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1 ENVIRONMENTAL IMPACT ASSESSMENT For AN EXTENT OF HACTARES OF IRON ORE MINE WITH A PRODUCTION OF 0.5 MillionTPA OF IRON ORE & 0.3 MillionTPA OF BENEFICIATION PLANT In Sy. No: 320, Chabali Village, Pendlamarri Mandal, Kadapa, Andhra Pradesh Proposed By SRI. KANDULA RAJAMOHAN REDDY Prepared By M/s. GLOBAL ENVIRO LABS (QCI- NABET Provisional Accreditation No:43), & (Recognised by Govt. of India, MoEF, New Delhi Vide Gazette Notification No. S.O. 773 (E)) /14/ /A/1, Tilaknagar X Roads, Bagh Amberpet, Hyderabad Ph. : ; Telefax: E.Mail:

2 UNDERTAKING BY THE PROPONENT This is to undertake that I own the contents (information and data) of the EIA Report. If at any stage, it is observed or brought to the notice of the MoEF/EAC, New Delhi, that the contents of the EIA/EMP report pertaining to this project have been copied from other EIA/EMP reports, the project shall be summarily rejected and I will initiate the process afresh including conduct of public hearing. Further, I am liable for any action initiated by the Authority as deemed fit. Signature of the project proponent with seal UNDERTAKING BY THE ENVIRONMENTAL CONSULTANT This is to undertake that the information and data of the EIA/EMP Report was prepared by our organization viz., M/s. GLOBAL ENVIRO LABS, Hyderabad. If at any stage, it is observed or brought to the notice of the MoEF/EAC, New Delhi, that the contents of the EIA/EMP report pertaining to this project have been copied from other EIA reports, the project shall be summarily rejected and I am liable for any action initiated by the Authority to delist our name from the list of the accredited consultants. Signature of the Environmental Consultant with seal.

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9 TOR LETTER & COMPLIENCE TO THE TOR S

10 Compliance to the TORs given by MoEF, New Delhi 1 Year-wise production details after the EIA Notification, 1994 coming into force. 2 A copy of the document in support of the fact that the proponent is the rightful lessee of the mine should be given. 3 All documents including approved mine plan, EIA and public hearing should be compatible with one another in terms of the mine lease area, production levels, waste generation and its management and mining technology and should be in the name of the lessee. 4 Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report. 5 Does the Environment Policy prescribe for standard operating process/ procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions? If so, it may be detailed in the EIA. 6 What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the EC conditions. Details of this system may be given. 7 Does the company have a system of reporting of non compliances / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA report. 8 The study area will comprise of 10 km zone around the mine lease from lease periphery and the data contained in the EIA such as waste generation etc should be for the life of the mine / lease period. 9 Land use of the study area delineating forest area, agricultural land, grazing land, wildlife sanctuary and national park, migratory routes of fauna, water bodies, human settlements and other ecological features should be indicated. 10 Land use plan of the mine lease area should be prepared to encompass pre-operational, operational and post Presented in EIA report in page no 14 Enclosed in the approved mining scheme at end of the EIA report The EIA report and approved mining scheme is compatible with one another in view of the mine lease area, production levels, waste generation and its management and mining technology is on the lessee name only. Yes. The Environmental Policy is furnished in the EIA report on pages The Environmental Policy is also presented hereunder as point. B of Additional information for your convenience and ready reference. Yes. The Environmental Policy is furnished in the EIA report on pages The Environmental Policy is also presented hereunder as point. B of Additional information for your convenience and ready reference. Kindly refer to page nos. 155 and 156 of the EIA report. The same is reproduced hereunder as point. B of Additional information for your convenience and ready reference Managing Director (M.D) is the administrative, financial and functional head of the company. There is no board of directors. Therefore the M.D is responsible for everything. All issues relating to of non compliances / violations of environmental norms shall be reported directly to the M.D The EIA report is prepared as per this condition only Presented in EIA report from page no Presented in EIA report from page no 19-20

11 operational phases and submitted. 11 Location of the proposed plant w.r.t. the source of raw material and mode of transportations of the ore from mines to the beneficiation plant, and outbound movement of the products should be provided. 12 Details of the technology and process involved in the project may be furnished. 13 Proposed treatment of run off from the fines/waste dump should be provided. 14 Estimation of the fines going into the washings and its management should be given. 15 Details of the equipment, settling pond etc. should be provided. Presented in EIA report from page no Presented in EIA report from page no Presented in EIA report from page no Presented in EIA report from page no Presented in EIA report from page no Detailed material balance to be provided. Presented in EIA report from page no Source of raw material and its transportation should be Presented in EIA report in page no 26 given. Steps proposed to be taken to protect the ore from getting air borne to be given. 18 Management and disposal of tailings and closure plan of the tailing pond, if any, after the project is over, should be provided. 19 Size distribution of the iron ore with percentage weight shall also be done to assess the source of fugitive dust emission of the ore feed to the plant. 20 Measures to manage the under size / over-size waste from the feed ore shall be provided. 21 Details of the solid waste to be generated and its management. Adequacy of the tailing pond, if any, for the life of the beneficiation plant should be provided with supporting data and documentation. Design and capacity of tailing pond should be such as to guard against overflow from the tailing pond during heavy rainfall. The provision of lining, nature of lining with supporting permeability studies should also be provided. 22 Details of the land for OB dump outside the mine lease such as extent of land area, distance from mine lease, its land use, R&R issues, if any should be given. 23 High Resolution Satellite Imagery of the proposed area clearly showing the land use and other ecological features of the study area (core and buffer zone). 24 A Certificate from the Competent Authority in the State Forest Department confirming the involvement of forest land, if any in the project area, or otherwise, based on land use classification (revenue record) as also in terms of the definition of forest as pronounced in the judgement of the Hon?ble Supreme Court of India in the matter of T.N. Godavarman Vs. Union of India. In the event of any claim by the project proponent regarding the status of forests, the site may be inspected by the State Forest Department along Presented in EIA report from page no Presented in EIA report in page no 91 Presented in EIA report in page no 91 The project does not envisage any tailing pond. Other details of solid waste management is presented in EIA report from page nos The same is reproduced hereunder as point. A of Additional information for your convenience and ready reference The overburden will be stacked within the mine lease area only. There are no oustees and hence no R&R issues are envisaged. The over burden management is Presented in EIA report from page no Presented in EIA report from page no The entire lease is govt. revenue land and no forest land is involved in the mine lease area.

12 with the Regional Office of the Ministry to ascertain the status of forests, based on which the Certificate in this regard as mentioned above be issued. In all such cases, it would be desirable for representative of the State Forest Department to assist the Expert Appraisal Committees. 25 Status of forestry clearance for the broken up area and virgin forestland involved in the project including deposition of net present value (NPV) and compensatory afforestation (CA). A copy of the forestry clearance should also be furnished. 26 Implementation of status of recognition of forest rights under the Scheduled Tribes and other Traditional Forest Dwellers (Recognition of Forest Rights) Act, Impact of the project on the wildlife in the surrounding and any other protected area and accordingly detailed mitigative measures required should be worked out with cost implications and submitted. 28 The vegetation in the RF / PF area should be given. Details in this regard should be given. 29 A study shall be got done to ascertain the impact of the mining project on wildlife of the area including on the elephant population and details furnished. 30 Location of National Parks, Sanctuaries, Biosphere Reserves, Wildlife Corridors, Tiger/Elephant Reserves (existing as well as proposed), if any, within 10 km of the mine lease should be clearly indicated supported by a location map duly authenticated by Chief Wildlife Warden Necessary clearance, if any, as may be applicable to such projects due to proximity of the ecologically sensitive areas as mentioned above should be obtained from the State Wildlife Department/ Chief Wildlife Warden under the Wildlife (Protection) Act, 1972 and copy furnished. 31 A detailed biological study for the study area [core zone and buffer zone (10 km radius of the periphery of the mine lease)] shall be carried out. Details of flora and fauna, duly authenticated, separately for core and buffer zone should be furnished based on field survey clearly indicating the Schedule of the fauna present. In case of any scheduled-i fauna found in the study area, the necessary plan for their conservation should be prepared in consultation with State Forest and Wildlife Department and details furnished. Necessary allocation of funds for implementing the same should be made as part of the project cost. Not applicable Not applicable Presented in EIA report as detailed study of flora & fauna from page no Presented in EIA report as detailed study of flora & fauna from page no Presented EIA report as detailed study of flora & fauna from page no The same is reproduced hereunder as point. G of Additional information for your convenience and ready reference Topomap enclosed in EIA report in page no 8 Presented in EIA report as detailed study of flora & fauna from page no Impact of change of land use should be given. Presented in EIA report from page no R&R plan / compensation details for the project affected No R&R issues envisaged people should be furnished. While preparing the R&R plan, the National Rehabilitation & Resettlement Policy should be kept in view. In respect of SCs / STs and other

13 weaker sections, need based sample survey, family-wise, should be undertaken to assess their requirement and action programmes prepared accordingly integrating the sectoral programme of line departments of the State Government. 34 One season (non-monsoon) primary baseline data on ambient air quality (PM 10, SO 2 and NOx), water quality, noise level, soil and flora and fauna shall be collected and the AAQ data so collected presented date-wise in the EIA and EMP report. Site-specific meteorological data should also be collected. The location of the monitoring stations should be justified. There should be at least one monitoring station within 500 m of the mine lease in the pre-dominant downwind direction. The mineralogical composition of PM 10 particularly for free silica should be given. 35 Air quality modeling should be carried out for prediction of impact of the project on the air quality of the area. It should also take into account the impact of movement of vehicles for transportation of mineral. The details of the model used and input parameters used for modeling should be provided. The air quality contours may be shown on a location map clearly indicating the location of the site, location of sensitive receptors, if any and the habitation. The wind roses showing pre-dominant wind direction may also be indicated on the map. 36 The water requirement for the project, its availability and source to be furnished. A detailed water balance should also be provided. Fresh water requirement for the project should be indicated. 37 Necessary clearance from the Competent Authority for drawl of requisite quantity of water for the project should be provided. 38 Details of water conservation measures proposed to be adopted in the project should be given. 39 Impact of the project on the water quality both surface and groundwater should be assessed and necessary safeguard measures, if any required should be provided. 40 Based on actual monitored data, it may clearly be shown whether working will intersect groundwater. Necessary data and documentation in this regard may be provided. In case the working will intersect groundwater table, a detailed hydro geological study should be undertaken and report furnished. Necessary permission from Central Ground Water Authority for working below ground water and for pumping of ground water should also be obtained and copy furnished. Details of first order stream, if any passing through lease area and modification/ diversion proposed, if any and the impact of the same on the hydrology should be brought out. 41 Details of rainwater harvesting proposed, if any, in the project should be provided. Presented in EIA report from page no Presented in EIA report from page no Presented in EIA report in page no 27,35 Applied for permission from CGWD. Presented in EIA report from page no Presented in EIA report from page no The ultimate pit limit is 20m and the GWL is 50m. Hence, the mine workings will not interest the ground water. No streams are passing through mine lease area Presented in EIA report in page no 143

14 42 Information on site elevation, working depth, groundwater table etc. should be provided both in AMSL and bgl. A schematic diagram may also be provided for the same. 43 Quantity of solid waste generation to be estimated and details for its disposal and management should be provided. The quantity, volumes and methodology planned for removal and utilisation (preferably concurrently) of top soil should be indicated. Details of backfilling proposed, if any, should also be given. It may be clearly indicated that out of the total waste generated during the mine life, how much quantity would be backfilled and how much quantity would be disposed off in the form of external dump (number of dumps, their height, terraces etc. to be brought out). 44 The reclamation plan, post mine land use and progressive greenbelt development plan shall be prepared in tabular form (prescribed format) and submitted. 45 Impact on local transport infrastructure due to the project should be indicated. Projected increase in truck traffic as a result of the project in the present road network (including those outside the project area) should be worked out, indicating whether it is capable of handling the increased load. Arrangement for improving the infrastructure, if contemplated (including action to be taken by other agencies such as State Government) should be covered. 46 Details of the infrastructure facilities to be provided for the mine workers should be included in the EIA report. 47 Conceptual post mining land use and Reclamation and Rehabilitation of mined out area (with plans and with adequate number of sections) should be given in the EIA report. 48 Phase-wise plan of greenbelt development, plantation and compensatory afforestation should be charted clearly indicating the area to be covered under plantation and the species to be planted. The details of plantation already done should be given. 49 Occupational health impact of project should be anticipated and preventive measures initiated. Details in this regard should be provided. Details of pre-placement medical examination and periodical medical examination schedules should be incorporated in the EMP. 50 Measures of socio economic significance and influence to the local community proposed to be provided by project proponent should be indicated. As far as possible, quantitative dimensions may be given with time frame for implementation. 51 Detailed environmental management plan to mitigate the environmental impacts which, should inter-alia also include the impact due to change of land use, due to loss of agricultural land and grazing land, if any, occupational health impacts besides other impacts of the projects. Presented in EIA report in page no 7, 13 Presented in EIA report in page no 91,92 Presented in EIA report in page no 19,20 Presented in EIA report in page no 66, 67 &140 Presented in EIA report from page no Presented in EIA report in page no 19,20 Presented in EIA report from page no Presented in EIA report from page no Presented in EIA report from page no Presented in EIA report from page no Public hearing points raised and commitment of the project Public hearing is completed and public

15 proponent on the same along with time bound action plan to implement the same should be provided. hearing minutes are enclosed in the end of the EIA report 53 Details of litigation pending against the project, if any, No. This project is free from any legal with direction /order passed by any Court of Law against litigations and court cases. the project should be given. 54 The cost of the project (capital cost and recurring cost) as well as the cost towards implementation of EMP should clearly be spelt out. Presented in EIA report in page no 156 Besides the above, the below mentioned general points should also be followed:- A A note confirming compliance of the TOR, with cross Yes. Provided as advised alongwith the referencing of the relevant sections / pages of the EIA EIA report report should be provided. B All documents may be properly referenced with index and All the documents are referenced with C D E F G continuous page numbering. Where data are presented in the report especially in tables, the period in which the data were collected and the sources should be indicated. Where the documents provided are in a language other than English, an English translation should be provided. The Questionnaire for environmental appraisal of mining projects as prescribed by the Ministry shall also be filled and submitted. Approved mine plan along with copy of the approval letter for the proposed capacity should also be submitted. While preparing the EIA report, the instructions for the proponents and instructions for the consultants issued by MoEF vide O.M. No. J-11013/41/2006-IA.II(I) dated 4 th August, 2009, which are available on the website of this Ministry should also be followed. index and continuous page numbers. The data is presented as per the condition No such documents of other than English language provided Submitted along with EIA report. Approved mining scheme is enclosed at the end of the EIA report All the instructions are fallowed

16 CONTENTS

17 CONTENTS QUESTIONER EXECUTIVE SUMMARY REIA & EMP CHAPTER PAGE No. 1. INTRODUCTION Preamble Background of Proposed iron ore Mine Present Project Proposal Justification for Production from the mine Environmental Clearance Report Format Scope of REIA study Methodology of REIA Micro Meteorology Ambient Air Quality Noise Environment Land Environement Biological Environment Socio Economic Environment Identification, Prediction and Evaluation of Impacts Formulation of Environmental Management Plan Project Description Location and Accessibility Leasehold Area Topography Geology Local Geology Details of Exploration Estimation of Reserves Mining Process 16

18 2.6 Reserves Extent of Mechanisation Drilling & Blasting Handling of waste & subgrade mineral Use of Mineral Site services Employment potential Conceptual Mining Plan Baseline Environmental Status Air Environment Climate and Meteorology of the Study Area Site Meteorology Wind pattern during Study Period Ambient Air Qualty Analysis of Baseline Concentrations Anticipated Impacts Air Emisions Quantitative Estimation of Impacts on Air Environment Sources of Dust Emission Emission Details Assumptions made in Prediction of Air Pollution Impacts Summary of Predicted GLC s of P.M Environment Management Plan Noise Environment Baseline Status Anticipated Impacts due to Noise Proposed Mitigating Measures Water Environment Baseline Status Impact on Water Environment Proposed Mitigating Measures Land Environment 48

19 3.4.1 Baseline Status Anticipated Impacts on Land Proposed Mitigating Measures Biological Environment Base Line Status Impacts on Biological Environment Proposed Mitigating Measures Socio-Economic Environment Base Line Status Impact on Socio-Economic Environment Proposed Mitigating Measures Disaster Management Plan Risk Assessment Identification of Hazards Filling up the mine pit due to excessive rains Failure of slope in the pit Failure of slope of external dump Accidents of Heavy Machinery Surface fire Preparedness Plan Training Implementation of EMP and Monitoring System General Implementation Activities to be monitored /inspected by EMC Slope Failure Land Erosion Drainage Blasting Effects Revegetation and Green belt development Air Quality Monitoring Water Quality Monitoring 72

20 4.7.8 Occupational Health Socio-Economic Development Environmental Management Plan Introduction Air Pollution Control Measures Noise Pollution Control Water pollution Control Measures Land Restoration and Pollution Control Restoration of Flora and Fauna Socio-Econmomic Development Measures Suggested Environmental Monitoring Programme Conclusion 83 LIST OF TABLES Table Descrption Page No No 2.1 Salient features of the study area Land Use Pattern in Core Zone for scheme period Environmental Attributes & Frequency of Monitoring Ambient Air Quality monitoring stations Fugitive and Non-Fugitive dust emissions mining Air Environment in Core & Buffer Zones - post project 37 scenario 3.5 Ambient Noise Monitoring Stations Noise levels in various locations Location of Water Sampling Stations Location of Soil Samples Land use in Buffer Zone Land use pattern in Core Zone List of plants identified for green belt stabilization of Over burden dumps Suggested Environmental Monitoring Programme Environmental - cost for proposed Mine 83

21 Fig / DRG LIST OF FIGURES / DRAWINGS Description 2.1 Topomap of the Proposed Mine Mine Lease Sketch Geological plan Windrose Diagram - Seasonal Location of Ambient Air monitoring stations Isopleth Showing GLC s Post Project Scenario Location of Noise Monitoring stations Location of Water Sampling stations Location of soil sampling stations A Typical proposed Check Dam across Nallah A Typical Proposed Retaining Wall at Dump Site Organisational Setup of EMC 70 ANNEXURES PUBLIC HEARING MINUTES APPROVED MINING SCHEME Page No.

22 QUESTIONER

23 PROFORMA FOR ENVIRONMENTAL APPRAISAL OF MINING PROJECTS (MINING SECTOR PROJECTS) Note 1 : Note 2 : Note 3 : Note 4 : All information to be given in the form of Annex/s should be properly numbered and form part of reply to this proforma. Please enter in appropriate box where answer is Yes / No No abbreviation to be used - Not available or Not applicable should be clearly mentioned. Core zone is the mining lease area. Buffer zone in case of ML area up to 25 ha. is to be considered as 5 km all around the periphery of the core zone and for ML area above 25 ha. an area 10 km all around the periphery of the core zone. Note 5 : Adopt Scoping process in carrying out EIA study. 1. General Information Note 6 : Please indicate source of data. (a) Name of the project : Ha of Iron Ore Mine & 0.3 MillionTPA of Beneficiation plant (i) Name of the proponent : Mailing Address #126, Palace Cross Road, Bangalore / : rvrns@yahoo.com Telephone : / Fax No. : (b) Objective of the project : Excavation of 0.5 MillionTPA of Iron Ore & 0.3 MillionTPA of Beneficiation (c) Location of mine (s) Village(s) Taluk/ Mandal District State Chabali Pendlimarri Mandal Kadapa Andhra Pradesh (d) Does the proposal relate to (i) New mine Yes No (ii) Expansion Yes No Increase in ML area Yes No Increase in annual Yes No production (iii) Renewal of ML Yes Yes No No Q-1

24 (iv) Modernisation Yes No (e) Site Information (i) Geographical Location Boundary Latitude Longitude Pillar No Survey of India Topo sheet number Elevation above Mean Sea Level Total mining lease area (in ha.) 57J/11 225m to m (ii) Dominant nature of terrain Flat Yes Yes No No Undulated Yes No Hilly Yes No 2. Land usage of the mining lease area (in ha.) (a) (b) (c) (d) (e) (f) Agricultural Forest Waste land Grazing Surface water bodies Others (Specify) Total Not applicable Not applicable Hectares Not applicable Not applicable Not applicable hectares 3. Indicate the seismic zone in which ML area falls. In case of zone IV & V, details of earth quakes in last 10 years. Q-2

25 (a) (b) Severity (Richter Scale) Impact i.e. Damage to Life Yes No Property Yes No Existing mine Yes No Q-3

26 4. Break-up of mining lease area (in ha.) as per approved conceptual plan: Purpose Mining Lease Area Total Area acquired Area to be acquired Government Private Government Private Government Private Forest Others Agri. Other s Forest Others Agri Others Forest Others Agri. Others 1. Area to be excavated Storage for top soil(stock Yard) Overburden / Dumps Mineral storage Infrastructure (Workshop, Administrative Building) Roads Railways Green Belt Tailings pond Effluent treatment plant Coal handling plant / mineral separation plant /Beneficiation Plant 12. Township area Other (Specify),Future Use TOTAL Q-4

27 5. Township (outside mining lease) (a) (b) Total area (in ha) No. of dwelling units ---- Not applicable (c) Distance from mine site N/A 6. Distance of water bodies (in km) Distance from River Bank * Other Water bodies * Sea / creek / lake / nalla etc. (specify) Mining lease boundary Papagni River 1.8 km -- Ancillary facilities Nil Not applicable [* From highest flood line / high tide line] 7. For projects falling within the Coastal Regulation Zone (CRZ) :NA Whether the mineral to be mined is of rare nature and not available outside CRZ? Yes No if yes, annex a scaled location map showing low tide line (LTL), high tide line (HTL) duly demarcated by one of the authorized agencies* [ *Director, Space Application Centre, Ahmedabad: Centre for Earth Sciences Studies, Thiruvananthapuram: Institute of Remote Sensing, Anna University, Chennai: Institute of Wetland Management & Ecological Designs, KolKata: Naval Hydrographers s Office, Dehradun: National Institute of Oceanography, Panjim, Goa: and National Institute of Ocean Technology, Chennai], boundary of mining lease area, distance of ML area from LTL and HTL CRZ boundary and CRZ classification of the project area as per the approved Coastal Zone Management Plan, and settlements, sand dunes, mangroves, forest land/patches, turtles breeding and nesting sites etc., if any, in the project area. 8. Indicate aerial distance from the periphery of core zone / area from the periphery of the buffer zone to the boundary of following (up to 10 km): S. No. Areas Name Aerial distance from (in km.) Core * Buffer* Zone Zone 1. National Park / Sanctuary Nil Not applicable 2. Biosphere Reserve / Tiger Not applicable Not applicable Reserve / Elephant Reserve / any other Reserve 3. Forest (RF / PF / Ganganapalle Reserve Forests 8.6 km South unclassified) 4. Habitat for migratory birds Nil Nil 5. Corridor for animals of Nil Nil Q-5

28 schedule I & II of the Wildlife (Protection) Act, Archaeological sites Nil Nil * Notified * Others 7. Defence Installation Nil Nil 8. Industries / Thermal Power Plants Nil Nil 9. Other Mines About 04 leases Adjacent & in the buffer zone 10. Airport Nil Nil 11. Railway Lines Kadapa - Hyderabad broad 28 km gauge line 12. National / State Highways Kadapa Pulivendula State highway About 5 kms from the mine site [* Buffer zone in case of ML area up to 25 ha. is to be considered as 5 km all around the periphery of the core zone and for ML area above 25 ha. an area 10 km all around the periphery of the core zone]. 9. Description of flora & fauna separately in the core and buffer zones.* [* Consult the Wildlife (Protection) Act, 1972 as amended subsequently and list species with (1) Common name (2) Scientific name and (3) under which schedule of the Wildlife (Protection) Act the identified species fall. Get the list authenticated by an Expert in the field / credible scientific institute / University / Chief Wildlife Warden office. Information to be based on field survey.] Details are enclosed separately as Annexure A A. Flora Core Zone Buffer Zone 1. Agricultural crops - Paddy 2. Commercial crops - Redgram, Groundnut, Cotton, Sun Flower, Chrysanthemum 3. Plantation - Lemon, Mango 4. Natural vegetation / forest type - Only thorny shrubs 5. Grass lands Endangered species Endemic species Others (Specify) - - Q-6

29 B. Fauna 1. Total listing of faunal elements Enclosed as Enclosed Annexure A Annexure A 2. Endangered species - - as 3. Endemic species Migratory species Details of aquatic fauna, if applicable Details of mineral reserves (as per approved Mining Plan) (a) (b) (c) (d) Quantity (in million tonnes) Proved Indicated/Possible Inferred/Reserves blocked In Buffer zone Mineable reserves/total reserves Major geological formation / disturbances in the mining lease area (a) Geological maps submitted Yes No (b) Geological sections submitted Yes No (c) Contour map submitted Yes No (d) Whether the presence, if any, noted of (i) Faults Yes No (ii) Dykes Yes No (iii) Shear Zone Yes No (iv) Folds Yes No (v) Other weak zones Yes No (e) Source of data (Indicate) :Approved Mining Plan from Indian Bureau of Mines Q-7

30 12. Production of mineral(s) and life of mine (a) Rated capacity of mine mineral wise (Tonnes / annum) (b) Life of mine at proposed capacity (Years) (c) Lease period (Years) (d) Date of expiry of lease (D /M /Y) (e) Indicate in case of existing mines (i) Date of opening of mine (ii) Production in the last 5 years 1 st year 5 th year from year to year in million tonnes (iii) Projected production for the next 6 th to 10 th year 5 years from year to year (upto Dec10) in million tonnes (iv) Whether mining was suspended after Yes No opening of the mine? 5,00,000 tons of Iron Ore 9.48 Years 20 Years If yes, details thereof including last production figure and reason for the same. The mine was closed since Feb 2011 due to domestic problem. Last production figure is: 1,23,299 TPA during (upto Dec2010) (f) Whether plans & sections provided? Yes No 13. Type and method of mining operations TYPE METHOD Opencast Manual Underground Both Semi-Mechanised Mechanised 14. Details of ancillary operations for mineral processing (a) Existing -- (b) Additional Proposes to establish a Beneficiation Plant with a thoughput capacity of 0.3 MillionTPA in the Mine L Q-8

31 15. Mine details (a) Opencast mine (i) Stripping ratio (mineral in tonnes to over burden in m 3 ) 1 : 0.40 (ii) (iii) (iv) Ultimate working depth (in m bgl) Indicate present working depth in case of existing mine (in m bgl) Thickness of top soil (in m.) Minimum Maximum Average 20m 10m Nil 0.5m 0.25m (v) Thickness of overburden (in m.) Minimum Maximum Average Nil 0.5m 0.25m (vi) Mining Plan Height and width of the bench in overburden / waste. Height & width of the bench in ore body / coal seam. Proposed inclination / slope of the sides of the opencast mine (separately for overburden, coal / ore and overall slope of the pit sides) both while operating the mine as well as at the time of closure of the mine. 10 m x 6 m 10 m x 6 m Overall slope of the mine is proposed at 45 degrees & the overburden dumps will have an slope of about degrees. (b) Whether transverse sections across the Yes No opencast mine at the end of fifth year and at the end of the life of the mine have been submitted? Jack hammer drilling and (vii) Type of blasting, if any, to be adopted. Sequential blasting by using latest delay detonators and Slurry Explosives Underground mine Q-9

32 (i) Seam / Ore body in.depth (m) Max. Depth (m) Avg. thickness (m) Nil Nil Nil (ii) (iii) Rate of dip in degree Nil Mode of entry into the mine Shaft Adit Incline Details of machinery Direction of dip Nil NA NA NA On surface Not applicable At Face NA For transportation NA Others NA (iv) Method of stoping (metalliferrous mines) Open Filled Shrinkage Caving Combination of above Others (Specify) NA NA NA NA NA NA (v) (vi) Extraction method Caving Stowing Partial extraction Subsidence Predicted max. subsidence (in m) Max. value of tensile strain (in mm/m) NA NA NA N/A N/A Max. slope change (in mm/m) N/A Q-10

33 Whether identified possible subsidence area(s) superimposed on Surface Yes N/A No Plan has been submitted? Major impacts on surface features like natural drainage pattern, houses, buildings, water bodies, roads, forest,etc Salient features of subsidence management (monitoring and control). 16. Surface drainage pattern at mine site (a) Whether the pre-mining surface drainage plan Yes No submitted? (b) Do you propose any modification / diversion Yes No in the existing natural drainage pattern at any stage? If yes, when. Provide location map indicating contours, dimensions of water body to be diverted, direction of flow of water and proposed route / changes, if any i.e. realignment of river / nallah / any other water body falling within core zone and its impact. 17. Embankment and / or weir construction (a) Do you propose, at any stage, construction of (i) Embankment for protection against flood? Yes No (b) (ii) Weir for water storage for the mine? Yes No If so, provide details thereof. (c) (d) Impact of embankment on HFL and settlement around. Impact of weir on down stream users of water. 18. Vehicular traffic density (outside the ML area) Type of vehicles (a) Existing Tippers/Tractor No. of vehicles per day (b) After the proposed activity Tippers/Tractor (c) Whether the existing road Yes network is adequate? If no, provide details of alternative proposal? Q-11

34 19. Loading, transportation and unloading of mineral and waste rocks on surface: (a) Manual Yes No (b) Tubs, mine cars, etc. Yes No (c) Scraper, shovels, dumpers / trucks. Yes No ] (d) Conveyors (belt, chain, etc.) Yes No (e) Others (specify). Not applicable 20. Mineral(s) transportation outside the ML area Qty. (in TPD) Percentage (%) (a) Road % (b) Rail NA NA (c) Conveyors NA NA (d) Rope way NA NA (e) Water ways NA NA (f) Pipeline NA NA (g) Others (Specify) Total NA 1666 NA 100% Q-12

35 21. Baseline Meteorological and Air Quality data (a) Micro-meteorological data [Continuous monitoring through autographic instrument for one full season other than monsoon] (i) Wind rose pattern for one full season (16 points of compass i.e. N, NNE, NE, ---) based on 24-hourly data. For coastal area also furnish day-time and night time data. Day time Night time 24 hours period (ii) Site specific monitored data Month Wind Speed (kmph) Temperature ( o C) Relative Humidity (%) Rain Fall * (mm) Cloud Cover** (Octas of sky) Mean Max. % of Mean Highest Lowest Mean Highest Lowest Total 24-hours No. of Mean calm (Dry Bulb) Highest rainy days December January February * 24-hours rainfall should be reported from 08:30 hrs. IST of previous day to 08:30 hrs. IST of the day. * Rainy day is considered when 24 hrs. rainfall is 2.5 mm. ** Visual observations of cloud cover should be recorded four times a day at regular intervals. (iii) Indicate name and distance of the nearest IMD meteorological station from which climatological data have been obtained for reporting in the EIA report, if any. Q-12

36 (b) Ambient air quality data* (RPM, SPM, SO 2, and NOx) [*Monitoring should be carried out covering one full season except monsoon same season as in 21 (a) (i)] [*Frequency of sampling: Sampling to be done twice a week for the entire season 24 hourly for SPM & RPM. For gaseous pollutants 24- hourly data be given irrespective of the sampling period. ] (i) Season and period for which monitoring has been carried out. (ii) No. of samples collected at each monitoring station Name of monitoring equipment used Equipment sensitivity Permissible AAQ standard (CPCB) R I S Monitoring Location No. of Samples Drawn Category* (R, I, S) P.M 2.5 P.M 10 SO 2 No x Pb** High Volume Air Sampler. (Envirotech Make) (Average flow rate not less than 1.1 cu.mtr/minute) Respirable particulate matter sampler (<10μm) High Volume Air Sampler. (Envirotech Make) with gaseous attachment Improved West & Gaecke method. High Volume Air Sampler. (Envirotech Make) with gaseous attachment Jacob & Hochheiser modified. (Naarsenic method) Min. Max. Avg Min. Max. Avg Min. Max. Avg Min. Max. Avg Min. AAS Method after sampling using EPM 2000 or equivalent matter. Core zone A 1 24 I Buffer zone A 2 24 I A 3 24 R A 4 24 R A 5 24 R A 6 24 R A 7 24 R A 8 24 R *R = Residential; I = Industrial; S = Sensitive *Pb for mineral specific sites only. Annex a location map indicating location of AAQ stations, their direction and distance with respect to project site. Map Enclosed Q-13 Max. Avg

37 22. Stack and emission details, if any* : Sl. No. Process / unit of operation (e.g. DG Set, Boiler) 1 Stack attached to Rotary Kiln in proposed Beneficiation Plan Height of stack (m) Internal top dia. (m) Flue gas exit velocity (m/sec) Emission rate (kg/hr) SPM SO 2 NO x CO Heat emission rate from top of stack (K.cal/hr) Temp O C Exhaust / Flue gas Density Specific Heat Volumetric flow rate (m 3 /hr.) , Details of fugitive emissions during mining operations* fugitive emissions will be controlled by water sprinklings through tanker & water sprinklers 24. Air Quality Impact Prediction (AQIP)* (a) Details of model(s) used for AQIP including grid : ISCST3 model is used. size, terrain features, and input meteorological data (b) Maximum incremental GLC values of pollutants based on prediction exercise (in μg/m 3 ) S. No. Pollutants Incremental Value Ambient Air Quality Resultant Air Quality 1. PM **. SO **. NO X [* Question Number 22, 23 & 24 need not be filled-in for mines having ML area of 25 ha. or less.] [**Information on item no. 2 & 3 to be provided in cases with captive power generation of 500 KVA and above] Q-14

38 25. Water requirement (m 3 /day) (For Mining & Beneficiation Plant combined) Purpose Avg. Demand Peak Demand A. Mine site 1. Mine operation 2. Land reclamation 3. Dust suppression 4. Drinking 5. Green Belt 6. Beneficiation 7. Washeries 8. Fire Service 9. Others (specify) B. Township 1. Green Belt 2. Domestic 3. Other (specify) KLD 20 KLD 25 KLD 242 KLD 50 KLD KLD 40 KLD 25 KLD 242 KLD 50 KLD - Total 377 KLD 377 KLD 26. Source of water supply* S. No. Source M 3 /day 1 River (name) Not applicable 2 Ground water 377 KLD 3 Mine water (sump / pit) - 4 Other surface water bodies (specify) - [*Annex a copy of sanction letter / permission from the concerned authority (Central Ground Water Authority in case of ground water abstraction is from notified area / State Ground Water Board in case of non-notified area / State Irrigation Department for surface water pumping) for drawing water.] 27. Lean season flow in case of pumping from river / nalla (cumecs) NA Q-16

39 28. Ground water potential of the study area Ground water availability (a) Range of water table (m bgl) (i) Pre-monsoon (April/May) Core Zone Buffer zone (ii) Post-monsoon (November) Core Zone Buffer zone (b) (c) Total annual replenishable recharge (million m 3 / year) By ground water table fluctuation method By rainfall infiltration factor method Annual draft excluding estimated draft through mine discharge (million m 3 / year) (d) Estimated draft through mine discharge (million m 3 / year) (e) Net annual ground water availability (million m 3 / year) (f) Stage of ground water development in % >210 m >35 m >210m >30m Not studied Not studied NA Not studied Water demand - Competing users of the water source S. No. Usage Present Consumption (m 3 /day) Additional proposed as per local plan (m 3 /day) Total (m 3 /day) Surface Ground Surface Ground Surface Ground 1 Domestic Irrigation/ Greenbelt Industry Mining Others (specify), Dust suppression & For washing, cleaning & other utilities Total Q-17

40 29. Water quality* (a) Annex physico -chemical analysis of water at intake point ** (b) In case of existing mine, annex report on quality of water discharge i.e. complete physico - chemical analysis** [*For non-discharging mines at least four ground water samples to be taken preferably from downstream direction of the mine in pre-monsoon and postmonsoon periods and analysed. For discharging mines six samples are to be analysed] **All parameters as per BIS Indicate name of Methodology, Equipment used for analysis, and Detection Level (DL) for each parameter. *** Wherever any analytical parameter is below detection level, BDL (Below Detection Level) should be written instead of NIL. 30. Impact on ground water regime / stream / lake / springs due to mine dewatering * (a) Radius of influence (in m) [To be estimated based on analysis of pumping Not studied test data and application of empirical formula] (b) Whether saline water ingress will take place? Yes No (applicable to coastal areas) (c) Impact on stream / lake / springs : No streams/lakes/springs are found in the area. [* Provide a comprehensive hydro-geological assessment report if the average mine dewatering is more than 100 m 3 /day and or going below water table in nonmonsoon period. The report should be based on preferably latest one year premonsoon and post-monsoon baseline data covering information on ground water situation, aquifer characteristics, water level conditions (April May and November), estimate of ground water resources, predicted impact of the project on ground water regime and detailed remedial / conservation measures such as artificial recharge of ground water etc. The report should be based on actual field inventory out of existing wells, at least 30 observation wells in the buffer zone with supplementary information from secondary sources (mention name). For estimation** of ground water resource (refer question no. 28 above) be designated study area of the buffer zone may be sub-divided into command and non-command areas, watershed-wise (in case of hard rock / consolidated formations) / block-wise / mandal-wise in case of alluvial / unconsolidated formations)] [**For estimating ground water resources in the area follow the Ground Water Estimation Committee recommendations of 1997] 31. Waste Water Management Mine (a) Daily average discharge (m 3 /day) from different sources (i) Mine water discharge during Lean period Nil Monsoon period Nil Q-18

41 (ii) Workshop Nil (iii) (iv) (v) Domestic (mine site) Beneficiation / Washeries Coal Handling Plant Nil 05 Nil (vi) (vii) Tailings pond Others (Specify) Nil Nil Total 05 (b) Waste water treatment plant; flow sheet for treatment process attached. Yes No (c) Quantity of water recycled / reused / : Not applicable no generation of waste water to be recycled in (i) Percentage (ii) m 3 /day (d) Point of final discharge Final Point Quantity discharged (in m 3 /day) 1. Surface (i) Agricultural land (ii) Waste land (iii) Forest land Not applicable (iv) Green belt 2. River / nallah Not applicable 3. Lake Not applicable 4. Sea Not applicable 5. Others (specify) Not applicable Total (e) Users of discharge water (i) Human Yes No (ii) Livestock Yes No (iii) Irrigation Yes No Q-19

42 (iv) Industry Yes No (v) Others (specify) Not applicable (f) Details of the river / nalla, if final effluent is / will be discharged (cumecs) (i) (ii) (iii) Average flow rate Lean season flow rate Aquatic life Not applicable Not applicable (iv) Analysis of river water 100 meters Yes No upstream and 100 meters downstream of discharge point submitted. Township (a) Waste water generation from township (m 3 /day) Not applicable (b) Are you planning to provide sewage Yes No treatment plant? (c) Usage of treated water 32. Attach water balance statement in the form of a flow diagram indicating source (s), consumption (Section-wise) and output. Water balance table is provided in EIA report 33. Ambient noise level leq db(a) Location of sampling station Noise level Day Time Night Time A. Core Zone N B. Buffer Zone N 2 N 3 N 4 N 5 N 6 N Solid Waste (a) Top soil and Solid waste quantity and quality Name (Lump/fines/slurry/ Sludge/others) Mining activity* a. Top Soil b. Over burden Composition Intercalated waste & Quantity (m 3 /month) - 60% of ROM from mine Method of disposal - will be disposed to waste dumps Q-20

43 waste in nonmineralized area. c. Others (specify) (from Beneficiation Plant) Effluent Treatment Plant (sludge) Total TPA Tailing sludge About 50% of the tailings (43,500 tons) will be sold to the brick manufacturers & the remaining 50% will be used for back-filling of the mined out areas Nil Nil Nil [* Annex layout plan indicating the dump sites.] (b) (i) Does waste (s) contain any hazardous/toxic substance/ radioactive materials or Yes No heavy metals? (ii) If yes, whether details and Yes No precautionary measures provided? (c) (d) Recovery and recycling possibilities. Possible user(s) of the solid waste. (e) (i) Is the solid waste suitable for backfilling? Yes No (ii) If yes, when do you propose to start backfilling. Solid waste (s) Already accumulated (A) To be generated (B) Over burden -- 60% of ROM from mine Others (specify) Simultaneous with mining operations (in million m 3 ) % of A & B to be backfilled A B - 80% Land reclamation Plan (f) In case waste is to be dumped on the ground, indicate (i) Associated environmental problems: Soil erosion Q-21

44 (ii) Number & type of waste dumps No. of external dumps Max. projected height of dumps (in m) No. of terraces and height of each stage Overall slope of the dump (degree) Proposed reclamation measures 4 10m (iii) Section of the waste dump in relation to the adjacent ground profile attached. Yes No 35. Fuel / Energy requirements* [*To be furnished for mines having ML area more than 25 ha. or captive power generation of 500KVA and above] (a) Total power requirement (in MW) S. No. Mine Site Township Others (specify) Total For Beneficiation Plant 1 Present Nil Nil Nil Nil 2 Proposed / Nil Nil 1.5 MW 1.5 MW additional Total Nil Nil 1.5 MW 1.5 MW (b) Source of power (in MW) S. No. SEB/Grid* Captive power plant DG Sets (Standby power source) 1 Present Nil Nil 2 Proposed 1.5 MW Nil 1.0 (c) Total 1.5 MW Nil 1.0 [* Annex a copy of the sanction letter from the concerned authority] Details of fuels S.No. Fuel Daily Consumption (TPD) Existing Proposed 1 HSD ltrs/hr (for DG 2 LSHS - set, which is standby 3 Other - power (specify) source) - - Calorific value (Kcals/kg) % Ash % Sulphur Q-22

45 36. Storage of inflammable / explosive materials S. No. Name Number of Storages Consumption (in TPD) Maximum Quantity at any point of time(in Tons) 1 Fuels Explosives Human Settlement Core Zone Buffer Zone Population* Nil No. of villages Nil 20 Number of households Nil village-wise [* As per 2001 census record or actual survey] 9576 (list enclosed) 38. Rehabilitation & Resettlement (R&R) Plan* [*Provide a comprehensive rehabilitation plan, if more than 1000 people are likely to be displaced, other-wise a summary plan] (a) Villages falling within the study area Number Core zone Nil Nil Villages Name 500 m from the blasting site (s) Nil Nil Buffer zone 20 List enclosed Township site Nil Nil (b) Details of village(s) in the core zone : Nil S. Village name Population* Average Annual No. Tribal Others Income (c) [*As per 2001 census / actual survey] Population to be displaced and / or Land oustees : Not applicable Name of village(s) falling within Number of oustees Land (only) Homestead (only) Land and Homestead (both) Q-23

46 Mining Lease 1. Township Site 1. Nil Nil Nil Nil Nil Nil (d) Whether R&R package has been finalised? : Not applicable If yes, salient features of R&R plan for oustees. (i) (ii) (iii) (iv) (v) Site details where the people are proposed to be resettled & facilities existing / to be created. Funds earmarked for compensation package. Agency /Authority responsible for their resettlement. Time of commencement of resettlement of Project Affected People (PAP). Period by which resettlement of PAP will be over. 39. Lease -wise plantation details (a) Lease area (in ha.) Existing mine New mine (i) (ii) (iii) Area broken up To be broken up Area not to be broken-up (b) (c) Township area (in ha.) Area afforested and proposed (in ha.) - Peripheral Dumps Roads Township Others (Mineral storage & separation plant) (i) Existing (ii) Proposed (d) No. and type of trees planted and proposed (i) Existing When plantation was started? Month / Year April 2008 Q-24

47 No.of plant species planted Number saplings (per ha.) Survival rate % 60% Avg. height 3 (ii) Proposed No. of plant species to be planted Number of saplings (per ha.) Environmental health and safety (a) What major health and safety hazards are anticipated? : No major health hazards are anticipated due to the proposed mining activity. Risk & possible hazard details from proposed beneficiation plant is provided in EIA report (b) What provisions have been made/proposed to be made to conform to health and safety requirements? Safety requirements such as ear muffs, respirators, hand gloves, shoes etc., are provided to the mining labor. Medical facilities in the form of first Aid, arrangements with the nearby town Hospital for periodical treatment of Employees are made. (c) In case of an existing mine (i) Comprehensive report on health status of the workers as under the Mines Act annexed. Yes No (ii) Mineralogical composition of RPM (dust) Free silica Chromium* (Total as well as Hexavalent) Lead** [* Only for Chromite mines] [**Only for Base Metal mines] (d) Information on radiation protection measures, if applicable. 41. Environmental Management Plan Detailed EMP for the proposed plant is provided in EIA report Salient features of environmental protection measures S. Environmental issues* Already practiced, if applicable Proposed No. 1 Air pollution Water sprinkling for dust suppression in the core & buffer zone & proper maintenance of haulage roads. Water sprinkling for dust suppression in the core & buffer zone & proper maintenance of haulage roads. 2 Water pollution Construction of gully plugs & Construction of gully plugs & Q-25

48 retaining walls all around the dumps existing & proposed in a phased manner. 3. Water conservation Rain water harvesting measures. 4. Noise pollution Minimise drilling & blasting for mining and proper maintenance of machinery and provision of ear plugs to all eligible employees. 5. Solid waste / Tailings Disposal of overburden to dumps situated in nonmineralized zone earmarked for the purpose as per the Mining Plan. 6. Land degradation Concurrent reclamation of the mining area with afforestation measures will help in reducing the land degradation. 7. Erosion & Sediment Construction of retaining walls, toe drains etc., will prevent soil erosion. 8. Top soil Top soil will be preserved separately and utilized for afforestation. 9. Ground vibration There shall be no vibration as there is no proposal for deep hole drilling & blasting for mining of Dolomite. retaining walls all around the dumps existing & proposed in a phased manner. Rain water harvesting measures. Minimise drilling & blasting for mining and proper maintenance of machinery and provision of ear plugs to all eligible employees. Disposal of overburden to dumps situated in nonmineralized zone earmarked for the purpose as per the Mining Plan. Concurrent reclamation of the mining area with afforestation measures will help in reducing the land degradation. Construction of retaining walls, toe drains etc., will prevent soil erosion. Top soil will be preserved separately and utilized for afforestation. There shall be no vibration as there is no proposal for deep hole drilling & blasting for mining of Dolomite. 10. Wildlife conservation Not Applicable as the area is devoid of any wildlife. 11. Forest protection Others (specify) - - [* As applicable] Not Applicable as the area is devoid of any wildlife. 42. Compliance with environmental safeguards (For existing units) (a) (b) Status of the compliance of conditions of environmental clearance issued by MoEF, Yes No if any, enclosed. Status of the compliance of Consent to Operate issued by SPCB, if any, enclosed. Yes No N/A (c) Latest 'environmental statement' enclosed. Yes No Q-26

49 43. Scoping of EIA Whether environmental impact assessment of the project has been carried out by Yes No following scoping process? If yes, a copy of scoping of EIA annexed. Yes No 44. Mine closure (a) Have you planned mine closure? Yes No (b) Submitted a conceptual mine Yes No closure plan. (c) If yes, indicate estimated amount for implementing the same (in Rs. lakhs) Capital cost of the project (in Rs. Lakh) (Based on latest estimate) with proposed Beneficiation Plant Crores 46. Cost of environmental protection measures Sl. No: Component Amount in Rs Lakhs Recurring Cost per 1 Pollution Control (check dam, gully plug, retention wall, settling tank, water tanker, etc.) in Iron Ore Mine 2 Pollution control equipments in Beneficiation Plant Annum Rs. in Lakhs Dust Suppression Chimneys Greenbelt Development in mine & Beneficiation Plant Environmental Pollution Monitoring in mine & plant 7 Occupational Health Socio-economic welfare measures in near by villages Total Amount earmarked for socio-economic welfare measures for the nearby villages other than R&R plans. 48. Public Hearing : 5% of the Capital cost will be utilized for welfare Activities under CSR. (a) Date of Advertisement Q-27

50 (b) (c) Newspapers in which the advertisement appeared Date of public hearing (DD/MM/YYYY): The Hindu, Eenadu d) Public Hearing Panel chaired by & members present : District Collector,Kadapa (e) (f) No. of people attended the public hearing meeting and number of people from the lease area. Summary/details of public hearing in tabular form. About 200 people Issues raised by the Public Sri Bandi Suryanarayana Reddy, R/o Choutupalli stated that several people are dependent on the mines. The mines created livelihood for workers, contractors, transporters. He requested the people to sort out any grievance with the management with a positive approach. Due to the management support, they filled up the lowlying areas. He pointed out to the assistance for schools and worship places. He expressed concern with some government rules those became hurdle in getting the management s support for building the houses. He acknowledge that the management has already given employment for the local people. He also expressed that the project will improve the livelihood opportunities in the future too. He however welcomed the proposed project. Sri Gangireddy, R/o. Pagadapalle stated there are some 10 mines surrounding to their village. The government schemes could not build the check dams and also troubling to take up constructions. He added that the ground water table is improved because the management developed a mine pit. The mining department will examine the case to grant the clearance. The promoter is well known for the last 25 years for his educational institutions and mines. The management provided livelihood for the local people in his mines. He advocated the people that there will be no adverse impacts. On the other hand it will benefit the area. He further stated that the local people especially women lost employment as the management stopped their mining. That is why they participated in the hearing in large numbers to vent their appeals. Sri Prasad Reddy. R/o Choutupalli stated that there was no employment before mining. The management facilitated livelihood for the local Response/Commitment of Project Proponents Sri Kandula Raja Mohan Reddy, Managing Director while thanking the people for their extending cooperation to the management stated that they involved in mineral business for the last 60 years. They are also doing Barytes mining in Mangampet mandal. They also are having engineering colleges. In all the establishments, he is giving top priority for the local people. He assured that they will resume the mining operations shortly. He also stressed the necessity of the beneficiation plant, which will ;improve or enchance the quality of iron ore through a series of systems and process.. It will improve the iron ore grade and make it useful for industrial purposes. They are establishing a plant at Mangampet in join venture with the APMDC at an approximate cost of Rs. 40 crores. The plant will improve the quality o0f Barytes, which stocks are piling up. Owning to demand for iron ore, they proposed to enhance its production and have one beneficiation plant. He is also working on the project for about 10 years and studied the projects located abroad. He admitted that the stringent statutory norms will not allow the industries to cause environmental pollution. If violated, the authorities will take stringent action. The industry will adopt necessary equipment and will avoid the pollutants. Thus there will not be any impact on air, water, agriculture, health, cattle etc as apprehended. He further assured that he will provide employment for the local qualified people in their major plant. Q-28

51 people in their mines. Since only labourers are getting jobs, he sought to create jobs for the eligible educated people. Due to plying of heavyloaded tippers, the roads are getting damaged. He requested to take repair the roads and address the problems emanating from transportations. He also sought to know the measures to be taken for education and health. He however thanked the management for providing livelihood. Smt. Ganga Lakshmi, R/o Repalle stated that the people availed benefits for the mines for about nine years. She concerned that there is no livelihood for the last four months as the management halted the operations. She sought to resume the mining operations for their benefit. Smt. Chandramma, R/o Repalle stated that they were working in the mines. They eked out a living, depending on the mines. For the last four months, they are facing problems due its closure. Sri Gangannan, R/o Gokarajupalle stated that they are in favour of the mines. Since they are living on it, he urged to continue the mining activity. Sri M. Chandra Reddy, ex-sarpanch, chabali stated that he functioned as sarpanch for the village for 30 years. The royalty-related issue is affecting the house constructions. He added that there was no development earlier. The management should sort out their grievances and help the people. The proposed iron ore mining and the beneficiation plant will create direct and indirect employment for the local people. Sri Subba Reddy, r/o Machunuru stated that he worked in Singapore in the last year. He acknowledged that there is no negative impact due to the existing mines. Several people are benefited with the management and its quantum is somehow reduced because of its closure. He exhorted the people to lsupport the project which will reciprocate. Being a diploma holder, he is in anticipation of job in the proposed project. He urged to facilitate one hospital in the area as the people are facing hardships. If it is established will be a great help for the locals. He also raised concern over power cut problems as they are availing it for mere 4 hours. The problem is hampering the interests of the farmers. He while supporting the project sought livelihood for the local people. Smt. Narsamma, Goparajupalle stated that there was no livelihood for their family because of the mine closure. She requested to resume the mining operations. As a part of pollution control measures, they will arrange water sprinkling. It will also earmark some portion of land for cattle grazing. He assured to set up a hospital under CSR in order to meet the emergency health needs of the people. It the Bellary mines resumed, the surrounding mines will become dysfunctional. He sought continued support from the villagers. He promised to allocate adequate budget for carrying out socio-economic welfare activities such as health, education etc. Q-29

52 Sri. Srinivasulu Reddy, R/o Aravetipalle stated that their houses are getting cracks due to the blasting activity in the mines. Their cattle could not find the grazing. It is also posing dust pollution besides depleting the ground water in the agricultural fields. The water pipelines are also damaged thereby jeopardizing the interests of the nearby farmers. Because of air pollution, the crop is getting affected. He complained that the management has not provided employment for ltheir villages. He added that the stakeholders should be benefited with the mines. Sri Ramachandra Reddy, R/o China Chabali stated that the people are facing certain problems due to the mining operations. The dust emanated from the mining activity has affected the agricultural fields. Their borewells became defunct of water depletion. The water is only stagnated in the mines whereas in other places there is no water. It is the situation prevailing not only in Chabali but also in other villages. He requested the authorities to make note of this issue and take suitable action. The people will have no objection if the mines are beneficial to them. He however requested to take remedial measured to avoid negative impacts. The Management further stated that the company would adopt latest delay technology in mining operations, which will avoid vibrations and some adverse environmental consequences. It will arrange water sprinkling system at various dust emanating sources. The facility will prevent the fugitive dust. The ground water is available at 50m depth in the area whereas the ultimate mine pit has the depth of monthly. Thus it has nothing to do with the ground water table. He assured that the management will take all appropriate measures to avoid adverse impacts. 49. Whether the following approvals* (wherever applicable) have been obtained? (i) Site clearance from MoEF Yes No (ii) Consent for Establishment from the Yes No State Pollution Control Board (iii) NOC from Atomic Mineral Division Yes No (iv) Mining plan approval from IBM / Ministry of Coal Yes No (v) In case of existing mines, mining scheme approval from IBM Yes No (vi) Forestry clearance under FCA, 1980 Yes No (vii) NOC from Chief Controller of Yes No Explosives (viii) Commitment regarding availability / Q-30

53 pumping of water from the concerned Yes No Authorities (ix) In case of ML area falling in notified areas of the Central Ground Water Authority, Yes No NOC from them. [* Annex copies of approvals and number them] 50. Was / is there any court case relating : No to the project or related activities? If so, provide details present status. Verification: The data and information given in this proforma are true to the best of my knowledge and belief. Date: Place: Kadapa Signature of the applicant* with full name & address K. RAJAMOHAN REDDY # , Court Road Kadapa Andhra Pradesh Q-31

54 EXECUTIVE SUMMARY

55 EXECUTIVE SUMMARY 1.0 INTRODUCTION SRI. K. RAJAMOHAN REDDY Residing at Kadapa district of Andhra Pradesh are involved in mineral business from the past 20 years. has applied for a mining lease for Iron Ore over an extent of Hectares in S.No.320 of Chabali Village, Pendlimarri Mandal, Kadapa district and the Government of Andhra Pradesh has granted the Mining Lease vide G.O.M.S.No. 173 dated The total mining lease area falls under revenue category. The mining plan was approved by Indian Bureau of Mines, vide lr. no. 659 (386)/Iron/2000/CDP/ Dated 20/1/2001 for production of iron ore with production capacity of 50,000 TPA. The present proposal is for enhancement of production of Iron Ore from 50,000 TPA to 0.5 MillionTPA (5,00,000 TPA) and setting up a Beneficiation Plant with a thoughput capacity of 0.3 MillionTPA in an extent of Hectares of Mine Lease area. Cost of the Project is Crores As per TOR Letter No: J-11015/164/2011 IA. II (M), Dated on 14 th February 2011, issued by Ministry Environment & Forestry (MoEF), New Delhi, the lessee has to obtain clearance from MOEF, GOI, New Delhi for this proposed project. Accordingly, the lessee has engaged the services of Global Enviro Labs, Hyderabad, for Preparation of REIA reports for submission to APPCB, Hyderabad and MOEF, New Delhi to obtain Environmental clearance. The baseline Environmental Status was assessed for Winter season i.e. from December 2011 to February The report covers the Environmental Impact Assessment (EIA) and EMP for the proposed enhancement of production of Iron Ore from 50,000 TPA to 0.5 MillionTPA (5,00,000 TPA) and setting up a Beneficiation Plant with a thoughput capacity of 0.3 MillionTPA in an extent of Hectares of Mine Lease area. The report has been prepared in accordance with the latest stipulations of MOEF, GOI, New Delhi. 2.0 PROJECT DETAILS 2.1 MINING The mine is being worked by semi-mechanized open cast method. The bench height is 3m (with 2 sub benches of 1.5 m height each). The over burden is removing by hydraulic shovel / wheel loader and loaded in to toppers and total ROM is transported to crushing and screening plant. Drilling by Jack Hammers is carried out for excavation of Iron Ore and removal of ROM in the working face. Drilling and blasting is required only for 20% of ROM excavated and balance 80% of ROM quantity can be removed with help of hydraulic excavators without using drilling and blasting.

56 2.1.1 Water Consumption & Wastewater Generation The water requirement for this mining activity will be 50 KLD. Breakup details are: Dust suppression purpose: 30.0 KLD, Domestic purpose: 10.0 KLD, Greenbelt purpose: 10.0 KLD About 5.0 KLD of Domestic effluent will be generated from this mine and this will be sent to septic tank fallowed by soak pit. There is no generation & discharge of wastewater from this mine. 2.2 BENEFICIATION PLANT The proposed Beneficiation Plant with a thoughput capacity of 0.3 MillionTPA in the Mine Lease area to improve or enhance the quality of the iron ore through a series of systems and processes. The word beneficiation implies a Process which is employed to upgrade the Lower Grade Mineral to level at which the Mineral could be used beneficially. Different Equipments are used for different processes. The type of Processes and Equipments which have to be employed would be based on a Mineralogical Test to be conducted on the Ore. Following is the process description - 1) Crushing - The low grade hematite iron ore is crushed between 50 mesh & 5 mm size, using Electromagnetic vibrating feeder, Jaw Crusher & Fine Crusher. The crushed ore is sieved in the vibrating screens & the over-sizes are returned back for re-crushing. Sized ore is taken to the rotary kiln by belt conveyor. 2) Rotary kiln - Sized ore of less than 5 mm size is passed through the inclined rotary kiln along with some quantity of coal for reduction & some small quantity of lime stone for binding sulphur in the coal. The travelling time is less than 2 hours & the temperature is less than 900 o C. Coal is used for both heat supply & for partial reduction. After partial reduction into magnetite, the ore is conveyed in the belt conveyor for natural cooling. The Rotary kiln is completely enclosed with dust collectors & cyclones. The flue gases are connected to the chimney, after de-dusting. 3) Ball mill grinding - The magnetite ore at this stage is conveyed to a hopper by belt conveyor & fed to the ball mill with electromagnetic vibrating feeder. Since the ore is already magnetite, it is easy to grind & takes less power. Ball mill grinds the iron ore between mesh, as per the liberation size required. 4) Magnetic separators - After wet grinding in the ball mill, material is sent to high frequency screen by slurry pump. Material above the screen is returned to the ball mill, while material below the screen is sent to a series of magnetic separators for coarse & fine selection separately. 5) Floatation - If Silica & Alumina in the raw material are still high, further removal of Alumina & Silica will be done in the floatation chambers.

57 6) Drying After magnetic separation & floatation, the final concentrate has 70% moisture, which is carried by slurry pumps to the fine powder open concrete tanks, equipped with water overflow & water screening system. After 7 days of storage, the dried 65% Fe concentrate with 10% moisture is removed from the concrete tanks and sent to the customers, who can use it in their pellet plant. 7) Plate & Frame Filters The mud (slime or tailings) containing 10% Fe+ some coal ash & gypsum is carried in the sand pump to the Plate & Frame filters, which separate mud from the water. The squeezed mud is taken to the storage area & removed from time to time by sending to the local brick plants. Part of the tailings is retained for land - filling in the mined area. After land-filling, suitable trees will be planted on them. The recycled water is taken back from Plate & Frame Filters to the water storage system for re-use. Since the mud is a fine ground powder with high silica & alumina contents and with minor quantities of coal ash & gypsum, it is much useful for clay brick making RAW MATERIAL REQUIREMENT S.N. Raw Material Requirement Source Mode of Transfer 1 IRON ORE FINES 3,00,000TPA From Tarpaulin (50% grade) 1.47 tons per ton Captive Mine covered trucks of beneficiated ore ( recovery of beneficiated iron ore is 2,05,000 tons) 2 COAL for reduction roasting in the Rotary kiln ( based on 5,000 kcal/kg & 40% Fixed kgs per ton of raw iron ore 3 LIMESTONE for reduction roasting TPA Open market/impor ted Coal Tarpaulin covered trucks 3000 TPA Open market Tarpaulin covered trucks WATER REQUIREMENT & WASTEWATER GENERATION FROM BENEFICIATION PLANT The proposed Beneficiation plant needs Kilo liters per Day. This water requirement is met from bore wells located within in the site. The details of water requirement are given below: Sr.No. Units Requirement (m 3 /day) Make-up Water (m 3 /day) 1. Beneficiation Process 3000* For washing, cleaning & other utilities 150* Dust Suppression Greenbelt Domestic Purpose Total 327 *In this unit water is one time requirement for process run

58 WASTEWATER GENERATION There is no generation of wastewater from the proposed iron ore beneficiation plant. Only evaporation losses, drift losses and spillages are encountered. About 5 m3/day of Domestic effluent will be generated from the proposed beneficiation plant and this will be sent to septic tank followed by soak pit. The net water requirement works out to be 0.3 m3 per ton of iron ore used as raw material. After Plate & Frame type filters, the project can use 100% recycled water in place of fresh water in the Ball mill & Magnetic separators. 3.0 COLLECTION OF BASELINE DATA The data collected for this project to know the existing quality of air, water, soil characteristics, flora & fauna, noise levels and socio economic details of the study area during the winter i.e. for the months of December 2011 to February AIR ENVIRONMENT In order to assess the existing ambient air quality in the study area of 10 km radius of the mine area, a network of 8 ambient air quality stations were selected and samples were collected to analyze for various parameters like PM2.5, PM10, SO2, NOx and CO concentrations. The sampling stations were selected based on the Topography/ Terrain of the study area, Populated areas, Residential areas etc. The values of ambient air quality of all the monitoring stations for various parameters during the study period (December 2011 to February 2012) will be as following. The maximum value of PM2.5 in the proposed project area is 17 μg/m3, PM10 is 36 μg/m3, SO2 is 2.9 μg/m3, NOx is 4.3 μg/m3 and CO levels are less than 1 ppm The average value of PM2.5 in the buffer zone in the range of μg/m3, PM10 in the range of μg/m3, SO2 in the range of μg/m3, NOx in the range of μg/m3 and CO levels are less than 1 ppm The concentrations of various parameters in the air quality of the study area were found to be well within the norms prescribed by NAAQ. 3.2 NOISE ENVIRONMENT In order o know the baseline noise levels, in and around the Mine site, Noise levels were measured at the Mine complex and also at 6 villages in the study area. The day-night noise levels were monitored at all locations and the maximum day noise levels ranging from 54.1 db(a) to 60.1 db(a) The noise levels recorded at all the stations were found to be less than the standards prescribed.

59 3.3 WATER ENVIRONMENT In order to assess the Groundwater quality impacts 7 nos of samples were collected. These samples were analyzed for various physical ad chemical and bacteriological parameters to know the potability levels. All the water samples collected shows that the parameters well within the drinking water standards specified in IS LAND ENVIRONMENT 6 nos. of soil samples were collected and analyzed for Physical & Chemical parameters. 3.5 BIOLOGICAL ENVIORONMENT The details of flora and fauna present in the study area were described elaborately in the EIA report 3.6 SOICIO-ECONOMIC ENVIRONMENT The detailed description of the Socio-Economic Environment is presented in the EIA report. 4.0 ENVIRONMENTAL IMPACTS 4.1 AIR ENVIRONMENT The impacts on air environment from a mining activity depend on various factors like production capacity, machinery involved, operations and maintenance of various equipments and vehicle. Apart from these, there will be other activities associated viz transportation of iron ore and waste, stocking facilities and dump management within the mine lease area that may contribute to pollution. The major air emissions from the proposed beneficiation plant are mainly from Rotary Kiln area where the dust is released through flue gases to the atmosphere. The Lessee will provide the bag filter to the rotary kiln, designed for an outlet concentration of less than 50 mg/nm3. The major pollutants emitted from this unit are particulate matter. For estimation impacts, an out let concentration of 50 mg/nm3 has been considered. The emissions from the proposed Rotary Kiln after treating in Bag filters will be let out into the atmosphere through a stack height of 45m. In addition to the above a highly efficient de-dusting system with pulse bag dust catcher will be provided near the Jaw crusher, fine crusher & screen, near the coal crusher & screen for exhaust gases before letting the same out through the stacks. An attempt has been made to predict the incremental rise of various ground level concentrations above the baseline status in respect of air pollution due to 0.5 MillionTPA of Iron ore production & 0.3 MillionTPA of Beneficiation plant. The Industrial Source Complex Short Term model (ISCST3) is a computerized air quality model, which was

60 approved by United States Environmental Protection Agency for mining applications is used for predicting the Ground Level Concentrations (GLC) due to the project activity. The maximum ground level concentration of PM is estimated to be about μg/m3 SO2 is 2.41 and NOx is 2.12 μg/m3 within the project area. The net concentration of PM, SO2 & NOx (maximum baseline cone. + predicted conc.) in the project area are given below. OVERALL SCENARIO WITHIN STUDY AREA (μg/m3) 24 Hourly Particulate Sulphur Oxides of Concentrations Matter (PM10) Dioxide (SO2) Nitrogen (NOx) Baseline Scenario (Max) Predicted Ground Level Concentration due to proposed Integrated Steel Plant (Max) Overall Scenario NAAQ Specified Limits The net concentrations of PM, SO2 and NOx, are will with the National Ambient Air Quality Standards (NAAQS). Hence there will not be any adverse impact on air environment due to the proposed project activity. 4.2 WATER ENVIRONMENT The Mining activity is on hill area and will not have any effect on the ground water and the static water table in this area is below 50 m. There are no major streams and rivers, which can get effected by the mining. Hence, there will be no effect on the surface water The rainwater drains the slopes of the area and joins to seasonal nallahs, which is running in out side the area. Water Consumption & Wastewater Generation for Mining Activity The water requirement for this mining activity will be 50 KLD. Breakup details are: Dust suppression purpose: 30.0 KLD, Domestic purpose: 10 KLD, Greenbelt purpose: 10 KLD About 5.0 KLD of Domestic effluent will be generated from this mine and this will be sent to septic tank fallowed by soak pit. There is no generation & discharge of wastewater from this mine. The proposed Beneficiation plant needs 327 Kilo liters per Day. This water requirement is met from bore wells located within in the site. The details of water requirement are given below:

61 Sr.No. Units Requirement (m 3 /day) Make-up Water (m 3 /day) 1. Beneficiation Process 3000* For washing, cleaning & other utilities 150* Dust Suppression Greenbelt Domestic Purpose Total 327 *In this unit water is one time requirement for process run WASTEWATER GENERATION There is no generation of wastewater from the proposed iron ore beneficiation plant. Only evaporation losses, drift losses and spillages are encountered. About 5 m3/day of Domestic effluent will be generated from the proposed beneficiation plant and this will be sent to septic tank followed by soak pit. Rainwater harvesting structures have been proposed to recharge the ground water. This indicates that there will not be any adverse impact on water environment due to the proposed project. 4.3 NOISE ENVIRONMENT The ambient noise levels in the mine area will be in with in stipulated standards. Hence, there will not be any adverse impact on noise environment due to the proposed project activity. 4.4 LAND ENVIRONMENT RECLAMATION The mining area is a hilly and undulating land. The top soil in the mining area is scanty. Whatever is available will have to be excavated during the development of the mine pits. Most of this soil is rocky in nature and will get mixed with the over burden. Temporary storage of top soil over burden may cause some loss of nutrients and this cannot be avoided. Since, the mining area is contained to only Ha, the effect on the land environment will be negligible. There shall be no leachate from the lease area. There shall be soil erosion of the loose soil of waste dumps which shall be contained. The adverse effect of the mining activity on the bio diversity shall be mitigated by employing proper mitigating measures. There is no generation and discharge of process effluents from this proposed beneficiation plant. Hence there will not be any adverse impact on the land environment. WASTE GENERATION FROM MINE In this mine 60% of ROM is considered as waste & intercalated waste. The total waste will be dumped out side the pit limit and the max. height of waste dump will be kept 10m.

62 SOLID WASTE GENERATION FROM BENEFICIATION PLANT About TPA of Tailing Sludge will be generated from the proposed beneficiation plant. About 50% of the tailings (43,500 tons) will be sold to the brick manufacturers & the remaining 50% will be used for back-filling of the mined out areas. 4.5 BIOLOGICAL ENVIRONMENT The area is devoid of any significant growth of shrubs and trees and is mostly covered with iron ore & dolomite and does not support any growth. The area is hilly and rocky. The entire vegetation, though scanty will disappear in areas where mining, dumping of waste rock, over burden road formations and infrastructural facilities. The loss will be more than compensated by compensatory afforestation and also green belt development planned in and around the mine which will rather increase the green cover and vegetation diversity. The fauna in the vicinity of the mine is restricted to common small species. The mine lease area is surrounded by few other Quarries and hence no significant fauna is found in the lease area. All these will be displaced from mine area and form new habitations away from mine. There are no endangered, threatened, rare or protected species in the study area. Some of the fauna displaced / scared away by the project may reappear in the mining area after abandonment of the mine. As such, the impact of mining project may have: Low impact on regional biological environment. The duration of impact will be throughout the mining period. No significant impact on bio-diversity on regional scale. 4.6 SOCIO-ECONOMIC ENVIRONMENT It will be obvious to assume that the activities of the proposed project have to be produced some improvements in the socio-economic levels in the study area. The proposed mining & beneficiation activities will provide employment to local persons of different skills and trades. The employment potential ameliorated economic conditions of these families directly and provided employment to many other families indirectly who are involved in business and service oriented activities. This in-turn will improve the socio-economic conditions of the area. 5.0 ENVIRONMENTAL MANAGEMENT PLAN The major objective and benefit of utilizing EIA in mining & beneficiation plant initial stage itself is to prevent avoidable losses of environmental resources and values as a result of well-planned EMP. Environmental Management Plan includes protection/mitigation/enhancement measures as well as suggestions for the post projectmonitoring programme to implemented y the project proponent.

63 5.1 AIR ENVIRONMENT MINE LEASE AREA Air pollution control measures would be of three types namely (i) dust suppression system (DSS) and (ii) vehicular emission control (VEC). Dust suppression system (DSS): Adequate water sprinkling arrangement would be provided to suppress dust emissions from the haul roads, mine working faces, ROM stockpiles and other areas susceptible to dust emissions due to surface wind. It is proposed to deploy water tankers fitted with pressurised multiple spray systems including side sprays. On the haul roads which cause maximum dust nuisance, water shall be sprinkled on the road mixed with dust suppressant chemical to enhance the soil moisture retention capacity. This chemical shall be non-toxic, non-corrosive and of neutral ph. Periodically the roads shall be graded and spillage material shall be removed to the earmarked areas. Source emission control: In opencast mining, operations such as, drilling and blasting and ore handling, generate appreciable levels of fugitive dust. In order to control the dust emissions at the above sources it is proposed to adopt the following work practices on routine basis. Usage of sharp and properly shaped drill bits by maintaining appropriate pressure on the bit and keeping the holes clear for cuttings shall be ensured. The mineral bed shall be moistened to a certain extent to minimise dust arising during various operations such as drilling & blasting. Vehicular emission control (VEC): Vehicular emissions from diesel operated transport equipment can be contained, by avoiding idle running and overloading of the engine. In addition, the engines shall be periodically serviced to ensure proper tuning and exhaust gases monitored on a regular basis to check smoke and CO levels AIR ENVIRONMENT BENEFICIATION PLANT The sources of air pollution are raw material handling system, materials transportation, raw materials feeding to the operating equipments. The automatic process equipments will be employed for the raw material feeding system. Air pollution control devices of A highly efficient de-dusting system will be employed near the Jaw crusher, fine crusher & screen, near the coal crusher & screen and near the Rotary kiln for exhaust gases before letting the same out through this stack.the following Environmental Management Plan will be implemented to control air emissions. Ball mill operations will be wet process in closed shade/system will not generate any dust emission.

64 Pulsjet bag filters will be installed. which will act as raw material recovering system as well as air pollution control equipment. This air pollution management system has been ensured by Chinese partner that installing bag filters will maintain pollution norms within permissible limits that is <50mg /NM 3, rather than wet scrubbers. Dust suction system will be employed in raw material handling points to minimize fugitive emission. The coal and iron ore fines after drying shall be conveyed through closed / covered material handling equipments like tube conveyor etc. to ensure minimum dust pollution. Action Plan to Control and Monitor Secondary Fugitive Emissions from all the Sources It is proposed to use the Dry Fog Type dust suppression system for all the secondary sources of fugitive dust emissions. In view of this, all transfer points, shall be covered with dust suction system. Where ever possible, the fugitive sources such as hopper, screens etc. shall be sprayed with mist/dry fogging agents. Recirculation of flue gas from kiln will reduce pollutant emissions. All transfer points, will be provided with dust suction system. Fugitive as well ambient air quality monitoring shall be carried out on regular basis to ensure the compliance with National Ambient Air Quality Standards (NAAQS) The monitoring frequency of air quality shall be as per the consent issued by State Pollution Control Board and reports shall be submitted as part of compliance. The records will be maintained The ambient air quality within the factory premises shall not exceed the standards (PM µg/m 3, PM µg/m 3 SO 2 80µg/m 3, NO X 80µg/m 3 and CO 04µg/m 3 ) prescribed by CPCB Regular Stack Monitoring will be done. All the emissions from the plant will be controlled to meet the relevant standard set by CPCB/State Pollution Control Board Details regarding volumetric flow, temperature and emission rate of pollutants from different stacks shall be collected and compiled regularly Proper maintenance of valves seals and flanges to minimize fugitive emissions. Effective steps shall be taken to control fugitive emission inside the plant. All internal roads will be Tar Roads. Efficient arrangements will be provided to control fugitive dust emission during handling/transportation of Raw materials / finished product etc A green belt will be developed to control fugitive emissions & gaseous pollutants to keep clean and healthy environment.

65 5.2 WATER ENVIRONMENT There will only 10 KLD (5 KLD from Mining project + 5 KLD from Beneficiation Plant) Domestic effluent will be generated from this proposed entire project and this will be sent to septic tank fallowed by soak pit. The salient features on the mitigation measures are: Garland drain will be provided to check soil wash off during monsoons. Construction of check dams & Gully plugs across seasonal/perennial nallahs flowing through the ML area Run-off from the mining area will be passed through a series of arrestor dams with filter beds to allow settling of solid particles. Contour bunding and trenches are proposed during monsoon to minimize soil erosion. Arrestor wall, protective bunds and trenches will be provided Water quality monitoring will be carried out in all the seasons 5.3 NOISE ENVIRONMENT To control noise pollution during the proposed mining & beneficiation operations following steps will be practiced. The noise generated by the machinery will be reduced by proper lubrication of the machinery and equipment. The workers employed should be provided with personal hearing protection equipment, with earmuffs and earplugs combined, as a protection from the high noise level generated at the plant site. Controlled blasting. The provision of green barrier along the boundary will further reduce the propagation of noise level generated. Limiting time exposure of workers to excessive noise. Speed of trucks entering or leaving the mine is limited to moderate speed of 25 kmph to prevent undue noise from empty tippers. 5.4 LAND ENVIRONMENT SOLID WASTE MANAGEMENT In this mine 60% of ROM is considered as waste & intercalated waste. The total waste will be dumped out side the pit limit and the max. height of waste dump will be kept 10m. About TPA of Tailing Sludge will be generated from the proposed beneficiation plant. About 50% of the tailings (43,500 tons) will be sold to the brick manufacturers & the remaining 50% will be used for back-filling of the mined out areas.

66 5.5 AFFORESTATION PLAN Under plantation programme, it is suggested to develop green belt along the boundary of mine lease area and on the backfilled areas and all sides of the beneficiation plant area. Apart from the green belts and aesthetic plantation for eliminating fugitive emissions and noise control, all other massive plantation efforts shall be decided and executed with the assistance and co-operation of the local community 5.6 OCCUPATIONAL HEALTH & SAFETY Providing a working environment that is conductive to safety & health The management of occupational safety & health is the prime responsibility of mine management from the executive level to the first line supervisory levels Employee involvement and commitment in the implementation of health and safety guidelines. Provision of all necessary resources Implementing safety and health management system and assessing the effectiveness through periodic audits Setting of safety and health objectives based on comprehensive strategic plans and measure performance against these plans Monitoring the effects of mining activities on safety and health and conducting regular performance reviews. Provision of necessary personal protective equipments Establishing and maintaining a system of medical surveillance for employees Ensuring employees at all levels receive appropriate training and are competent to carry out their duties and responsibilities. 5.7 IMPLEMENTATION OF EMP & MONITORING PROGRAMME The lessee will ensure the implementation of the measures within the mine lease area and carryout efficient monitoring. In order to implement the measures suggested for mitigating the adverse impacts on the environment, it is suggested to monitor the environmental parameters regularly.

67 CHAPTER I 1.0 INTRODUCTION 1.1 Preamble Mineral resources of any country contribute maximum for the economic growth of any country. Mining industry is associated and is solely responsible for the exploration and excavation of these resources. Eventhough mining industry is an essential activity for the growth of any country, this activity is associated with the creation of many environmental problems and hence mining industry is considered as an essential evil. Many of these problems can be avoided, if during conceptual stage of the mining project, adequate environmental control considerations are thought of. Once the mining activities are set up, it becomes very costly to install pollution control measures and implement other environmental control measures, if the same is not considered in the conceptual stage. Mining industry exerts both positive and negative environmental impacts. Negative impacts cause environmental degradation. It is the responsibility of Mining Engineers, and Environmentalists to document these impacts separately so that these can be identified and attempts may be made to minimize negative impacts and maximize the positive impacts for better development with least environmental degradation. Environmental Impact Assessment (EIA) and Environmental Management Plan (EMP) have been considered as the most important tools / documents which can be utilized by the project proponent and Government Regulating Agencies and the Public to clearly understand the environmental implications of the proposed mining project with respect to sustained development and to take decisions in the interest of environment and the national economy. It also helps to analyze the techno-environmental feasibility of the proposed project. The present EIA and EMP report for the proposed Iron Ore Mine & Beneficiation Plant located at Sy. No: 320, Chabali village, Pendlimarri Mandal, Kadapa district of Sri. Kandula Rajamohan Reddy, is prepared strictly adhering to the guidelines and TOR s issued by MoEF,New Delhi. 1.2 Background of PROPOSED IRON ORE MINE has applied for a mining lease for Iron Ore over an extent of Hectares in S.No.320 of Chabali Village, Pendlimarri Mandal, Kadapa district and the Government of Andhra Pradesh has granted the Mining Lease vide G.O.M.S.No. 173 dated The total mining lease area falls under revenue category. The mining lease was granted for 20 years with effect from to The mining plan was approved by Indian Bureau of Mines, vide lr. no Global Enviro Labs, Hyderabad

68 (386)/Iron/2000/CDP/ Dated 20/1/2001 for production of iron ore with production capacity of 50,000 TPA and mining operations were started since Due to the growing demand for Iron ore, both in Domestic and International markets, the lessee enhanced the iron ore production from 50,000 TPA to 5,00,000 TPA with effect from and for this purpose Modifications in Approved Mining Plan was Approved by Indian Bureau of Mines vide lr. No. 659 (386)/Iron/2000/CDP/ Dated 23/1/2008 and subsequently the mining scheme was approved by by Indian Bureau of Mines, vide lr. no. 659 (386)/Iron/2000/CDP/ Dated 28/3/2011 for an annual production of 0.5 MillionTPA (5,00,000 TPA) of Iron Ore. As observed the mining operations and ROM the recovery of Iron Ore is taken as 40 % only. Out of total ROM, 40 % is considered as Iron Ore and remaining 60 % is considered as waste and intercalated waste. Considering the growing demand for high grade iron ore in the global market the Lessee is proposes to establish a Beneficiation Plant in the Mine Lease area only located at Sy. No: 320 of Chabali Village, Pendlimarri Mandal, Kadapa district of Andhra Pradesh to improve or enhance the quality of the iron ore through a series of systems and processes. The word beneficiation implies a Process which is employed to upgrade the Lower Grade Mineral to level at which the Mineral could be used beneficially. Different Equipments are used for different processes. The type of Processes and Equipments which have to be employed would be based on a Mineralogical Test to be conducted on the Ore. 1.3 Present project proposal The proposal is for enhancement of production of Iron Ore from 50,000 TPA to 0.5 MillionTPA (5,00,000 TPA) and setting up a Beneficiation Plant with a throughput capacity of 0.3 MillionTPA in an extent of Hectares of Mine Lease area. Cost of the Project is Crores 1.4 Justification for production from the mine: The increased demand for Iron and steel has increased the demand for Iron Ore. Considering the growing demand for high grade iron ore in the global market the Lessee is proposes to establish a Beneficiation Plant and also there are few proposed and upcoming Steel plants coming up in Andhra Pradesh state and hence the demand for Iron Ore shall increase in the near future. The iron ore produced from this mining project being very near to the steel industries shall have good demand. 1.5 Environmental clearance The proposal for Environmental Clearance of proposed enhancement of iron ore with setting up a Beneficiation Plant in Hectares of Mine Lease area requires environmental impact assessment (EIA) to be carried out. This is primarily to ascertain 2 Global Enviro Labs, Hyderabad

69 the potential impacts the proposed mining activity and initiate necessary corrective actions at the operational stage as well as appraise the environmental protection regulating authorities for issuing environmental clearance for the project under the relevant provisions of Environmental Protection Act, 1986, Rules and Notifications there under. As per TOR Letter No: J-11015/164/2011 IA. II (M), Dated on 14 th February 2011, issued by Ministry Environment & Forestry (MoEF), New Delhi, the lessee has to obtain clearance from MOEF, GOI, New Delhi for this proposed project. Accordingly, the lessee has engaged the services of Global Enviro Labs, Hyderabad, for Preparation of REIA reports for submission to APPCB, Hyderabad and MOEF, New Delhi to obtain Environmental clearance. The baseline Environmental Status was assessed for Winter season i.e. from December 2011 to February The report covers the Environmental Impact Assessment (EIA) and EMP for the proposed enhancement of production of Iron Ore from 50,000 TPA to 0.5 MillionTPA (5,00,000 TPA) and setting up a Beneficiation Plant with a thoughput capacity of 0.3 MillionTPA in an extent of Hectares of Mine Lease area. The report has been prepared in accordance with the latest stipulations of MOEF, GOI, New Delhi. 1.6 Report format Introduction Scope and methodology Project profile Present environmental status Identification of impacts Assessment of impacts Evaluation of Impacts Environmental Management Plan (EMP) EMP implementation and monitoring 1.7 Scope of the REIA Study Sri.K. Raja Mohan Reddy proposes for enhancement of production of Iron Ore from 50,000 TPA to 0.5 MillionTPA (5,00,000 TPA) and setting up a Beneficiation Plant with a thoughput capacity of 0.3 MillionTPA in an extent of Hectares of Mine Lease area at Chabali village. Keeping in view of concern for environment and to comply with statutory requirement of the MOEF and APPCB, the lessee has proposed to identify possible environmental impacts arising out of the proposed mining and handling of the material by conducting the Environmental Impact Assessment (EIA) study. 3 Global Enviro Labs, Hyderabad

70 The scope of the study includes the characterization of various environmental components such as meteorology, air, noise and vibration, water, land, biological and socio-economics within 10 KM radius around the mine both at pre and post project scenario. The following are the objectives of REIA study: To establish the present environmental scenario. To identify and quantify the significant positive and negative impacts due to various mining operation in various components of the environment through identification and prediction of impacts. To prepare a detailed action plan for implementation of mitigative measures. To suggest preventive measures to minimize adverse impacts and to maximize beneficial impacts. To anticipate the impacts of proposed future mining operations on the environment. To suggest a monitoring programme to evaluate the effectiveness of mitigative measures. To suggest the formation of a core group responsible for implementation of environmental control and protective measures and monitoring of such implementation. To prepare a capital and running cost estimates for Environmental Management Plan (EMP). 1.8 METHODOLOGY OF REIA Mining activities such as drilling, blasting, ore extraction and material hauling of iron ore & beneficiation of iron ore process are expected to cause impacts on surrounding environment. The impacts may be beneficial or adverse. For assessing environmental impacts due to the proposed Mine, an area of 10 KM radius was selected. The 10 KM radius was split into two zones viz., core and buffer zones. The core zone represents the mining lease area, which is a potential source of pollution. The buffer zone consists of the balance of 10 KM radius area. The methodology adopted for each parameter of study is discussed briefly below. 1.9 Micro-meteorology Meteorological data has been collected using weather monitoring station located near the mine site during the study period. The parameters like daily maximum and minimum temperatures, relative humidity, wind speed and wind directions were collected for all the three months (December 2011 to February 2012). Wind speed and wind directions data recorded during the study period were used for computation of relative percentage frequencies of different wind directions. The data was also used in 4 Global Enviro Labs, Hyderabad

71 air quality modeling for computation of ground level concentrations of dust contribution by the proposed mining activities in the core and buffer zones Ambient air quality Ambient air quality data from the core and buffer zone villages of 10 KM radius is obtained through a network of eight ambient air quality stations. The locations of air monitoring stations were fixed after considering the predominant wind direction. Out of the eight stations, one station represents the core zone station and seven stations represent the buffer zone. The air samples were collected continuously for 24 hours. The parameters such as P.M 2.5, RSPM, SO 2, NOx and CO were monitored. The frequency of sampling is 2 days in a week for a period of 3months. The standard procedures and methods as outlined by Central Pollution Control Board (CPCB) and Bureau of Indian Standards (BIS) were adopted for chemical analysis Noise environment Noise monitoring locations were fixed after identifying different noise sources in buffer zone. Noise levels were recorded at an internal of 30 minutes during the day and night times to compute the day equivalent levels. The noise levels were measured in db(a) Land environment Soil samples were collected during the month of January 2012 from eight locations and representing various land uses in and around 10 KM radius of the mine site. Soil samples were collected using core cutter and augur combination upto 30 cm depth, which represents top soil. Standard procedures were followed for sampling and analysis to determine the fertility of soil. Land use and land cover pattern of the study area has been assessed through secondary information Biological environment Data on biological environment (terrestrial and aquatic flora and fauna) were collected from various Government Departments such as Forest, Agriculture, Fisheries and Animal Husbandry within 10 KM radius of the mine site. The status of Flora and Fauna within core zone and buffer zone were studied by conducting field surveys and identifying different species that are prevalent within the 10 Km radius of the mine site during the season Socio-economic environment A field survey was conducted among the villages falling within the 10 Km radius from mine site. Information regarding population, family status, occupation, literacy level and amenities etc. was also obtained from the district statistics records to determine 5 Global Enviro Labs, Hyderabad

72 the developmental activities to be undertaken by the mine management. Such developmental activities would result in upliftment of the economic status in the area Identification, prediction and evaluation of impacts Various operations involved in mining have been studied in detail to identify areas leading to impact / change in environmental quality. A matrix method was adopted for identification of impacts. The overall scenario estimated has been checked for compliance with various statutory requirements / standards Formulation of environmental management plan Based on the existing environmental status and quantified impacts, a detailed Environmental Management Plan (EMP) has been formulated for implementation at various levels by the mining management. 6 Global Enviro Labs, Hyderabad

73 CHAPTER PROJECT DESCRIPTION OF HA. OF IRON ORE MINE 2.1 LOCATION AND ACCESSEBILITY The area lies in Topo sheet No.57J/11 of Survey of India within the following coordinates. Table 2.1 shows the location of the proposed mining site. Table 2.1 Coordinates of MLA Boundary Latitude Longitude Pillar No This mine is approachable from Kadapa by travelling a distance of 28km on the Kadapa Pulivendula road. Salient Features of the mine site State : Andhra Pradesh District : Kadapa. Mandal : Pendlimarri Village : Chabali Lease Area : Ha. Owner ship : Govt. Revenue waste Land Topo sheet No : 56J/11 Altitude : 225m to m above M.S.L Topography : Hilly and undulating Nearest river : 1.8 km, Papaghni (Ephemeral) Nearest Highway : 5 km State Highway Nearest railway station : Kadapa, 28km Nearest city : Kadapa 28 Km Nearest industry : Stone Quarries & Dolomite Mines Maximum Day Temperature 0 C: 45 0 C Minimum Day Temperature 0 C: 15 0 C Maximum Humidity in % : 86% Average annual rainfall : 660mm Nearest Forest range : Ganganapalle Reserve Forest 8.6 km S Topo Plan of the Ha Iron Ore Mine is given as Figure Global Enviro Labs, Hyderabad

74 Global Enviro Labs, Hyderabad 8

75 2.2 Leasehold area The proposed iron ore mine has been granted mining lease over an extent of hectares and the outline of the mine lease area is as below. Fig.2.2 Lease hold sketch of the Ha. Iron Ore mine 2.3 TOPOGRAPHY The terrain is hilly and undulating. The highest & lowest elevation of the M. L. area is 225 m & m. Except, some thorny bushes in isolated patches, the area is mostly devoid of any thick vegetation. The Mine is about 1.0 km from Chabali village. The Iron ore produced from mine will undergo for beneficiation process for improvement of quality and will be dispatched to domestic & international market. 2.4 GEOLOGY Local Geology The geological formations of the region belongs to vempalli stage of Papaghni series of lower Cuddapah system. The general sequence of the rock formations found in the area are given below. Soil cover + Iron Ore float Ferrugenous Quartzites(with encompassing pockets of Iron Ore) Ferrugenous Shale Quartzites 9 Global Enviro Labs, Hyderabad

76 The soil cover in the area is about 0.30m to 1.5m depth with Iron Ore float. The general trend of the deposit is N 70 E with near vertical dip. The mining explorations in the ML area indicating that Iron Ore is occurring as float and massive variety and proved up to 20m depth. The recovery of the Iron Ore about 40% of the total volume and remaining 60% is intercalated waste. Out of total Iron Ore production about 70% is occurring in the form of fines i.e -10mm to 420 mm and 30% is in the form of lumpy ore. The float Ore is grey to Iron black in colour with metallic luster, where as the Ore occurring in the lower Ore zone is of light steel grey in color. The white quartzite occurring as lenses is occupying the peripheral zones of the Iron Ore zone. It is off white in color and hard, massive and compact in nature Estimation of Reserves The Iron Ore reserves were estimated based on the existing mining operations and DTH bore holes drilled. The bore hole data indicating the Iron Ore is occurring up to 20 m depth from the general surface and below this depth Phyllites and Quartzites are occurring. So it is concluded that the total thickness of Iron Ore is considered 20 m only. As observed the mining operations and ROM the recovery of Iron Ore is taken as 40% only. Out of total ROM, 40% is considered as Iron Ore and remaining 60% is considered as waste and intercalated waste. The tonnage factor of Iron Ore is taken 3. Based on the mining operations done in the ML area, a total thickness of 20m is considered for calculation of reserves purpose. Proved reserves are considered only in the area where DTH bore holes and mining operations were done and a maximum of 20 m thickness proved in DTH bore holes is considered. Probable and Possible reserves are considered where no exploratory data is available and details are furnished as follows: Category Iron Ore Tons Classification under UNFC Proved 15,72, Probable 18,09, Possible 37,76, Total 71,59, DEPLETION OF RESERVES : Depletion of reserves for the last seven years ( to (up to Dec 2010): Year Production of iron ore (Tons) ,04, ,20, ,76, ,63, Global Enviro Labs, Hyderabad

77 ,47, ,59, ,83, (DEC 2010) 1,23,299 Total 20,79,150 After depletion the reserves will be as follows; Category Iron Ore Tons Classification under UNFC Proved Probable 13,03, Possible 37,76, Total 50,80,050 Out of the total Production 62% constitutes Iron Ore Fines with Fe Content around 38% constitutes Lumpy Iron ore with Fe content of around 50%. ADDITIONAL RESERVES ESTABLISHED No additional reserves are established. No exploratory work was done during the last plan period hence no additional reserves are established. As there is no any documentary evidence of drilling data, the reserves are re estimated based on mine workings only as G 2 and G 3 category. G 2 Category reserves are considered up to the depth where iron ore is proved in the mine workings and G3 category considered below the proved depth of mine workings and up to 20 m depth and in other non workings areas 20 m depth is considered. As observed the ROM the recovery of Iron Ore is taken as 40% only. Out of total ROM, 40% is considered as Iron Ore and remaining 60% is considered as waste and intercalated waste. The tonnage factor of Iron Ore is taken as The Iron ore occurring as fines and pebbles is having around 40% and lumpy Iron ore is having around 50% of Fe content. The details of the up dated reserves and the reserves blocked in 7.5 m barrier zone and pit slope are follows: Category Iron Ore (in Tons) Classification under UNFC Probable 15,24, Possible 37,53, Total 52,77,240 CATEGORY WISE UP DATED RESERVES : The summery of updated reserves are as below : 11 Global Enviro Labs, Hyderabad

78 Category Iron Ore Lumps & Fines in Tons Classification under UNFC Probable 15,24, Possible 37,53, Reserves locked in pit 5,35, slope & buffer zone Total 47,42,240 It is indicating that Iron ore pebbles and fines occurring in the mine are with Fe content ranging from 38 to 44% and lumpy Iron ore is having with Fe content ranging from 44 to 53%. As observed the marketing of Iron ore to different industries and its consuming quality, 62% is placed under low grade i.e Fe content between % and 38% placed at high grade i.e 45 to 53% of Fe content. On this basis around 18,02,051 tons are of high grade and 29,40,189 tons are of low grade variety. Life of the Mine: Total Reserves/Annual Production = 47,42,240/5,00,000 = 9.48 Years The Geological Plan is shown in Fig Global Enviro Labs, Hyderabad

79 Global Enviro Labs, Hyderabad 13

80 2.5 MINING PROCESS The mine is being worked by semi-mechanized open cast method. The bench height is 3m (with 2 sub benches of 1.5 m height each). The over burden is removing by hydraulic shovel / wheel loader and loaded in to toppers and total ROM is transported to crushing and screening plant. Drilling by Jack Hammers is carried out for excavation of Iron Ore and removal of ROM in the working face. Drilling and blasting is required only for 20% of ROM excavated and balance 80% of ROM quantity can be removed with help of hydraulic excavators without using drilling and blasting. 2.6 YEAR WISE PRODUCTION DETAILS: Mining operations were started since The year wise achieved quantity of production and development details for the respective years is given below: (as per the modified approved mining scheme) Year Production of iron ore (Tons) ,04, ,20, ,76, ,63, ,47, ,59, ,83, (DEC 2010) 1,23,299 Total 20,79,150 The Mine is reported to be closed presently since February YEAR WISE DEVELOPMENT PLAN PROPOSED FOR THE NEXT 5 YEARS (SCHEM PERIOD): A systematic mine development programme for the three years i.e to has been planned. Developments will be done all along the strike direction. During to year period about 6,15,840 tons Iron Ore produced and 3,07,920 Cu.mts of waste resulted. During year plan period 5 benches are proposed with benches length is 90m and width ranging from 70m to 115m. About 13,669 sq.m area is selected towards N-E corner of the lease boundary between grid lines N and E with an estimated production of 1,84,800 tons of Iron Ore and 92,400 cu.mts of waste. About 50,000 sq mts area selected between grid lines of N and E and dumped the waste with 3 mts height. During plan period 4 benches are proposed, with benches length is 98m and width ranging 14 Global Enviro Labs, Hyderabad

81 from 170m to 211m. The mining operations will be restricted between gridlines of N and E by extending the previous year workings towards southwestern side covering an area of about 18,600 sq.mts with an estimated production of 2,12,400 tons of Iron Ore and about 1,06,200 cu.mts of waste and this waste will be back filled covering an area of about sq.mts with 14 mts height. During plan period 4 benches are proposed with benches length 100m and width ranging from 210 to 250m. The mining operations further extended towards south-western side of previous year between grid lines of N and E covering an area of about 22,700 sq.mts with an estimated production of 2,18,640 tons of Iron Ore and 1,09,300 cu.mts of waste and this waste is proposed to back fill over an area of 20,000 sq.mts with 11 mts height. During the proposed plan period all the benches are proposed in N.W S.E direction and extended from north-east to south-west direction and the bench height will maintained at 3 m. with an angle of 60. After the scheme period the dimensions of the pit will be around 400 mts length, 250 mts width and 20 mts depth. The year wise summary of production & development of pure waste and intercalated waste for scheme period is given below: Year Production of Iron Ore (tons) development of waste (cub.mts) ,84,800 92, ,12,400 1,06, ,18,200 1,09,320 Total 6,15,840 3,07,920 The Production and Development Plan is shown in Fig.No Global Enviro Labs, Hyderabad

82 Global Enviro Labs, Hyderabad 16

83 2.7 Extent of Mechanisation The list of mining machineries deployed in the mine are as below : S.No. Name of Machinery Capacity Nos. Existing 1 Tata Tippers 10 tons 10 2 Wheel loaders 1.71 Cum Samsung hydraulic excavators CAT 320 B&C Hydraulic Excavators Tractor mounted compressor VT-4 with jack hammer 1.10 Cum Cum cft 02 6 Water tanker 6000 ltrs 01 7 Crushing & Screening plant 200ons/hour 01 8 Generators 63 kva 01 Loading equipments: Hydraulic excavators: Handling of waste are done with excavators of 1.10 & 0.88 cum bucket capacity the maximum quantity of ore /waste to be handled is 5,13,200 cum(please see annexure no.2) during the scheme period of Assuming 300 working days / annum and for 3 years i.e. 5,13,200 /3*300= 570 cum/day. The average capacity of excavator is 100 cum/hour and for shift 8 hours as effective working 200*8 = 1600cum/day. So the existing excavators are more than sufficient to meet the day to day operations. Wheel loaders : The 1.71 cum bucket capacity wheel loader will be used for loading from the ore stock yard to the trucks for dispatch to crushing and screening plant. In addition the bench roads and cleaning of the benches, dumping leveling and wheel loader will not used for primary loading at the benches. Trucks: The waste to be handled shall be about 5,13,200 cum during the scheme period of Assuming an average of 3.5cum per trip 5,29,400/3.5 = 1,46,628 trips/3 years and 48,876 trips per annum and 163 trips per day. This will be handled by 10 trucks at an average of (163/10=16.3 trucks) 16 trips per day / truck. So existing trucks are sufficient to handle the ore and waste. 17 Global Enviro Labs, Hyderabad

84 Drilling equipments: The quantity of ore and waste to be handled will be 5,13,200 cu.m. Out of 5,13,200 cu.m only 20% is required drilling and blasting i.e. 1,02,640 cum and balance quantity 4,10,560 cu.m can be handed by hydraulic excavator without using drilling and blasting. The amount of drilling required is calculated as under: The quantity of rock broken / hole spacing and burden of 1m x 0.75m = 0.75m and 2.7t/cu.m average bulk density of ore and waste. Therefore rock broken for one cu.m is = 2.25 tons. Total meterage drilling requirement is 2,77,120 tons (102,640 x 3)/2.25 = 1,23,168 cu.m and with 1.5 m hole i.e. 82,112 holes and an average of 91 holes/day. With two tractor mounted compressors with a capacity of 100 m per day per compressor and 300 working days the capacity is sufficient. 2.8 USE OF MINERAL As per the analysis report enclosed the average Fe content is around 47.37%. Presently the mineral is being used in Cement industries, Steel and Sponge iron plants and will be continued in future. Generally the Cement industry is consuming the Iron ore having 38 to 44 % of Fe content and other Steel Companies with Iron ore having Fe content ranging from 45 to 53 % depending upon the availability of Iron ore quality SURFACE TRANSPORT: Iron Ore is transported by tractors to the stock yard through an all weather mine road. The mineral is further transported to the market by means of trucks SITE SERVICES: Sri K. Raja Mohan Reddy has provided canteen, work shop, first aid station, vocational training centre and rest shelters near mine. A bore well is drilled in the lease area and providing drinking water to mining staff & workers and a tanker is also provided for sprinkling of water mainly on village roads to suppress the dust generated due to vehicular movement EMPLOYMENT POTENTIAL: The list shows the technical personnel and staff, adequate to meet the statutory requirement as well as the practical needs of the mine. S.No NAME OF THE POST No. REMARKS 1 Mine Manager cum Mining Engineer 1 A Person holding II Class Mine Manager s Certificate 2 Mine Foreman 1 A Person holding Mine Foreman certificate 3 Mine Mate Cum Blaster 1 A Person Holding Mine Mate Certificate 4 Mine Surveyor Part Time A Person holding Mine surveyors Certificate. 5 Mechanic 1 Experience to operate Machines 18 Global Enviro Labs, Hyderabad

85 6 Drillers 4 Skilled workers 7 Muckers 190 Unskilled Workers 8 Watch & ward 3 Unskilled Workers TOTAL 202 The proposed mine will operate from the dawn to dusk beginning at 8 am at everyday. The Mine will be operated General shift from 8 A.M to 5 P.M with a lunch break of one hour. Therefore it would be safe to assume an effective working of 8 hours per day. Mine would operate for 300 days per annum i.e. 25 days in a month LAND USE PATTERN IN THE CORE ZONE The Iron ore in the mine lease area occurs as an outcrop and is in the shape of blanket all along the lease area. The entire area has very scanty or no vegetation due to the rocky and bedded nature of the mineral. Initially during the first five years production is very less due to the less market demand. However, presently few Iron & Steel plants are coming up in the area and with the increased demand for the mineral, more area shall be put to use. An area of 15.00Ha., was mined during the Scheme period i.e. till 2013 and an additional Ha., shall be mined for conceptual period i.e. till The buffer zone will remain unaffected by the mining activity due to the precautions taken/adopted by the lessee. The impact of mining on the buffer zone agricultural lands will be negligible, as, they are located more than 1km, away from the mining area. CORE-ZONE: The proposed Land use in the core zone during the Scheme period, and Conceptual Period is shown in Table 2.2 Table 2.2 Land Use Pattern in the Core Zone S. No. Core Zone Land Use Details Land Use till 2013 Land Use for Conceptual Period till Area under mining Overburden dump Mineral storage Roads Greenbelt Mineral separation plant Undisturbed area (Future Use) TOTAL The land use plan is shown vide Fig.No Global Enviro Labs, Hyderabad

86 Global Enviro Labs, Hyderabad 20

87 2.13 MINERAL BENEFICIATION : Presently the ROM is transported from mines to the yard at the foot hill of the mine. At the yard a stationary crusher and screening plant has been established. Mainly Hard lumpy Iron Ore and BHQ (Banded Hematite Quartzite) of oversize is crushed as per the specifications of the user industry. Only physical classification is done at present. In view of the growing demand for high grade iron ore in the global market the Lessee is proposes to establish a Beneficiation Plant with a thoughput capacity of 0.3 MillionTPA in the Mine Lease area to improve or enhance the quality of the iron ore through a series of systems and processes. The word beneficiation implies a Process which is employed to upgrade the Lower Grade Mineral to level at which the Mineral could be used beneficially. Different Equipments are used for different processes. The type of Processes and Equipments which have to be employed would be based on a Mineralogical Test to be conducted on the Ore PROJECT DESCRIPTION OF BENEFICIATION PLANT INTRODUCTION India has 70 billion tons of proven iron ore reserves, out of which 25 billion tons are only fines. It is estimated that at various stages of mining & screening, 60-80% of the ROM (Run of Mines) become fines. These fines pile up & form heaps & mountains. During the rainy season, they flow along with rain water, lead to water blockages & result in formation of sludge & silt in the dams, thus creating huge environmental problems. According to a study carried out by the Economic Research Unit (ERU) under the Steel Ministry, the percentage of iron ore fines production across the country is likely to reach 72% by , as against 52% in At the stage of mining itself, 60% becomes fines. Another 10-12% lump gets reduced to fines during conversion of lumps to calibrated lump ore and also during handling, loading & un-loading. On the other hand, India is making 62 million tons of steel per year and also importing another 10 million tons of steel. Indian steel making industry suffers from acute shortage of calibrated iron ore of 5-20 size with good tumbler index & good Fe grade. While recovering 1 ton of good quality ore, 2.5 tons of fines & bad quality ores are recovered in the mines, which are normally exported, as there is no domestic demand. This also encourages selective mining, a waste of national resources. The only ways to solve this problem is to beneficiate the low grade iron ore into high grade ore & subsequently pelletise the concentrated ore. These pellets can be used both in the Blast furnaces to make pig iron & in the Rotary kilns to make DRI. 21 Global Enviro Labs, Hyderabad

88 For example in China, there are 10,000 Beneficiation plants & 3,000 Pelletisation plants. China is producing 600 million tons of steel per year. To feed the Pellet plants, they are also importing Pellet feed concentrates from countries like Brazil, at high prices. Low grade (50 %+) iron ore fines in India are estimated to be 25 billion tons. In China, iron ores of even 6% Fe are beneficiated & used for steel making, while in India, iron ores with less than 45% Fe are not at all considered as Reserves. There are hardly 15 beneficiation & 10 pelletisation plants in India, while the demand for pellets is increasing day-by-day. The project aims at converting low grade iron ore into Iron ore concentrates, so that these concentrates can be used in pellet making. The draft National Mineral Policy, 2008 published by the Government of India states that about 80% of the iron ore produced in the Country is in the form of fines & to convert these fines into Steel, the Government will provide fiscal & non-fiscal incentives to the Mine owners. By considering the above factors Sri K. Rajamohan Reddy is proposes to establish a Beneficiation plant in Survey No. 320 of Chabali village, Pendlamarri Mandal, Kadapa District, Andhra Pradesh. Suitable land is available within the lease-hold mining area. The beneficiation plant will utilise low grade iron ore fines (50% Fe) available in his mines to make high grade concentrates (65% Fe), adopting reduction-roasting method. The main raw material, i.e., low grade iron ore of 50% Fe on an average, will be supplied from the captive mine by dumper trucks. The distance between raw material storage area & the mining area is less than 500 metres. Two dumper trucks of 30 tons raw material holding capacity are needed for the transportation of iron ore from the mining area to the Beneficiation plant. The proposed Beneficiation plant will use 300,000 tons per year low grade hematite ore containing average 50% Fe into high grade magnetite ore containing 65% Fe. The plant proposes to adopt a unique Reduction-roasting method, to convert Fe2O3 (Hematite ore) into Fe3O4 (Magnetite ore). The efficiency of recovering the Fe is 96% & the recovery of high grade iron concentrates is 2,05,000 tons per year, after deducting loss on account of difference in molecular weights & Loss on Ignition. The project aims at adding enormous value to the low grade iron ore fines, which are wasted at present. 22 Global Enviro Labs, Hyderabad

89 COST OF THE PROJECT & IMPLEMENTATION The estimated total project cost is Rs. 30 crores & the net sales at 100% production are Rs. 82 crores. The pay-back period on the entire investment is 3 year & 129 days. The project needs 12 months for implementation from the date of placing orders on machineries. The main equipments for Beneficiation plant will be imported from China under EPCG scheme with some export obligations, while the balancing equipments are sourced from India. In total, this project has the following strong points 1) Flexibility to use low grades iron ores from 40-55% Fe available in the captive mine. 2) Higher Fe grade (65%) after Beneficiation. 3) Higher value addition & faster pay-back SITE SELECTION CRITERIA Selection of project site requires study of various aspects like land, water, fuel, environmental aspects etc. The study area of the proposed project site is free from ecologically sensitive areas. The following factors have been considered. a. Flexibility to use low grades iron ores from 40-55% Fe available in the captive mine. b. Higher Fe grade (65%) after Beneficiation c. Higher value addition & faster pay-back d. Availability of suitable and adequate facilities e. Availability of water. f. Proximity of highway. g. Availability of raw materials. h. Availability of man power. i. Availability of infrastructural facilities j. Suitability of land from geological and topographical aspects k. Environmental aspects etc. Based on the above the mine site in Sy. No: 320 of Chabali village, Pendlamarri Mandal, Kadapa District, Andhra Pradesh has been chosen for the Proposed Project facility INFRASTRUCTURE NEEDED FOR PROPOSED BENEFICIATION PLANT : LAND REQUIREMENT The proposed Beneficiation plant will come up in the Ha Mine Lease area. An area of 15.0 ha of Excavated Mine lease area will used for the settingup of the proposed beneficiation plant 23 Global Enviro Labs, Hyderabad

90 LAYOUT OF THE PLANT The topography of site is suitable for industrial construction of heavy structures, buildings and foundations. The proposed plant layout indicating Iron Ore Beneficiation section, auxiliary facilities, services and ancillary buildings are presented in Figure-2.6. All facilities in the plant area will be identified so as to rationalize and minimize the extent of land required. The layout will also facilitate movement of men and materials between the various facilities during construction, operation and maintenance of the plant. LAND USE / LAND BREAK UP OF PROPOSED BENEFICIATION PLANT The proposed Beneficiation plant will come up in the Ha Mine Lease area. An area of 15.0 ha of Excavated Mine lease area will used for the settingup of the beneficiation plant. Details of land use/land break-up are presented in Table 2.3 Table 2.3 Land Use/Land Break-Up S.N. Land Use Land Break-Up (Ha.) % Area 1 Beneficiation Plant Raw Material Storage Area KILN Area Dryer Area Cooling Tower Area Finished Product Storage Area Miscellaneous Facility (Administration Building. Material weighing etc.) 9 Green Belt Area Internal Road Area Open Space TOTAL Global Enviro Labs, Hyderabad

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92 : RAW MATERIAL REQUIREMENT The main raw material, i.e., low grade iron ore of 50% Fe on an average, will be supplied from the captive mine by dumper trucks. The distance between raw material storage area & the mining area is less than 500 meters. Two dumper trucks of 30 tons raw material holding capacity are needed for the transportation of iron ore from the mining area to the Beneficiation plant. Other raw materials such as coal & limestone are delivered to the Beneficiation plant by the suppliers, using their logistics. Outbound transportation is needed for both iron ore concentrate, which is a fine powder and loaded on to the trucks by Front end loaders. These trucks are covered by tarpaulins to prevent any possibility of dust emissions. In case required, 5 ton capacity Jumbo bags will be used to pack the iron ore concentrates before dispatch. Raw material requirement for proposed beneficiation plant presented in Table 2.4 and raw material analysis presented in Table 2.5. Table 2.4 Raw Material Requirement S.N. Raw Material Requirement Source Mode of Transfer 1 IRON ORE FINES (50% grade) 1.47 tons per ton of beneficiated ore ( recovery of beneficiated iron ore is 2,05,000 tons) 2 COAL for reduction roasting in the Rotary kiln ( based on 5,000 kcal/kg & 40% Fixed kgs per ton of raw iron ore 3 LIMESTONE for reduction roasting 3,00,000TPA From Captive Mine TPA Open market/impor ted Coal Tarpaulin covered trucks Tarpaulin covered trucks 3000 TPA Open market Tarpaulin covered trucks Table 2.5 Analysis of Raw Material Iron Ore Coal Limestone Parameter Low High Parameter Parameter Grade Grade mm Fe as Fe 2 O 3 52% 62% Fixed Carbon 40-42% CaO 50% O % 26.5% Sulphur(S) 0.50% MgO 3% Al 2 O 3 9.2% 3.7% Moisture 10% SiO2 5% Phosphorus 0.01% 0.065% Volatile 18-20% Al2O3 1.5% (P) matter LOI (Loss On Ignition) 3.8% 4.2% GCV (Kcal/Kg) Global Enviro Labs, Hyderabad

93 WATER REQUIREMENT The proposed Beneficiation plant needs 327 Kilo liters per Day. This water requirement is met from bore wells located within in the site. The details of water requirement are given below: Sr.No. Units Requirement (m 3 /day) Make-up Water (m 3 /day) 1. Beneficiation 3000* 242 Process 2. For washing, 150* 50 cleaning & other utilities 6. Dust Suppression Greenbelt Domestic Purpose Total 327 *In this unit water is one time requirement for process run DETAILS OF NEW TYPE BENEFICIATION TECHNOLOGIES There are two main technologies for beneficiating low grade iron ore 1) Conventional Beneficiation plant Conventional method uses a combination of floatation, heavy magnetic selection & density separation for beneficiating Indian hematite ore. Here, the efficiency of recovering the Fe is only 60-70% & the unrecovered Fe in the Tailings (slime) is 30-40%, which again depends on the Lemonite & Goitite ores associated with the hematite ore. This method is not suitable for the present project, as Fe in the raw material is low (50%) & the recovery will be again lower. More over, the finished concentrate will be in the form of Hematite ore, making it very difficult to pelletise the same. 2) New type of Beneficiation plant, using conversion method from Fe2O3 to Fe3O4 The project adopts this new type of technology for beneficiation, which converts the Hematite ore (Fe2O3) into Magnetite ore (Fe3O4) for the purpose of easy beneficiation. This technology was prevalent in Russia for the last 100 years, where they used to burn Fe2O3 & Coal in layers inside the earth & convert the same into Fe3O4. Ten years back, China developed this technology for commercial exploitation & more than 100 plants are operating successfully now. This technology can convert minimum 40% Fe2O3 (hematite) iron ore into 63-67% Fe3O4 (Magnetite) iron ore. Efficiency of the process is 90-98% & the unrecovered Fe in the tailings is 4-10%. These tailings can be sold to the brick manufacturers, as they are fine powders & useful to them. 27 Global Enviro Labs, Hyderabad

94 The efficiency of recovering the Fe is calculated below - Average Fe in the raw material - 50% (raw material - 3,00,000 tons) - Average Fe in the washed ore - 65% - Theoretical recovery of Fe X 100% =76.92% (2,30,000 tons) - Recovery, based on molecular weight (Molecular weight of 3 Fe2O3 is 480, this becomes 2 Fe3O4 with 464 molecular weight) X 76.92% = 74.36% (2,23,000 tons) - Loss on ignition (LOI) - 3% (on 3,00,000 tons=9,000 tons) - Net theoretical recovery % (2,14,000 tons) - Efficiency of Fe recovery - 96% - Recovery of washed ore per ton of raw material - - Balance of mud containing 10% Fe = 79,000 tons per year - Loss on Ignition & molecular weight loss = 16,000 tons per year 96 X 71.36%X 3,00,000 tons = 2,05,000 tons per year It is important to note that the mud (slime) generation is around 79,000 tons per year, which has left-over Fe contents of 10%. In addition, coal ash (4,500 tons) & gypsum (3,000 tons) get mixed with the tailings, making the total quantity of 86,500 tons. Importance of converting low grade hematite ore into high grade magnetite ore for making iron ore Pellets- Pelletisation is the process of formation of green balls ( 9-16 mm) by rolling the iron ore concentrate (generally 63-65%) with a small quantity of binder & hardening the same by heat treatment under oxidising conditions up to a temperature of 1,250-1,3500C. As a result, binding occurs & sufficient pellet strength is developed. The process includes feed preparation (including grinding), mixing with binder, balling by a disc Pelletiser & hardening by drying, pre-heating, firing & cooling. The hardening process can be done by Vertical Shaft Kiln (VSK) or Travelling Grate Furnace. Travelling Grate Furnace needs higher capital investments (for example Rs. 60 crores for 3,00,000 tons per year plant) & suitable for large capacities of 1 to 5 million tons per year. The cost of production is also higher, i.e., Rs. 1,750 per ton. On the other hand, Vertical Shaft Kiln needs lower capital investment (for example Rs. 30 crores for 3,00,000 tons per year plant) & suitable for lower capacities of 100,000 to 600,000 tons per year). In Vertical Shaft Kiln, thermal efficiency is higher & the overall cost of making pellets is lower i.e., Rs. 750 per ton. However, this process can only use magnetite ore, while most of the Indian ores are hematite. 28 Global Enviro Labs, Hyderabad

95 Beneficiation of Hematite ore using roasting method, to convert of the same into Magnetite & subsequent Pelletisation of the Magnetite feed concentrate is an ideal method. Since Hematite is converted into Magnetite in the roasting method, it is now possible to adopt Vertical Shaft Process for Pelletisation, which is most economical PROCESS DESCRIPTION OF PROPOSED BENEFICIATION PLANT Hematite ore containing 40-55% Fe is suitable for this special process of beneficiation, to increase the Fe content to 65% by reduction-roasting & by converting the same into magnetite ore for subsequent beneficiation. Once the hematite becomes magnetite ore with 65% Fe, it will be more useful to the customers, as magnetite ore can be pelletized easily. Following is the process description - 1) Crushing - The low grade hematite iron ore is crushed between 50 mesh & 5 mm size, using Electromagnetic vibrating feeder, Jaw Crusher & Fine Crusher. The crushed ore is sieved in the vibrating screens & the over-sizes are returned back for re-crushing. Sized ore is taken to the rotary kiln by belt conveyor. 2) Rotary kiln - Sized ore of less than 5 mm size is passed through the inclined rotary kiln along with some quantity of coal for reduction & some small quantity of lime stone for binding sulphur in the coal. The travelling time is less than 2 hours & the temperature is less than 9000C. Coal is used for both heat supply & for partial reduction. After partial reduction into magnetite, the ore is conveyed in the belt conveyor for natural cooling. The Rotary kiln is completely enclosed with dust collectors & cyclones. The flue gases are connected to the chimney, after de-dusting. 3) Ball mill grinding - The magnetite ore at this stage is conveyed to a hopper by belt conveyor & fed to the ball mill with electromagnetic vibrating feeder. Since the ore is already magnetite, it is easy to grind & takes less power. Ball mill grinds the iron ore between mesh, as per the liberation size required. 4) Magnetic separators - After wet grinding in the ball mill, material is sent to high frequency screen by slurry pump. Material above the screen is returned to the ball mill, while material below the screen is sent to a series of magnetic separators for coarse & fine selection separately. 5) Floatation - If Silica & Alumina in the raw material are still high, further removal of Alumina & Silica will be done in the floatation chambers. 29 Global Enviro Labs, Hyderabad

96 6) Drying After magnetic separation & floatation, the final concentrate has 70% moisture, which is carried by slurry pumps to the fine powder open concrete tanks, equipped with water overflow & water screening system. After 7 days of storage, the dried 65% Fe concentrate with 10% moisture is removed from the concrete tanks and sent to the customers, who can use it in their pellet plant. 7) Plate & Frame Filters The mud (slime or tailings) containing 10% Fe+ some coal ash & gypsum is carried in the sand pump to the Plate & Frame filters, which separate mud from the water. The squeezed mud is taken to the storage area & removed from time to time by sending to the local brick plants. Part of the tailings is retained for land - filling in the mined area. After land-filling, suitable trees will be planted on them. The recycled water is taken back from Plate & Frame Filters to the water storage system for re-use. Since the mud is a fine ground powder with high silica & alumina contents and with minor quantities of coal ash & gypsum, it is much useful for clay brick making. 30 Global Enviro Labs, Hyderabad

97 31 Global Enviro Labs, Hyderabad

98 32 Global Enviro Labs, Hyderabad

99 33 Global Enviro Labs, Hyderabad

100 DETAILED MATERIAL BALANCE Input Quantity in TPA Output Quantity in TPA Iron Ore 3,00,000 Recovery of beneficiated iron ore 2,05,000 Coal 30,000 Volatile matters in the coal converted into energy & 25,500 Fixed carbon in the coal used up for converting hematite into magnetite (85% of 30,000 tons) Limestone 3,000 Coal converted into ash & mixed with tailings ( 15% 4,500 of 30,000 tons) Limestone converted into gypsum & mixed with 3,000 tailings Tailings from beneficiation plant containing 10% Fe 79,000 ( please see note below) Loss on ignition (9,000 tons) & loss of molecular weight ( 7,000 tons) Total 3,33,000 Total 3,33,000 Note - Calculation of iron recovery & tailings- - Average Fe in the raw material - 50% (raw material - 3,00,000 tons) - Average Fe in the washed ore - 65% - Theoretical recovery of Fe X 100% =76.92% (2,30,000 tons) - Recovery, based on molecular weight (Molecular weight of 3 Fe2O3 is 480, this becomes 2 Fe3O4 with 464 molecular weight) X 76.92% = 74.36% (2,23,000 tons) - Loss on ignition (LOI) - 3% (on 3,00,000 tons=9,000 tons) - Net theoretical recovery % (2,14,000 tons) - Efficiency of Fe recovery - 96% - Recovery of washed ore per ton of raw material - 96 X 71.36%X 3,00,000 tons = 2,05,000 tons per year - Balance of mud containing 10% Fe = 79,000 tons per year - Loss on Ignition & molecular weight loss = 16,000 tons per year It is important to note that the mud (slime) generation is around 79,000 tons per year, which has left-over Fe contents of 10%. In addition, coal ash (4,500 tons) & gypsum (calcium sulphate - 3,000 tons) get mixed with the tailings, making the total quantity of solid wastes 86,500 tons. This solid waste is in the cake form, with mesh particles containing 40-50% moisture at the point of generation. After natural drying, it loses moisture & becomes powder. Hence necessary provision will be made to sprinkle water regularly into the tailing mount. 34 Global Enviro Labs, Hyderabad

101 The proposed disposal method for tailings is as under 1) For clay brick making plants - 50% 2) For land-filling in the mined out area 50% Since these tailings are already mesh powder containing substantial amounts of Al2O3 & SiO2, they are suitable for making clay bricks. There are more than 100 clay brick making plants within 100 Km radius of the proposed Beneficiation plant & the average size of each plant is 10 lakh bricks per year, needing 2,500 tons of clay material. By using the tailings, they will be able to save on the cost of grinding the clay materials. It is estimated that these units will be able to use up to 50% tailings in their brick formula, so that brick making plants will be enough to dispose off 50% of the tailings generated by the beneficiation Plant. The remaining 50% will be used for backfilling the mined areas, where soil gets removed & the earth surface becomes uneven. By filling this un-even area with tailings, it is possible to grow suitable trees WATER BALANCE OF THE PLANT Sr.No. Units Requirement (m 3 /day) Make-up Water (m 3 /day) Loss (m 3 /day) Waste water generation (m 3 /day) 1. Beneficiation 3000* Process 2. For washing, 150* cleaning & other utilities 6. Dust Suppression Greenbelt Domestic Purpose Total *In this unit water is one time requirement for process run The net water requirement works out to be 0.3 m3 per ton of iron ore used as raw material. After Plate & Frame type filters, the project can use 100% recycled water in place of fresh water in the Ball mill & Magnetic separators. WASTEWATER GENERATION There is no generation of wastewater from the proposed iron ore beneficiation plant. Only evaporation losses, drift losses and spillages are encountered. About 5 m3/day of Domestic effluent will be generated from the proposed project and this will be sent to septic tank followed by soak pit. 35 Global Enviro Labs, Hyderabad

102 TECHNICAL DETAILS OF EQUIPMENTS OF BENEFICIATION PLANT This 1,000 tons a day or 3,00,000 tons per year Beneficiation plant consists of the following equipments. a. Front end loader - For feeding iron ore into the hopper b. Hoppers - For receiving iron ore & coal for further processing. c. Vibrating Feeders The vibrating feeders feed the iron ore uniformly into the Jaw crusher, into the coal crusher & also into the ball mill. This machine is suitable for metal ore selecting procedure. The area of vibrating feeder is 4 m3. The project needs 3 Vibrating feeders. d. Jaw Crusher Jaw Crusher is widely applied to crush both hard & soft rocks & ores. The pressure resistance of the crusher is less than 200 MPa & hence it is suitable for primary crushing. The machine has a large feed opening for its size, an ideal nip angle, giving smooth material flow, high reduction efficiency & high capacity. The machine design is simple, but it has many advanced features such as easy operation, simple maintenance, long life & low cost of crushing per ton. The Jaw Crusher includes Main frame, Main Axial, Roller bearings, Eccentric shaft, Jaw plates, Side plates, Toggle mechanism, Fly wheels & springs. 36 Global Enviro Labs, Hyderabad

103 Specifications Size of Feed opening Maximum feeding size Crushing capacity per hour Motor power Weight Requirement 600 mm X 900 mm 480 mm tons 75 KW 16.5 tons 1 No. e. Vibrating Screens Two Vibrating Screeners are needed for the project, one for screening the iron ore of above 5 mm & feeding them back into the Fine crusher and the other for screening the coal before crushing and sending back the over-sized coal for crushing. f. Fine crusher - Fine Crusher is a new type of Crusher, which combines the advantages of hammer crusher, impact crusher & vertical shaft impact crusher. The fineness of iron ore can be adjusted in the machine between 50 mesh & 20 mm & its hammer has a long service life. Its maintenance cost is lower & the working efficiency is higher. The project needs a Fine crusher, for initial crushing of iron ore from 50 mesh to 5 mm, after Jaw crushing. 37 Global Enviro Labs, Hyderabad

104 The advantages of Fine Crusher are large feeding size, high crushing chamber, suitable for materials of high hardness, large block, less power consumption, new type of hammers, big impact, long life of hammer, adjustable grid size, granularity & particle shape control, abrasion resistance, compact structure, high mechanical strength, exceptional rigidity, easy installation & high efficiency. Technical Data Model Rotor dia (mm) Rotor length (mm) Rotor speed (RPM) Input size (mm) Out-Put size (mm) Capacity tons / hour Power (KW) FC < Weight of the machine 13.6 tons g. Hammer mill Coal crusher A Hammer mill is employed in the project to crush the coal after initial screening, as the required coal size is 0-5 mm for reductionroasting. h. Belt Conveyors The belt conveyors carry the iron ore from Jaw Crusher to the Fine Crusher, from Fine Crusher to the Rotary kiln, from Rotary kiln cooler to the hopper before ball mill. In the coal preparatory line, the belt conveyors are needed for feeding to the screen & from screen to the coal crusher & from coal crusher to the Rotary kiln. Specifications Rubber Belt conveyors 1,000 mm width X average 20 metre length, average power 11 KW Requirement 12 No. i. Rotary kiln for reduction roasting Rotary kiln is used for several applications. Rotary kiln features simple structure, convenient & reliable control of the production process, less wearing parts & high rates of operation. It has a strong structure, stable operation & is generating consistent products. 38 Global Enviro Labs, Hyderabad

105 Specifications of Rotary Kiln Diameter 1900 mm Length 36 metres Gradient 3% Approximate weight 86 tons Speed ( RPM) 0.4 to 4 Total power KW Requirement 1 No. There are 4 zones in the Kiln. They are combustionsupporting zone, reducing zone ( degree C), ending zone ( degree C) and cooling zone ( degree C). There is no need for pre-heater or separate cooler. The temperature of the Flue gas is degree C. j. De-dusting system - A highly efficient de-dusting system will be employed in 3 places i.e., near the Jaw crusher, fine crusher & screen, near the coal crusher & screen and near the Rotary kiln for exhaust gases before letting the same out through this stack. Following are the specifications of the de-dusting system De-dusting system with pulse bag dust catcher -Model DM -32 -Air handling capacity 1,500-2,100 m3/hour -Filtration area 24 m2 -No. of bags 32 -Complete with blower, motor & structures 1 no. -Blower Motor rating -2.2 kw 39 Global Enviro Labs, Hyderabad

106 k. Ball mill Ball mill is an efficient tool for grinding many materials into fine powders. It is widely used in mineral beneficiation, building materials, chemical industry, etc. There are two ways of grinding - the dry process & the wet process. Wet ball mill is suitable for the present project, and the capacity of wet ball mill is 2 times more than dry ball mill. The ball mill mentioned above is a skeleton pattern ball mill with horizontal cylindrical turning gear; drive by outer gear & with 2 hoppers. The material goes into the first hopper after spiraling by the quill shaft from the feeding equipment. The hopper has ladder sheathing or corrugated sheathing with steel balls inside, which will fall under the effect of centrifugal force by barrel, turning to ram hard and grinding the material. After kibbling in the first hopper, by monolayer partition panel, the material will enter the second hopper which has plane scale board with steel balls inside to further grind the material. The powder material will be discharged from the grid plate to finish the grinding. This new type of ball mill improves the structure of traditional ball mill. Its bucket and support frame is an integral system, when it is being fixed, it will be hung on the foundation at once. Equipped with double-tiered centripetal roller bearing, its power consumption will be reduced by 30%. The intrinsic grill pattern forcing discharge is adopted instead of by overall pattern controlling discharge. Due to this, the fineness of final product is enhanced, and capacity is increased by 15-20%. By increasing the fineness of final size of the iron ore, it is possible to improve the finished Fe content in the concentrate. 40 Global Enviro Labs, Hyderabad

107 Specification Diameter Length Power Total weight Weight of the balls Speed of the drum Size of the feed opening Size of the output Production (tons/hour) Requirement 2,400 mm 6,500 mm 380 KW 52 tons 20 tons RPM < 25 mm mm -0.4 mm tons 1 No. l. Drum wet magnetic separator Description- The special series of wet powder magnetic drum separator (from single drum to four drums) is made from rare earth permanent magnetic materials to generate the required magnetic field. It is a kind of specialized equipment to remove the wet ferrous powder materials automatically and continuously. The Magnetic Separator can separate the raw materials with different magnetic rigidities. The machine works under the magnetic force and machine force. Magnetic Separators are designed to recover Ferro-magnetic materials. The separators are available in designs and sizes to provide solutions for all applications. The heart of each separator is the magnetic system with its unique design, which has a proven record of high efficiency. The Magnetic Separators are available in cyclic design with process vessel diameters from 220 mm to 3,050 mm, to meet different capacity requirements. Specifications Coarse Magnetic Separator Diameter 1,050 mm Length 2,400 mm Power 5.5 KW Speed 30 RPM Capacity per hour 95 m3 Requirement 2 No. 41 Global Enviro Labs, Hyderabad

108 Specifications Fine Magnetic Separator Diameter 900 mm Length 1,800 mm Power 4 KW Speed 35 RPM Capacity per hour 80 m3 Requirement 2 No. n. High Frequency vibrating screen - This machine is suitable for metal ore selection procedure, for grading the ore slurry by size & is often used in close circle with the ball mill. High-frequency screen consists of vibration exciter; ore pulp distributor, screen frame, machine frame, suspension springs and sieve, etc. Specifications Area of screening 8 square metres Thickens of input material 30-40% Capacity hour tons per hour Power 2 KW Requirement 1 No. o. Water pumps Power - 90 KW Requirement 2 Nos. p. Concentrate Slurry pumps - Power - 30 KW Requirement 2 Nos. q. Mud Pumps- Power 40 KW Requirement 2 Nos. 42 Global Enviro Labs, Hyderabad

109 r. Floatation chambers Floatation chambers are provided in the project, for any possibility that silica & alumina are to be reduced further to the acceptable levels & the Fe should be increased to minimum 65% level. Working Principle- Flotation machine is applicable for the separation of non-ferrous metals and ferrous metals. The impeller is driven by V-belts, which can bring the centrifugal effect to form negative pressure. While extracting sufficient air to mix with ore pulp, the machine stirs ore pulp and mixes it with chemicals to form mineralized froth. By adjusting the height of the flash board to control the liquid level, the useful froth can be scraped from the loam board. The height of the strobe must be adjusted carefully to keep the stabilization of liquid level and scrape the mineralized froth to the launder. Specifications Trough capacity Blade diameter Production capacity Blade rotation speed Requirement Power (each) Weight each Overall dimension 4 m3 650 mm m3 per minute 238 RPM 6 Nos. 15 KW KW 2.66 tons 1850 X 2050 X 1200 mm The selection of floatation machine and the number of cells depends on excess silica & alumina contents to be removed from the ore. In case all the above are within the standard, there is no need for Flotation machine. When floatation machine is used, it needs extra water, which is already included in the calculations. s. Mixer When floatation machines are used, they need a mixer to mix small quantity of frothing agents, which help excess silica & alumina to float in the floatation chamber. For 1,000 tons a day plant, we need one mixer of 2,000 mm X 2,000 mm size, which is equipped with 7.5 KW motor. 43 Global Enviro Labs, Hyderabad

110 t. Auto hydraulic plate & frame type filters - Hydraulically operated Plate & Frame type filter presses are simple, economical, practical & suitable for recovering water from the tailings in iron ore beneficiation plants, without the need for any Concentrator. Following are the Filtration capacities needed for the project- Water disposal per hour m3 Percentage of mud in the tailing water 10-15% Filter area (m3) 650 Size (L X W X H, mm) 11650X3000X2500 Weight (kg) each No. of Filter units needed 2 Working principle of Frame Type Filter Press- The Frame type Filter press uses polypropylene fibre or non-woven fabric as filter cloth. The frames are made up of PP material and can withstand 6 kg / cm2 pressure. The frames have a life span of 8-10 years. The Frame type filters work on the pressure difference principle. The effects of filtration are much better than Vacuum filter. Even difficult materials can be processed. Its structure is single, easy for operation, equipment price is lower & the cost of water recycling is also lower. Since hydraulic pressure is used, the power requirement is only 5.5 KW in the Filter Press. The entire operations are automatic - from Feed pump to the discharge of filter cakes. 44 Global Enviro Labs, Hyderabad

111 Photos of Filter Press & Pressed mud u. Concentrated iron ore drying & water seepage tanks Constructed at site. v. Necessary cyclones, de-dusting system, chutes, hoppers, interim water storage tanks, pipelines, ladders & other supporting structures - Constructed at site. Details of settling pond It is proposed to use a new technology of on-line Plate & Frame type Filter system, in place of settling pond, & the details are already explained in the beneficiation process above OTHER UTILITIES REQUIREMENT Power The installed power for the project is 1.5 MW, while the average load is 1.2 MW. This 1.5 MW is proposed to be drawn from the state grid. 45 Global Enviro Labs, Hyderabad

112 Auxiliary power The Rotary Kiln should not be kept in idle condition, due to high temperature being maintained in the kiln. An emergency power will be needed to put the system in the auxiliary mode. Hence it is proposed to install a 1 MW diesel generator for stand-by arrangement Thermal Energy The thermal energy needed for the reduction-roasting process is made available by burning the coal in the rotary kiln Man power The plant needs a total of 66 workers & Supervisory staff, 6 administrative & sales staff, 2 managerial staff and a General Manager in charge of all the operations. The total requirement of man power is Fire Fighting System The fire fighting system will be designed in conformity with the recommendations of the Tariff Advisory Committee (TAC) of Insurance Association of India. While designing the fire protection systems for proposed facilities its extreme ambient conditions need special attention. Codes and Standards of National Fire Protection Association (NFPA) will be followed, as applicable. 46 Global Enviro Labs, Hyderabad

113 CHAPTER-III 3.0 BASELINE ENVIRONMENTAL STATUS 3.1 AIR ENVIRONMENT Collection of base line data is an integral part of the preparation of environmental impact assessment reports. The possible effects of the proposed expansion of iron ore mining with beneficiation project at the mine site are estimated and superimposed on the compiled base line data to assess environmental impacts. Pre-project environment assessment was conducted in the study area in Winter , i.e December 2011 February Studies were undertaken to generate baseline data of micrometeorology, air quality, water quality, noise levels, flora and fauna, land use, soil quality, and socio-economic status of the community in a radial distance of 10 km surrounding the project site CLIMATE AND METEOROLOGY Regional climate and meteorology: The study area lies in semi-arid region where climate is characterised by hot summer, moderate monsoon and mild winter seasons. Summer is typically from March to May, when temperature ranges to a maximum of 46 C during day time to a minimum of 27 C at night. Winter will be from December to February, when the maximum temperature during day time goes up to 32 C and minimum temperature 15 C at night. The mean maximum and minimum temperatures of study area is presented in table 3.1 Table 3.1 Mean maximum and minimum temperatures of study area (District Census Hand Book, 2006) S.No Months NORMAL Max. Temp 0 C Min.Temp 0 C 1 January February March April May June July August September October November December The district receives annual normal rain fall of 700.0mm and the proposed lease area receives an annual rainfall of 677.0mm. 47 Global Enviro Labs, Hyderabad

114 The rains are predominant between June to September due to south-west monsoon. Rains also occur in the months of October to December due to north-east monsoon. Table 3.2 presents average yearly rainfall (District census hand book, 2006). The pattern of rain fall is highly irregular and varied significantly from year to year. Table 3.2: Annual Rainfall (mm) Year Normal Total Wind speed and wind direction have a significant role on the dispersion of atmospheric pollutants and therefore the air quality of area. METEOROLOGICAL DATA Prevailing micro-meteorological conditions at site regulate the dispersion (and hence dilution) of air pollutants in the atmosphere. Therefore, study of meteorological conditions is an integral part of environmental impact assessment studies. Hence, a meteorological station was set up near the site on top of a platform (10m height). The following parameters were recorded at hourly intervals during the December 2011 February Air temperature ( C) Relative humidity (%) Wind speed (m/s) Wind direction (sixteen quadrants) The data collected on wind speed and wind direction was used for computation of wind percentage frequencies in all the twelve directions for wind speed in the range of , , , , , >3.0. Predominant Wind directions during this period were from the NE to SE. Wind speeds during this period were varying between kmph. The wind of less than 2.0 kmph were treated as calm, and calm conditions are nil. The summary of the wind pattern for the Winter season is given Annexure E The meteorological data recorded continuously during the months of December 2011 to February 2012 on hourly basis on wind speed, wind direction and temperature has been processed to extract the 24- hourly mean meteorological data as per the guidelines of IMD and MoEF for application of ISCST3 model. Stability classes computed for the mean hours is based on guidelines issued by CPCB on modeling. Mixing heights representative of the region have been taken from the available published literature. Annexure E provides the mean meteorological data used for modeling. The seasonal wind rose diagram is presented in Fig Global Enviro Labs, Hyderabad

115 Fig.3.1 SEASONAL WINDROSE Ambient air quality To assess the impact of the Mining & Beneficiation and allied activities on the ambient air quality, it is necessary at first to evaluate the existing ambient air quality of the core and the buffer zones. The existing ambient air quality in terms of Particulate Matter2.5 (P.M 2.5 ) Respirable Particulate matter (PM10), Sulphur dioxide (SO 2 ), Nitrogen dioxide (NO 2 ) and Carbon monoxide (CO) was carried out during Winter Monitoring stations location: To assess the ambient air quality level, eight monitoring stations were set up. Out of these eight stations, one was set up in core zone, while the rest were outside the mining lease and within a radius of 10.0 km. Table 3.4 and Fig. No 3.2, presents the location of the air quality monitoring stations. Table 3.4: Ambient air quality monitoring stations S.No. Location Station code Direction to mine site Distance (km) 1. Mine site A Downwind station A 2 NW 0.5km 3. Chinnachapalle A 3 NNE 1.1 km 4. Aretipalle A 4 NE 1.43 km 5. Kottasamipalle A 5 SE 4.5 km 6. Nagayapalle A 6 SW 4.0 km 7. Tummaluru A 7 W 2.4 km 8. Venkatapuram A 8 NW 2.5 km While selecting the stations, the following points were considered: 49 Global Enviro Labs, Hyderabad

116 Meteorological conditions, Downwind and Upwind directions, Topography of the study area; Likely impact areas due to mining activities and Stations were setup in the settlements/villages surrounding the mine lease. Monitoring schedule At all the stations, samples were collected twice a week for 12 weeks. Samples of 24 hourly duration were taken for monitoring P.M 2.5, RPM and eight hourly duration for SO 2, NO x and CO. Pre-calibrated Fine Particulate Samplers (PM2.5) & R.D. Samplers (PM10) have been used for monitoring the existing AAQ status. Maximum, Minimum, Average and Percentile values have been computed from the raw data collected at all individual sampling stations to represent the Ambient Air Quality Status. Sampling & Testing Methodology Below table gives the standard procedures adapted for sampling and testing. The procedures are in compliance with CPCB & MoEF. Parameter Duration of Sampling Recommended Analytical Procedure PM2.5 and PM10 24 hours - continuous Gravimetric Method as per IS: 5182 SO2 8 hours continuous Pararosaniline Colorimetric method NOx 8 hours - continuous Modified Jacob & Hochheiser method CO Grab Sample As per IS Global Enviro Labs, Hyderabad

117 51 Global Enviro Labs, Hyderabad

118 ANALYSIS OF BASELINE CONCENTRATIONS BUFFR ZONE Particulate Matter PM 2.5 Average value of Particulate Matter (PM 2.5 ) monitored in the study area ranging between μg/m3. Highest value of 26 μg/m3 was recorded at Tummaluru in the buffer zone. The values of PM 2.5 monitored in the study area are well within the limits of NAAQ standards Particulate Matter PM 10 Average value of Particulate Matter (PM10) monitored in the study area ranging between μg/m3. Highest value of 59 μg/m3 was recorded at Tummaluru in the buffer zone. The values of PM 10 monitored in the study area are well within the limits of NAAQ standards. Sulphurdioxide - SO2 Average value of Sulphur dioxide in the study area from the monitored data was in the range of μg/m3. Maximum value of sulpurdioxide of 6.8 μg/m3 obtained near the sampling location Nagayapalli. The values of SO2 monitored in the study area are well within the limits of NAAQ standards. Oxides of Nitrogen - NOx Average value of Oxides of Nitrogen in the study area from the monitored data was in the range of μg/m3. Maximum value of oxides of nitrogen of 8.5 μg/m3 obtained near the sampling location Nagayapalle. The values of NOx monitored in the study area are well within the limits of NAAQ standards. Carbon Monoxide - CO CO concentration at all the locations was found to be less than 1 ppm CORE ZONE Particulate Matter PM 2.5 Average value of Particulate Matter (PM 2.5 ) monitored in the core zone is 13.3 μg/m3. The highest value of PM 2.5 level 17 μg/m3 was observed. The value of PM 2.5 monitored in the core zone is well within the limits of NAAQ standards. Particulate Matter PM 10 Average value of Particulate Matter (PM 10 ) monitored in the core zone is 31.8 μg/m3. The highest value of PM10 level 36 μg/m3 was observed. The value of PM10 monitored in the core zone is well within the limits of NAAQ standards. 52 Global Enviro Labs, Hyderabad

119 Sulphur dioxide - SO2 Average value of Sulphur dioxide in the core zone is 2.6 μg/m3. The maximum value of sulphur dioxide of 2.9 μg/m3 was observed. The values of SO2 monitored in the study area are well within the limits of NAAQ standards. Oxides of Nitrogen - NOx Average value of Nitrogen oxides in the core zone is 3.7 μg/m3. The maximum value of nitrogen oxides of 4.3 μg/m3 was observed. Carbon Monoxide - CO CO concentration in the plant area was found to be less than 1 ppm. Summary of AAQ monitoring at each location is given in Table 3.5 and Results of of ambient air quality is enclosed in Annexure - A. Table 3.5 Summary Of AAQ Monitoring Locations 98 th Percentile Values PM 2.5 PM 10 SO2 NOx Mine site Downwind station Chinnachapalle Aretipalle Kottasamipalle Nagayapalle Tummaluru Venkatapuram Note: CO at all locations was found <1.0 ppm NAAQ Standards Specified By Central Pollution Control Board Pollutants Sulphur Dioxide (SO2) Oxides of Nitrogen as NO2 Particulate Matter (PM10) Particulate Matter (PM 2.5 ) Time-weighed Average Concentration in ambient air Industrial, Residential, Rural and Other Areas Annual Average * 50 µg/m 3 20 µg/m 3 24 hours ** 80 µg/m 3 80 µg/m 3 Annual Average * 40 µg/m 3 30 µg/m 3 24 hours ** 80 µg/m 3 80 µg/m 3 Annual Average * 60 µg/m 3 60 µg/m 3 24 hours ** 100 µg/m µg/m 3 Annual Average * 40 µg/m 3 40 µg/m 3 24 hours ** 60 µg/m 3 60 µg/m 3 CO Concentration 8 hours * 2.0 µg/m µg/m 3 1 hour ** 4.0 µg/m µg/m 3 Ecologically sensitive areas (Notified by Central Govt.) 53 Global Enviro Labs, Hyderabad

120 It has been observed that during study period the PM2.5 and PM10 values are with in the limits, in the villages which use fuel wood for domestic purposes. The villages are surrounded by barren area & gardens on all sides causing amount of wind blown dust, especially in the dry seasons to some extent ANTICIPATED IMPACTS DUE TO THE MINING OPERATIONS In the open cast mine envisaged, mining operations such as drilling, blasting, excavation, loading and unloading and movement of tractors on haul roads, are expected to generate air-borne fugitive dusts. Fugitive and non-fugitive dust emissions sources during the mining are presented in Table 3.6. Table 3.6: Sl. No. 1. Fugitive and non-fugitive dust emissions during mining Source Construction of infrastructural facilities (building, roads) 2. Drilling 3. Blasting 4. Excavation of ore 5. Material transport Nature of emission Fugitive and area source Fugitive and point source Fugitive and point source Fugitive and area source Fugitive and line source Frequency of emission Infrequent and pre-mining Infrequent and pre-mining Frequent and post-mining Very frequent and post-mining Very frequent and post mining Nature of air pollution Dust Dust Dust, CO, NO x, SO 2, H 2 S (slurry explosives) Dust Dust Opencast mining activity causes some adverse impacts on the surround environment unless proper environmental management plan is adopted. Selecting suitable sites for mining and adopting the guidelines prescribed by the Ministry of Environment & Forests (MoEF) and Indian Bureau of Mines (IBM), one can minimize the major possible impacts. The following aspects have been studied to identify the possible impacts while achieving the total production of 5,00,000 tonnes per year. The magnitude and significance of the environmental pollution caused by mining depends on method of mining, scale and concentration of mining activity. The impacts on air environment from a mining activity depend on various factors like production capacity, machinery involved, operations and maintenance of various equipments and vehicle. Apart from these, there will be other activities associated viz transportation of mineral and waste, stocking facilities and dump management within the mine lease area that may contribute to pollution. 54 Global Enviro Labs, Hyderabad

121 AIR EMISSIONS Prediction of impacts on air environment has been carried out taking into consideration of the proposed production and increase in emissions. The proposal is for iron ore production of 5,00,000 TPA. Hence, to estimate the impacts, total production of 5,00,000 TPA has been considered. The proposed mining is carried out by opencast method by using drilling & blasting. The air borne particulate matter is the main air pollutant contributed by mining and mineral process operations. Resultant ground level concentration for the prevailing meteorological conditions, using the mathematical model were estimated QUANTITATIVE ESTIMATION OF IMPACTS ON AIR ENVIRONMENT An attempt has been made to predict the incremental rise of various ground level concentrations above the baseline status in respect of air pollution due to proposed mining production for a total quantity of 500,000 TPA. The mathematical model employed for predictions in the present study is ISCST3 model, which was approved by United States Environmental Protection Agency for mining applications. The Industrial Source Complex Short Term model (ISCST3) is a computerized air quality model specifically designed for computing concentrations and deposition impacts of various emission sources. The model is based on the well-known Gaussain Plume formulation for computing concentrations and also the model has been specifically adapted to incorporate an improved gradient transfer deposition algorithm. Emissions for each source are apportioned into a series of particle size classes. Gravitational settling velocity and deposition velocity are calculated. Salient features of the ISCST3 model are given hereunder. Excavation operations are considered as area sources. Transportation of material on haulage roads has been considered as line source The predicted ground level concentrations for study period computed using EPA approved ISCST3 model are plotted as isopleths SOURCES OF DUST EMISSION Mining is carried out by open cast method by using drilling & blasting. Based on the various operations involved in the production of minerals, the various emission sources has been identified as given below. a. Point soruces b. Area sources. c. Line sources. 55 Global Enviro Labs, Hyderabad

122 Drilling operations of the mine are considered as point sources. Extraction of mineral from mine, are considered as area sources. Transportation of material from mining benches to various end points are considered as line sources. The impact of above sources on air environment is discussed below: a) Drilling & Blasting Drilling and Blasting is required to mine the minerals in this area. The blast holes will be drilled to maximum depth of 30 mm with the help of jackhammer. In order to achieve a total production of 500,000 TPA of iron ore, about 91 holes of 1.5 m depth to be drilled and blasted per day in one round. Blasting will done using small diameter slurry based explosives and detonators. Air pollutants will be generated during blasting are in the form of particulate matter. Blasting will be carried out during day time only and will be avoided during high windy periods. The concentrations due to instantaneous blasting will be high and is confined to a maximum distance of 100 m from the area of the blast around each pit. These concentrations will not be emitted continuously. However presence of personnel near the blasting site during blasting will be totally avoided. So, the impact of blasting on the air environment will be minimal. b) Extraction & Loading Extraction & Loading will be done manually Loading activity of mine operation is contributing to the area source emission and the extent of influence of this operation is about 100 m 2. c) Haulage &Transportation In the operating mine, the excavated material form mine face to the proposed beneficiation plant / consumers is transported by lorries/tippers. The tippers will be well maintained so that exhaust smoke does not contribute abnormal values of noxious gases and unburnt hydrocarbons. The other sources of air pollution is due to the dust generated during the movement of tractors on the haul road. In the operating mine, the excavated material form mine face to the processing yard is transported by tippers. The tractors are well maintained so that exhaust smoke does not contribute abnormal values of noxious gases and unburnt hydrocarbons. The other sources of air pollution is due to the dust generated during the movement of tippers /Vehicles on the haul road. The above sources, which include blasting, excavation, haulage for transport of mineral will contribute to dust pollution in the air. The dust generated in the operating mine is that of topsoil. 56 Global Enviro Labs, Hyderabad

123 EMISSION DETAILS All the emissions discussed above are quantified for proposed iron ore production of 5,00,000 TPA. The existing air quality levels are covered in the baseline scenario. The emissions are computed based on AP-42 emission factors. Operational hours, activity rate, wind speed and moisture content have been considered for estimation of emissions from point and area sources. For line source, apart from operational hours, activity rate, moisture, silt content and vehicle weight have been considered. The emissions computed for the proposed production are given below. Predictions are carried out for the worst-case scenario of simultaneous operation of excavators (area sources) and tippers for transportation from mine pit to loading pit (line sources) over a distance of 750 m. the manual operations are covered to an extent of 100 m. in the mine. The number of working days has been taken at 300 days per year with 8 hours of operation/day, hence the concentrations predicted are considered to be the worst case. With control measures, the emissions have been taken at 30% of uncontrolled emissions for handling and 10% of uncontrolled emissions for transportation. EMISSION DETAILS (BASIS AP-42:EMISSION ESTIMATION TECHNIQUE MANUAL FOR MINING) Table 3.7 A Excavation of Minerals Area Source Proposed Quantity, TPA 5,00,000 Operational Hours per year 2400 Activity Rate, t/hr Emission of dust, gm/t 0.1 Emission of dust gm/hr Area of influence, m Uncontrolled Emission Rate g/s/m Controlled emission rate g/s/m Table 3.8 B Transport of Minerals Haulage Emissions Proposed Quantity, TPA 5,00,000 Operational Hours per year 2400 Capacity of each Tractors (T) 10 Total No. of Tractors/year Lead length/trip, Km 1.5 Total VKT/year Km Emission kg/vkt 0.91 Total emission kg/year Uncontrolled emission rate g/s/m Controlled emission rate g/s/m Note: Emission factor computed based on wind speed of 2m/sec and moisture of 10% Emission factor computed based on silt content of 10% and moisture of 10% 57 Global Enviro Labs, Hyderabad

124 3.1.4 ANTICIPATED IMPACTS DUE TO INSTALLATION OF PROPOSED BENEFICIATION PLANT In the proposed Iron Ore Beneficiation Plant the environmental impacts will be studied during construction and operation phase of proposed activities for apply suitable mitigation measures. Several scientific techniques and methodologies are available to predict impacts of proposed activities and such predictions are superimposed over the baseline (Pre-project) status of environmental quality to derive the ultimate (Postproject) scenario of environmental conditions Considering the issues involved in proposed Iron Ore Beneficiation Plant, the activities can be divided into two phases viz; Construction Phase Operation Phase CONSTRUCTION PHASE Construction phase activity involves erection of equipment and units, infrastructure development like roads, water storage, electricity, drainage etc. The project activities during the Construction phase will be of short-term in nature: During construction phase following major activities are involved: Construction of roads, ware houses, buildings etc. Erection of structures, plants and machinery Construction of storage areas Laying conveyors, ducts, pipe lines etc. Auxiliaries and service centres The proposed activities will be limited to the Mine Lease area only. Mitigation measures After completion of the construction phase, the surplus earth shall be utilized to fill up the low lying areas, the rubble will be cleared and all un-built surfaces will be reinstated. The top soil from the excavated during the construction phase will be preserved in separate stacks for green belt development Green belt development and related activities will be taken up at construction phase so that plantation grows to adequate height by the time of plant commissioning. Entire plant area will be aesthetically landscaped and as much as feasible natural gradient will be maintained. There will be minimum concerting of the top surfaces so that there is a scope for maximum ground water recharge due to rainfall. 58 Global Enviro Labs, Hyderabad

125 Impact on Air Quality During construction phase, dust will be the main pollutant, which will be generated from the site development activities and vehicular movement on the road. Further, concentration of NO x and CO may also slightly increase due to increased in vehicular traffic movement. Mitigation Measures The dust generated will be fugitive in nature, which can be controlled by sprinkling of water. It is necessary to control the dust emissions particularly during dry weather. This will be achieved by regular water sprinkling all over the exposed area, at least twice a day using truck-mounted sprinklers. The nose-mask will be provided to workers in dust prone area. Ambient SO x and NO x levels will increase due to operation of construction machinery such as excavators, trucks etc. However, increase in levels of those pollutants is expected to be insignificant since these machines will be operated intermittently. These equipment are not stationary and would be moving from one place to other, hence there will not be increase in concentration of emissions at a single location. Nevertheless, it will be ensured that both gasoline and diesel powered construction vehicles are properly maintained to minimize exhaust emissions. The impacts will be localized in nature and the areas outside the project boundary are not likely to have any significant adverse impact. The construction will not carry out in night time OPERATIONAL PHASE Impact on Air Quality The impacts on air quality due to source of the air pollution in the proposed facilitt have been identified. Sources of Emissions Emissions released from the stack during operation phase will get dispersed in the atmosphere and finally reach the ground at a specified distance from the sources. From the proposed activities the possible environmental impact on air quality has been envisaged due to the following sources. Raw Material Handling /Transport System The possible pollutants are fugitive dust emissions from raw materials handling areas, viz., loading/unloading, fuel stockyard, crushing units, etc. Raw materials will be fed to hopper with the help of pay-loader/tipper. 59 Global Enviro Labs, Hyderabad

126 Mitigation Measures The Lessee shall provide dust suction system which will control fugitive emission due to raw material handling. Dust suppression system will be provided in the form of water sprinklers. All vibrating screens and weigh feeders below the hopper, day bins etc are totally covered to prevent leakages of dust. The entire length of conveyors is covered to prevent dust pollution. All bins are totally packed and covered so that there is no chance of dust leakage. All discharge and feed points wherever the possibility of dust generation is there is provided with dust suppression system. All material transfer points are connected with dust suppression water nozzles to avoid air pollution. The major air emissions from the proposed beneficiation plant are mainly from Rotary Kiln area where the dust is released through flue gases to the atmosphere. The Lessee will provide the bag filter to the rotary kiln, designed for an outlet concentration of less than 50 mg/nm3. The major pollutants emitted from this unit are particulate matter. For estimation impacts, an out let concentration of 50 mg/nm3 has been considered. The emissions from the proposed Rotary Kiln after treating in Bag filters will be let out into the atmosphere through a stack height of 45m. The counter- current flow of hot gases enables to remove the moisture content from the raw material. The gases contain large amounts of fine dust comprising oxides and small quantities of un-burnt carbon & carbon monoxide. It needs treatment before discharging into the atmosphere. Initially, After Burning Chamber (ABC) is provided, that acts as Dust settling chamber. About 15-20% coarse dust settles in Dust settlement chamber by means of gravity. In ABC, CO content of gases is converted into CO 2. Due to this exothermic reaction, the temperature of the gas may raise to C. Then the gases pass through Dedusting system with pulse bags dust catcher. The cleaned gases are emitted through a stalk of 45 metre height. The final suspended particulate matter content of treated gases of Rotary kiln shall be less than 50 mg / Nm 3. The ABC system at the feed end of the Rotary kiln will have emergency stack /safety cap on the top, to maintain positive pressure inside the kiln & to avoid chances of CO related explosion. The dust collected from the de-dusting system will be taken to the ball mill for mixing with the roasted iron ore for further grinding & for magnetic separation. This dust mainly composes of iron ore (Fe 3 O 4 ), Silica (SiO 2 ) & Alumina ( Al 2 O 3 ) with small quantity of calcium (CaO) from the lime stone. 60 Global Enviro Labs, Hyderabad

127 In addition to the above a highly efficient de-dusting system with pulse bag dust catcher will be provided near the Jaw crusher, fine crusher & screen, near the coal crusher & screen for exhaust gases before letting the same out through the stacks. Emission Details of proposed Stack: Type Of Fuel Coal Coal Consumption (t/day) 100 Sulphur content (%) 0.5 (max) No. Of stacks 1 Height of stack (m) 45 Diameter of stack (m) 1.5 Temperature of flue gas ( o C) 150 Velocity of flue gas (m/s) 7.85 Particulate matter at outlet of Bag filter (gm/sec) 1.38 (Based on 100 mg/nm 3 at outlet) Sulphur dioxide emission (gm/sec) Oxides of Nitrogen (gm/sec) 6.94 (based on 500 mg/nm 3 at outlet Emission Details of Proposed Bag Houses: Sl. No Stack Attached to: 1 Bag house at Jaw Crusher 2 Bag house at Fine Crusher & Screen 3 Bag house at Coal Crusher & Screen Stack Height (m) Diameter of Temp. of Exit Stack (m) exhaust Velocity gases ( o C) (m/sec) SPM (Mg/Nm 3 ) STACK HEIGHT ESTIMATION The height of the stack is calculated based on the formula prescribed by CPCB i.e., H=14 (Q) 0.3 on SO2 basis, where H is the physical height of the stack in meters and Q is emission rate of SO2 Kg/hr. The stack height is calculated for the fuel char with 0.5% Sulphur content in gasses for the proposed Kiln. The height of the stack is calculated as fallows. To represent the worst scenario 100 TPD (100%) of coal will be used in the proposed Beneficiation plant Total coal consumption : 100 TPD Max. Sulphur content in Coal : 0.5% (By mass) SO2 emission (Q) : 100 x 1000 x 0.5 x 2/24 x 100 : kg/hr Stack height calculated (SO2) : H=14 (41.66) 0.3 = m Height of Stack should be provided mt for the proposed Rotary Kiln In the proposed Beneficiation plant, The Lessee proposes to provide a tall stack of 45 m height to exhaust flue gas generated from the Rotary Kiln. 61 Global Enviro Labs, Hyderabad

128 3.1.5 MAXIMUM GROUND LEVEL CONCENTRAIONS Ground level concentrations of PM, SO2 and NOx were estimated using the mean meteorological data to project the incremental increase of concentration above baseline concentrations due to emission from the proposed 0.5 MilllionTPA of Iron ore production & 0.3 MillionTPA Beneficiation Plant. The following table shows the summary of the same. Incremental Ground Level Concentration due to proposed 0.5 MilllionTPA of Iron ore production & 0.3 MillionTPA Beneficiation Plant Distance of Maximum concentrations from source, km Particulate Matter Sulphur Oxides of Dioxide Nitrogen Figure represents the spatial distribution of the predicted ground level concentrations of PM, SO2, and NOx due to emissions from the proposed 0.5 MilllionTPA of Iron ore production & 0.3 MillionTPA Beneficiation Plant, which are coming up in the Ha. of Mine lease area POST PROJECT SCENARIO Maximum ground level concentrations are predicted considering 24-hourly mean meteorological data of December 2011 February 2012, superimposed on the maximum baseline concentrations obtained during the study period to estimate the post project scenario, which would prevail at the post operations phase. The Overall Scenario with predicted concentrations over the maximum baseline concentrations is shown below. OVERALL SCENARIO WITHIN STUDY AREA (μg/m3) 24 Hourly Particulate Sulphur Oxides of Concentrations Matter (PM10) Dioxide (SO2) Nitrogen (NOx) Baseline Scenario (Max) Predicted Ground Level Concentration due to proposed Integrated Steel Plant (Max) Overall Scenario NAAQ Specified Limits IMPACT ON VILLAGES It may be observed that the maximum predicted concentrations are falling within 0.7 km from the source. The nearest village is located at a distance of about 1.0 km, which is beyond the impact zone 62 Global Enviro Labs, Hyderabad

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