land-Double crop area

1323.8 13.23 3.42

2.3 Agricultural land-fallow-current fallow

60.726 0.42 0.2

2.4 Agricultural land-plantation-agriculture plant

22.518 0.22 0.08

3 Forest 3.1 Forest-Forest plantation 421.8 4.21 1.4

3.2 Forest-deciduous(dry/moist/thorn)- 6310.103 63.225 18.9


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S. No.

Level – I S. No Level – II Area in Ha Area in Sq. Km

% Geographic

al Area

dense/closed

3.3 Forest-deciduous(dry/moist/thorn)-open 4161.446 41.01 14.1

3.4 Forest-scrub Forest 1806.747 18.041 5.14

3.5 Tree Cover 268.581 2.7 1

4 Waste Land 4.1 wastelands-barren rocky/stony waste 109.608 1.9

0.6

4.2 wastelands-scrub land-dense scrub 432.584 4.3 1.1

4.3 wastelands-scrub land-open scrub 330.997 3.2 1.06

5 Water Bodies

5.1 Water bodies-lakes/ponds-dry 210.594 2.2 0.6

5.2 Water bodies-lakes/ponds-perennial 421.419 4.1

1.29

5.3 Water bodies-river/stream-perennial 400.129 4.0615

1.2

5.4 Reservoir 229.326 2.178 0.67

6 Mining Area 6.0 1231.663 12.316 4

TOTAL 31428.558 314.28 100

Ref: LISS III Satellite Image March 2011

The graphical presentation of the major land use pattern of the buffer zone of the study

area has been shown as Figure-2.

FIGURE-2

GRAPHICAL PRESENTATION OF LAND USE/LAND COVER OF THE BUFFER ZONE

5.5 Existing Infrastructure

Chrome Ore Beneficiation Plant

Quality Assurance laboratory

Central Workshop

Explosive magazine

Effluent Treatment Plants

Drinking Water supply system.

Quarry Pump House

Sewage Treatment Plant

Weigh Bridges

Central Store

Administrative Office

Geotechnical Laboratory


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Security Control & Fire Fighting Station and

Electrical Substations

Hazardous waste yard

Workmen canteen

The above infrastructures shall be used for underground operation also. Beside

the above few more infrastructures are likely to come in future.

• Underground shafts with winders and declines

• Surface infrastructure for the underground mine

• Ventilation raises with Main Mechanical ventilators

5.6 Soil Classification

The soil ranges in colour from brown, reddish brown, brownish red, brownish

black. The texture is clayey sand to sandy loam. The reaction in the soil is usually

neutral. The soil is porous with good water holding capacity. The Organic matter

content and phosphorus is high in the afforested over burden dumps and top soil

supports proper plant growth.

5.7 Climatic Data

The climate of the study area is humid and tropical. It is characterized by a hot

and dry pre-monsoon from March to May, a monsoon or rainy season from June

to September and a cool winter from October to February.

Temperature

The annual maximum daily mean temperature is 33.30C, while the absolute

maximum temperature is 47.20C. Similarly, the annual minimum daily mean

temperature is 20.70C and the absolute minimum temperature is about 11oC. In

general, May is the hottest month and January is the coldest. Extreme

temperatures prevail in the area.

Relative Humidity

Humidity is fairly high through the major part of the year and it rises above 80%

in the months of July, August and September. The driest months are March and

April. The average relative humidity is around 53%.

Rainfall

The average annual rainfall is 1598.36 mm and there are on the average, 97

rainy days in a year. Rainfall peaks during July and August with the four months

(June to September) recording 65% of the total rainfall.

Wind Speed

The maximum mean monthly wind velocity is 1.5 m/s and the maximum wind

velocity is 4.7 m/s.


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Wind Direction

The predominant wind directions in the study region are from NE and NW

followed by South easterlies in Winter season but in later winter some winds

from SW & SE is also found. In the Summer season predominant winds are from

SE and NW. In the Monsoon season predominant winds are from NE & SE. The

post monsoon season has predominant winds from the NE and SE besides NW at

times.

5.8 Social Infrastructure:

Most of the social infrastructural facilities like medical, post office, schools, police

station, clinic, hospital etc. are available at nearby towns

6.0 Planning Brief

6.1 Planning Concept

The present infrastructure like road, outbound transportation, town services shall

continue to operate in future. Underground mining shall have separate access in

the form of declines and shafts to raise the ore to surface. Although there shall be

some additional manpower due to proposed mine expansion mining no such

significant change is being envisaged.

6.2 Population Projection

The Management and supervisory personnel already employed in the mine and

the proposed personnel required during future mining operations are

Sr. No Personnel Qualification Existing

1 Mines Manager Degree/Diploma in Mining Engineering with first class certificate of competency (with

more than 10 years’ experience).

1

2 Asst Manager Second Class Mines Managers Certificate Holder

6

3 Mining Engineer Degree in Mining Engineering (with more than

10 years’ experience).

1

4 Geologist M. Sc in Geology (two geologists are with more than 10 years’ experience.

10

5 Surveyor Mine’s surveyor’s certificate of competency 3

6 Mines Foreman Foreman certificate of competency 12

7 Mining mate Mate certificate of competency 18

Total 51

Employment placement Location and nature of

work Total

Departmental (Regular) Mines 232

Departmental (DRM) Mines 39

Departmental Corporate office 14

Contractual Workers

Supply Worker 32

Loading 265

Processing 32

Processing 41


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Employment placement Location and nature of work

Total

Equipment Hire 5

Vehicle Hire 1

Security 33

Mining 356

Total 1050

6.3 Land use Planning

The land use plan is given in Section-4.2.

6.4 Assessment of Infrastructure Demand:

Many of the infrastructure exits, no such significant change in the physical and

social infrastructure are being envisaged. However the same can be enhanced as

per future requirement after the expansion of mining operation takes place.

6.5 Amenity/ Facility

The existing amenities/ facilities like canteen, dispensary, VT centre, Drinking

water supply, communication etc have been provided to the employees and

communities are sufficient in the present context. However, additional

requirement if any shall be provided in future as per the needs perceived as the

project progresses or otherwise statutorily required.

a) Mines office

This will serve as the administrative office for the mine and supervision of the

mining operations. The facilities will include vocational training centre, mine

planning & quality control cell, central stores, core library, environment cell etc.

Besides the above, some facilities will be provided for this mine. These are given

below:

b) Blasting shelter

Two portable blasting shelters will be provided in the underground mining area.

c) Lighting arrangements

Adequate portable lighting arrangements will be made at the mine faces. The

main power source will be drawn from CESU Bhubaneshwar.

d) Rest Shelter

A small rest shelter with drinking water facilities will be provided.

e) Residential facilities

Suitable area is not available within the mining lease for setting up residential

colony. Most of the employees are expected to come from nearby areas and in


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Report


addition to this company has arranged housing arrangement in nearby area/town

on rental basis for employees who are coming from distance places. In addition

to this conveyance facility is being provided to such employees. However For the

employees not belonging to the nearby areas, housing facility shall be provided in

a nearby land purchased by company in future.

7.0 Proposed Infrastructure

7.1 Industrial Area

Balasore Alloys Limited (BAL) is currently operating chromite mine with 0.6 MTPA

capacities. BAL is operating a full fledge Chrome Ore Beneficiation plant

consisting of two stage grinding cyclone and spirals to produce the chrome ore

concentrate. The existing mine lease is having all the Infrastructure facilities like

mine office including geology office canteen and dispensary, beneficiation plant,

workshop garage, power substation, diesel general shed, magazine, vocational

training center, ETP, administrative building, etc. The same facilities will cater

the requirements of the proposed expansion.

7.2 Residential Area

Suitable area is not available within mine lease area for development of

residential area. Hence no such infrastructure development is envisaged.

7.3 Green Belt

BAL has already taken up plantation activities in and around mine. Green belt will

be developed @ 2500 saplings per ha and will be continued.

7.4 Social Infrastructure

BAL has been contributing towards development of social infrastructure in the

nearby areas for villagers as well as inside Lease area for employees. The same

shall be continued.

7.5 Connectivity

The mine lease area is located at Kaliapani village, Tehsil Sukinda, Jajpur District,

Odisha. The total ML area is 64.463 ha . The site is easily accessible via roads due

to proximity of National and State Highways. The nearest railway station is JK

Road Railway station at a distance of 53 km towards ESE direction. The nearest

airport is Bhubaneswar, which is 150 km in south direction from the mine site.

7.6 Drinking Water Management

Drinking water requirement is being met from bore well present inside ML area.

7.7 Sewerage System

The domestic wastewater is routed to septic tanks, soak pit, followed by Sewage

Treatment plant.


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7.8 Industrial Waste Management

Industrial waste like steel scarp and used oil drums will be sold to authorized

recyclers.

7.9 Solid Waste Management

The overburden/topsoil generated from underground and opencast mining will

be stored in three dump sites (Dump-1, Dump-2 and Dump-3).

The overall slopes of the dump will be maintained 280.

Individual bench height will be restricted to 20m, gullies will be provided in

the bench slopes for smooth draining of water.

Terracing will be made to control surface runoff in the dump slope

Garland drain have been provided around the dumps

Barrier has been erected around the dump yard.

The dump slope has been vegetated with grasses for binding soil and to arrest

soil erosion.

Later on bushes and shrubs has been grown on the dump slopes along with

tree species, waste disposal/reclamation is carried with full environmental

consideration.

Geotextile mating is provided on dump slopes

The tailings generated from the beneficiation process shall be stored in the

existing tailing pond of 0.020 ha area within the mine lease.

7.10 Power Requirement & Supply/Source

Existing

As per the agreement with CESU Max. Load Demand of open cast mine, COB

plant & ETP Plant is 1300KVA. However to meet this requirement of power is

being drawn at 33KV Voltage level from OPTCL 132/33KV Grid Sub-Station

through a 4.3KM length common transmission line of CESU. After receiving 33KV

supply at mines this has been given as input to the existing Sub-Stations i.e.

33/0.433 KV, 500 KVA & 2000 KVA located in the mines. The outgoing power of

500 KVA Sub-Station is being distributed through PCC ( Power Control Center ) at

415 Volt to various loads of COB Plant, ETP, Office premises, Canteen, Street

lighting purposes etc. through underground LT cable lines. Similarly the outgoing

power of 2000 KVA Sub-Station is being distributed at 415 Volt for Dewatering

system of open cast mine, Mobile equipments shop, High Mast lighting towers,

Movable lighting tower, Open Cast Mine illumination purpose through

underground LT cable lines as well as 4 KM length of over head line.

As per DGMS norm one no of 500 KVA, 415 Volt stand by Diesel Generator Set is

provided near 500 KVA Sub-Station as alternative source to be used during the

failure of normal grid power for running loads pertain to 500 KVA Sub-Station.

Similarly another 1500 KVA, 415 Volt Diesel Generator Set is installed in the

Open Cast Mine as alternative source for catering power to the load of Open Cast

Mine pertains to 2000 KVA Sub-Station.


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Report


Future Underground Project

Requirement of construction power for Underground Mining project is 7000 KVA &

after completion of project operational power requirement is 13000 KVA. However

to meet the above requirement it has been purposed for drawing power from

OPTCL Grid Sub-Station in two phases ( During construction & after construction )

through a dedicated 33 KV over head line. After receiving the power at voltage

level of 33 KV it will be further made step down to the voltage level of 0.44 KV for

distribution to various load centers. Electricity: During expansion/construction

period Electricity requirement will be fulfilled from State Grid with enhanced load

of 8.5 MVA as against the existing load of 1.3 MVA. DG sets of 2 MVA capacities

are available for standby power.

8.0 Rehabilitation & Resettlement (R&R) Plan

There will be no rehabilitation and resettlement issues envisaged.

9.0 Project Schedule & Cost Estimate

9.1 Time Schedule

The tentative time schedule to commission 1.692 MTPA capacities Chromite Ore

Mine is given below

Activity Months

→ 1 2 3 4 5 6 7 8 9 10 11 12

Approval of Mining plan

Completed

Application for EC

Obtaining ToR

Conducting Baseline studies

Environmental Clearance

Capital

Scheme preparation

Pre Tender

Tender

Pre Project activity

Start Decline

9.2 Estimate of Project Cost

The tentative capital investment for the proposed Kaliapani Chromite Mine has

been estimated to be Rs 1500 Crores.


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Report


10.0 Analysis of Proposal

10.1 Financial & Social Benefit

Financial Benefits

The estimate capital investment to be made over a period of 4 years, for the

proposed expansion activities. Based on the cash flow the IRR (Internal rate of

Return) is estimate to be around 34.47 %.

Social Benefits

Economic Growth

Increased Chromite Ore Production shall help in overall industrial growth with

further increase in production of value added products. This in turn will generate

more royalty and other revenues to State exchequer.

Employment

The proposed mining expansion shall help in the sustainability of the chrome ore

production from the mine. Thus the mine shall continue to provide employment

and assistance to local communities.

. €overnnen! et 0F.ssa

Deps:rtsent of gteel & ftttnest

Y(e)sur {nsy 97I1,**i;,FbaRestearl tlae 4/^&aS

-g"ry* of the s"*Ga'y (Lees@e) f,roaH/* Iqrat Afloye &td. to rVs, gatrasre AIIoys lrtda

ffiereas tbe qlrrtng leaee for ehromite eyer aa area c*f53 hects. of rbn-fiorest land ia qrkiada valley of Je,ipur di.stcletgranted La fanrur. sf Wa. r,ryat ilroys f,td. for a per:lod ef

Fars vide thLs Dqeartment Frceeedirgs b"gtfg Dt.22.F.A00 ,.Hhercas tFre leaee nas exeerted ga l5i?c800 & registered,

t l . ' l . D O O , . -rahereas la the EGan ti.ee the ressee aro4wi.th fresh

flcate of l.noryoratloa hae appLled ta the State Governnent :

frce F{s. Ispat AIIoIraaeeqpt tUe errar,rge of name sf tf,le c6epany

t*,retreaer,tlre -1ess6€ haye Erhitted reguired dosameate iart of theC.r rr#reeentatioa ,

Howi theref,orel the state @vesnment kave beera pleased tothe r'eEEee F!/s. rryat Auoys r,ta. to ebarge thelr aame ts

s. Baramre Ar.roys r,td. erbJect to. eqditioa tr,rat thg asl.y naeedshall bea"r arl. tbe tiald,rities of the earriei aamed @qraprr

the terss & endltioas {qrosed oa, t{/e. rqrat arroys rrtd. wl,tln hlndl.ag oa S,/e1 balae@re Alleys Ltd.rshtdl Ehalt obtala ,

ssa$Jr clearaace ef the !4.Q.9.F.. 6ovto of Indta uader F.C.A@t*lftO ln .reryeet of, foreet laad pepooed to be granted.

ta H/ s. Ealasre Altoys Ltdo t '

b &e **ao

.folnt

By grder of, the €over,rpf

Joint BEcretar.y to Goverameot5

/w. b\ ,3, og

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@g Y^ fotwarded to H/ s.".I ryat Al Io ye. &tdn (W s. $aLaepre ' i.-81"y" Ltd.)r. Pa* Plaza..7l, PaSc Street, Ko-Ikata for faeoahaU.on &Ieessary.ae-tJ,oa. t r

'

Ehey are requeEted to el,raage/rcdtf,y theilr e,x@cuted lease-d ia eissaltatioa with the Oslleetorr rlaJptrr.

F. T .O .

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Documents

PRE-FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY Name of the Project Kaliapani Chromite Mineenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0... · 2015-08-21 · Kaliapani Chromite