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ENVIRONMENTAL CLEARANCE APPLICATION
For
Expansion of Silica Sand
Beneficiation Plant
At Village Momidi, Gudur, Andhra Pradesh
Being Developed by
M/s Mangalore Minerals Pvt. Ltd.
Mineral House, Hampankatta,
Mangalore-575001
Prepared By
Environmental Consultant
M/s Perfact Enviro Solutions Pvt. Ltd.
(NABET Registered wide list of accredited consultants organizations/ Rev 11/ 5th August, 2013 at S.No-113)
(An ISO 9001:2008 &ISO 14001:2004 Certified Company) 5th Floor, NN Mall, Sector 3, Rohini, New Delhi-110085
Form – 1 (I) Basic Information
S. No. Item Details
1. Name of the Project Expansion of “Silica Sand Beneficiation plant”
2. S. No. in the schedule 2(b)
Proposed Capacity/area/ Length/tonnage to be
Existing Capacity- About 6 Lakh MT/Year Existing Capacity- About 6 Lakh MT /Year
3. handled/ command area/ lease area/ number of wells
to be drilled. Plant Area- 8.66 Acres
4. New/Expansion/Modernization Expansion
5. Existing Capacity/Area etc. Plant Area is 8.66 Acres
6. Category of project i.e. 'A' or 'B' A
Does it attract general conditions? If yes, PleaseYes it attract general condition
7. as the production s more than
Specify.
0.1 Million TPA.
8. Does it attract the specific condition? If yes, please
NA
specify.
9. Location Momidi, Andhra Pradesh
a. Plot/survey/Khasra No. 302 & 302B1
b. Village Momidi
c. Tehsil Chillakur Mandalam, Gudur
d. District Nellore
e. State Andhra Pradesh
Gudur Railway station (30
Nearest Railway station/ airport along with distancekm)
10.
in kms.
Village panchayats, Zilla parishad, Municipal
11. corporation, local Body(complete postal addresses Momidi Panchayat
with telephone nos. to be given)
The site is well connected to
Nearest Town, city, district Headquarters along withdistrit Headquaters at a distance
12.
of 65 km and the plant is 30 km off Main Gudur – Nellore Highway
distance in kms.
1
13. Name of the applicant
M/s Mangalore Mineral Pvt. Ltd.
14. Registered Address Mineral House, Hampankatta,
Mangalore – 575001
15. Address for correspondence: Mineral House, Hampankatta,
Mangalore – 575001
a. Name Mr. Santhosh Mendon
b. Designation(Owner/Partner/CEO) Executive Director
c. Address Mineral House, Hampankatta,
Mangalore – 575001
d. Pincode 57001
e. E-mail [email protected]
f. Telephone No. 0824-2428028
g. Fax. No. O827-2422076
Details of alternative Sites examined, if any.Existing land for Silica Sand
washing plant was upgraded to
16. Location of these sites should be shown on a topo
land for Silica Sand
sheet.
Beneficiation Plant.
17. Interlinked Projects NA
18. Whether separate application of interlinked project
NA
has been submitted?
19. If Yes, date of submission NA
20. If No, reason NA
Whether the proposal involves approval/ clearance
under: if Yes, details of the same and their status to
21. be given. NA
(a) The forest (conversation) Act, 1980 ?
(b) The wildlife (Protection) Act, 1972 ?
(c) The C.R.Z. notification, 1991 ?
22. Whether there is any government order/ policy
No
relevant / relating to the site?
23. Forest Land involved(Hectares) There is no forest land.
Whether there is any litigation pending against the
project and/ or land in which the project is propose to
be set up?
24. (a) Name of the court NA
(b) Case No.
(c) Orders/ directions of the court, if any and its
relevance with the proposed project.
(II) Activity 1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
S.No. Information/Checklist Details thereof (with approximate quantities
Yes/No /rates, wherever possible) with source of
confirmation
information data
Permanent or temporary change
in land use, land cover or The total area for silica sand beneficiation
1.1 topography including increase in
plant is 8.66 Acres
intensity of land use (with Yes
respect to local land use plan)
1.2 Clearance of existing land,
No There is no vegetation at site.
vegetation and buildings?
1.3 Creation of new land uses?
Yes Installation of beneficiation plant.
1.4 Pre-construction investigationsYes Soil investigation will be carried out.
e.g. bore houses, soil testing?
Plant will have some essential permanent
1.5 Construction works? yesconstruction.
1.6 Demolition works? No No
Temporary sites used for
1.7 construction works or housing of Yes Approx 20 temporary sheds shall be provided.
construction workers?
Above ground buildings,
1.8 structures or earthworks
NO10 nos. single room houses and 1 canteen will
including linear structures, cut be provided for workers.
and fill or excavations.
1.9 Underground works including No N.A.
mining or tunneling?
1.10 Reclamation works? No NA.
1.11 Dredging? No NA
1.12 Offshore structures? No NA
Production and manufacturing Mineral beneficiation will be carried out in the
1.13 Yes following phases.
processes?
Details are given in EIA report.
Facilities for storage of goods or Sand purchased from the local mines and
1.14 Yes loaded to the plant site storage yard of the
materials?
MMPL
3
Residue Clay is generated after separation of
Facilities for treatment or earth clay from Silica Sand. This comes as
1.15 disposal of solid waste or liquid Yes under flow from the Water Recycling Plant
effluents? and is used in Land Filling. Waste process clay
is 15 %.
1.16 Facilities for long term housing
Yes10 nos. single room houses will be provided
of operational workers? for workers.
New road, rail or sea traffic No new rail, will be expected during
1.17 Yes construction & operation, however there will
during construction or operation?
be a formation of new road.
New road, rail, air waterborne or No new rail, will be expected during
1.18 other transport infrastructure
Yesconstruction & operation, however there will
including new or altered routes be a formation of new road.
and stations, ports, airports etc?
Closure or diversion of existing Noclosureordiversioninexisting
1.19 transport routes or infrastructure
No transportation.
leading to changes in traffic
movements?
1.20 New or diverted transmission
NoNo transmission line or pipeline will be made.
lines or pipelines?
Impoundment, damming, Beneficiation Plant will not impact on surface
1.21 culverting, realignment or other
Nohydrology.
changes to the hydrology of
watercourses or aquifers?
Stream crossings? No stream crossing.
1.22 Abstraction or transfers of water No
form ground or surface waters?
The monsoon water gets drained off through
Changes in water bodies or the the natural valleys. Bunding of plants shall be
made all around the beneficiation plant so that
1.23 land surface affecting drainage No
no water enters the site from the surrounding
or run-off?
area and water within the site will stored in
reservoir and used for water sprinkling.
Transport of personnel or The ore is transported by the road.
1.24 materials for construction, Yes
operation or decommissioning?
Finished goods are dispatched by road transport.
Long-term dismantling or NA
1.25 decommissioning or restoration No
works?
Ongoing activity during NA
1.26 decommissioning which could
No
have an impact on the
Environment?
Influx of people to an area in Most of the employees will be hired from
1.28 either temporarily or Yes local/neighboring villagers. 10 nos. single
permanently? room houses and 1 canteen will be provided.
1.29 Introduction of alien species? No None
No species exist at the site. Therefore, no such
Loss of native species or genetic
loss is anticipated.
1.30 No
diversity?
1.31 Any other actions? No NA
2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are nonrenewable or in short supply):
S.No. Information/Checklist Details thereof (with approximate
Yes/No quantities /rates, wherever possible) with
confirmation
source of information data
Land especially The land is Patta Land under ownership of
2.1 undeveloped or Yes MMPL. It has been converted into industrial
agricultural land (ha) use by the collectrate.
The company has water recycling plant and
Water (expected source is only using minimum water as make-up
water. Water requirement for process is 200
2.2 & competing users) unit: Yes
KLD and domestic water requirement
KLD
will be 8 KLD.
2.3 Minerals (MT) YesSilica Sand is the only raw material required
for this operation.
Construction material – For sheds construction material will be
stone, aggregates,
2.4 Yes asbestos along with iron pillars. The
sand / soil (expected
foundation will be of concrete.
source – MT)
2.5 Forests and timber
NoNA
(source – MT)
Energy including
electricity and fuels
Power requirement is 700 KW. APSTDCL
2.6 (source, competing users) Yes Substation is 8 km from the location and has
Unit: fuel (MT), Direct dedicated power line.
energy (MW)
Any other naturalNo NA
2.7 resources (use
appropriate standard
units)
3. Use, storage, transport, handling or production of substances or materials,
which could be harmful to human health or the environment or raise concerns
about actual or perceived risks to human health.
S.No.
Information/Checklist Details thereof (with approximate
Yes/No quantities /rates, wherever possible) with
confirmation
source of information data
Proper management of HSD
Use of substances or shall be done.
materials, which are
3.1 hazardous (as perNo
MSIHC rules) to human
health or the environment
(flora, fauna, and water
supplies)
Suitable drainage and waste management
Changes in occurrence of measures has been adopted. This restricts
3.2 disease or affect disease No stagnation of water or accumulation of water.
vectors (e.g. insect or No occurrence of Diseases.
water borne diseases)
The plant shall be installed to beneficiate
Silica Sand. It is expected, this activity will
benefit more than the losses. Most of the
3.3 Affect the welfare ofYes
employees are tribal labours being trained to
people e.g. by changing do plant operation. The direct (63) and
living conditions?
indirect (150) employment will enhance thethe
income level hence will lead to civilization
of local people.
People of local/neighboring village will be
Vulnerable groups of benefitted.
3.4 people who could be Yes
affected by the project
e.g. hospital patients,
children, the elderly etc.,
3.5 Any other causes No
NA.
4. Production of solid wastes during construction or operation or decommissioning
(MT/month)
S.No. Information/Checklist Details thereof (with approximate
Yes/No quantities /rates, wherever possible) with
confirmation
source of information data
4.1 Spoil, overburden or
NoNA
mine wastes
Municipal waste The solid waste generated will be dispose off
4.2 (domestic and or Yes in composting site within plant area.
commercial wastes)
Used oil from engines will be carefully
stored in HDPE drums in isolated covered
Hazardous wastes (as per facility. The used oil will be sold to vendors
authorized by CPCB for the treatment of the
4.3 Hazardous Waste Yes
same.
Management Rules)
Suitable care will be taken so that spills /
leaks of used oil from storage will be
avoided.
Residue Clay is generated after separation of
Other industrial process Earth Clay from Silica Sand. This will come
4.4 yes as under flow from the water recycling plant
wastes
and is used in Landfilling. Waste process clay
will be 3%.
4.5 Surplus product No
NA
Sewage sludge or other Sewage Sludge generated will be
sludge from effluent Yes biodegradable.
4.6 treatment
4.7 Construction or
NoNA
demolition wastes
4.8 Redundant machinery or
yesAfter the completion of life of Beneficiation
equipment Plant it will be sold as second hand.
4.9 Contaminated soils or
YesSome traces of waste water generated is
other materials taken back to circuit and recycled.
4.10 Agricultural wastes
NoNA
4.11 Other solid wastes
NoNA
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
S.No. Information/Checklist Details thereof (with approximate
Yes/No quantities /rates, wherever possible) with
confirmation
source of information data
Emissions from The combustion from fossil fuel will be from
5.1 combustion of fossil
yesuse of diesel operated machinery/DG sets,
fuels from stationary or only during the hours when electric supply
mobile sources will not be there.
Crushing and transfer points of dry material
Emissions from will produce dust. Dust extraction system for
5.2 yes the crushing unit and water sprinkling on
production processes
transfer points will be provided. For the
reduction of emission development of Green
Belt will be done.
Dust and emission are likely to be generated
fromhandlingof SilicaSandand
Emissions from materials transportation for which regular sprinkling of
water and alternatives like closed conveyors,
5.3 handling including Yes
closed silos, direct loading of closed vehicles
storage or transport
to transport dusty material etc. will be used
to reduce the emission.
Emissions from Dust and emission are likely to be generated
5.4 construction activities
Yesfrom construction activities. Stored water
including will be used for regular sprinkling of water to
plant and equipment reduce the emission.
Dust is likely to be generated form
beneficiation process for which water
sprinkling and dust collection system will be
Dust or odours from installed wherever necessary so that the
handling of materials impact on the environment will be minimal.
5.5 including construction Yes No odour from the Sewage Sludge because
materials, sewage and sewage slude generated will be
waste biodegradable.
5.6 Emissions from
NoNo incineration will be done.
incineration of waste
Emissions from burning No such activity will take place.
5.7 of waste in open air (e.g.
No
slash materials,
construction debris)
None
5.8 Emissions from any other
No
sources
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
S.No. Information/Checklist Details thereof (with approximate
Yes/No quantities /rates, wherever possible) with
confirmation
source of information data
Beneficiation operations will require
equipment such as, screen grinding mills,
From operation of scrubber, etc. All the equipments
6.1 equipment e.g. engines,
Yeswill be of highest standard of reputed make
ventilation plant, and adhered to international standards. These
Driers standards itself will take significant care of
noise pollution control. Further, a green belt
barrier of natural vegetation is also proposed
for the purpose. All the equipments will be
regularly maintained to keep noise level with
in the prescribed limits of 65 dB (A). Rubber
liner bonded to the inner surface of grinding
mill and use of synthetic screen surface,
rubber & polyurethane effectively reduce
noise level while offering resistance to
abrasion. Also noise reducing pads will be
provided below crushing mill to reduce the
noise.
6.2 From industrial or similar
No None
processes
6.3 From construction or
No NA
demolition
6.4 From blasting or piling No NA
Noise and vibration will be there during
6.5 From construction or
Yesconstruction but it will be for temporary
operational traffic period. Also, noise will come during
incoming and outgoing of trucks.
From lighting or cooling None
6.6 No
systems
6.7 From any other sources No None
7. Risks of contamination of land or water from releases of pollutants into the
ground or into sewers, surface waters, groundwater, coastal waters or the sea:
S.No. Information/Checklist Details thereof (with approximate
Yes/No quantities /rates, wherever possible) with
confirmation
source of information data
Proper management of HSD
shall be done.
From handling, storage,
7.1 use or spillage of Yes
hazardous materials
From discharge of Soak pits will be used to discharge the
sewage or other effluents sewage generated from the workers during
7.2 to water or the land Yes operational phase.
(expected mode and
place of discharge)
By deposition of Fugitive Dust is likely to be generated for
7.3 pollutants emitted to air
Nowhich water sprinkling to be done and proper
into the land or into vegetation belt shall be maintained along to
water the periphery to minimize the environmental
impact. Closed vehicles to transport dusty
material etc. will be used.
7.4 From any other sources No NA
Is there a risk of long None
term build up of
7.5 pollutants in the No
environment from these
sources?
8. Risk of accidents during construction or operation of the Project, which could
affect human health or the environment.
S.No. Information/Checklist Details thereof (with approximate
Yes/No quantities /rates, wherever possible) with
confirmation
source of information data
Disaster management plan and emergency
response system with proper organization set
up for safe mineral beneficiation. Fire
extinguisher shall be provided at plant area.
Also sand will itself act as fire extinguishing
material. Proper management of HSD
shall be done.
From explosions, Used oil from engines will be carefully stored
in HDPE drums in isolated covered facility
spillages, fires etc from
The used oil will be sold to vendors
8.1 storage, handling, use or No
authorized by CPCB for the treatment of the
production of hazardous
same
substances
Suitable care will be taken so that spills /
leaks of used oil from storage will be
avoided.
8.2 From any other causes No NA
Could the project be The area has no flood history. There is no
affected by natural
possibility of landslide.
disasters causing
8.3 environmental damage No
(e.g? floods,
Earthquakes, landslides,
cloudburst etc)?
10
9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality.
S.No. Information/Checklist Details thereof (with approximate
Yes/No quantities /rates, wherever possible) with
confirmation
source of information data
Lead to development of It is a specialized product for glass and
supporting facilities, foundry industries. MMPL project is linked
ancillary development or to the development of Foundries and Glass
development stimulated industries in and around Andhrapradesh area.
by the project which
could have impact on the
environment e.g.:
•Supporting
infrastructure (roads,
9.1 power supply, waste or Yes
waste water treatment,
etc.)
• housing development
• extractive industries
• supply industries
• other
Lead to after-use of the Sheds will be used for community along with
9.2 site, which could have an
Yesgreen belt at the periphery of the plant.
impact on the
environment
9.3 Set a precedent for later
No NA
developments
Have cumulative effects NA
due to proximity to other
9.4 existing or planned No
projects with similar
effects
11
(III) Environmental Sensitivity
S. No. Areas Name/Identity Aerial distance (within 15 km) from Proposed project location boundary1 Areas protected under NA
international conventions, national
or local legislation for their
ecological, landscape, cultural or
other related value
2 Areas which are important or 1 Natural Drain in S.W. 1 km
sensitive for ecological reasons -
Wetlands, watercourses or other
water bodies, coastal zone,
biospheres, mountains, forests
3 Areas used by protected, important NA
or sensitive species of flora or
fauna for breeding, nesting,
foraging, resting, over wintering,
migration
4 Inland, coastal, marine or NA
underground waters.
5 State, National boundaries NA
6 Routes or facilities used by the NA
public for access to recreation or
other tourist, pilgrim areas
7 Defence installations NA
8 Densely populated or built-up are Momidi Village 1 km N
9 Areas occupied by sensitive man- School 1 Km
made land uses (hospitals,
schools, places of worship,
community facilities)
12
10 Areas containing important, high Certain mining
quality or scarce resources activities are occurring
(Ground water resources, surface in nearby areas
resources, forestry, agriculture,
fisheries, tourism, minerals)
11 Areas already subjected to NA
pollution or environmental
damage. (Those where existing
legal environmental standards
are exceeded)
12 Areas susceptible to natural hazard There is a possibility of
which could cause the project to Cyclone
present environmental problems
Proper control measures
(Earthquakes, subsidence,
will be taken for this.
landslides, erosion, flooding or
extreme or adverse climatic
conditions)
I hereby give an undertaking that the data and information given in the application and enclosures are true to the best of my knowledge and belief and I am aware that if any part of the data and information submitted is found to be false or misleading at any stage, the project will be
rejected and clearance given, if any to the project will be revoked at our risk and cost.
Date:07/08/2013
Place: Momidi
Executive Summary
For
Expansion of Silica Sand
Beneficiation Plant
At Village Momidi, Gudur, Andhra Pradesh
Being Developed by
M/s Mangalore Minerals Pvt. Ltd. Mineral House, Hampankatta,
Mangalore-575001
Prepared By Environmental Consultant
M/s Perfact Enviro Solutions Pvt. Ltd. (NABET Registered wide list of accredited consultants organizations/ Rev 11/ 5th August,
2013 at S.No-113) (An ISO 9001:2008 &ISO 14001:2004 Certified Company) 5th Floor, NN Mall, Sector 3, Rohini, New Delhi-110085
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 2
1. Introduction of the project / Background information
The project is being promoted with view to serve Indian glass and ceramic industries in particular and chemicals, paints and refractory industry in general, with supply of high grade processed silica sand. Promoters experience over 3 Decades in the similar field has been the main driving force behind conceptualizing this project. Silica sand is the main raw material for glass industry and one of the major raw materials for ceramic, chemicals, paints and refractory industry. Silica Sand is found in abundance. Silica sand in its original form contains impurities like clay, iron, small quantities of lime etc. Particularly for glass industries, silica purity must not be less than 99.0%. However, for specialty glasses Silica purity is required to be as high as 99.8%. Unfortunately in India, there is no industry in the organized sector to process the sand with means of sophisticated water washing equipment, leave aside chemically treated silica. Therefore, the consumer industry has to rely on existing supplies which contain above impurities and therefore the quality of end product leaves much to be desired.The mineral property selected belongs to M/s Mangalore Minerals Private Limited (MMPL). MMPL identified Several Silica Sand Sites in Andhra Pradesh and Shortlisted Gudur area of Nellore district as a potential Site to Setup Silica Sand Washing Plant for its Foundry Requirements for the State of Andhra Pradesh. MMPL purchases silica sand from local mines in Momidi, Siddavaram, Karlapudi areas of Kota and Chillakur Mandalam, Nellore district. Need of the Project: As informed earlier that in India, there is no industry in the organized sector to process the sand with means of sophisticated water washing equipment; hence there is necessity of this project
2. Project Description
MMPL identified Several Silica Sand Sites in Andhra Pradesh and Shortlisted Gudur area of Nellore district as a potential Site to Setup Silica Sand Washing Plant for its Foundry Requirements for the State of Andhra Pradesh. MMPL purchases silica sand from local mines in Momidi, Siddavaram, Karlapudi areas of Kota and Chillakur Mandalam, Nellore district.. MMPL project is linked to the Development of Foundries and Glass industries in and around the Andhra Pradesh area. The Sand purchased from local mines is Prewashed and latter scrubbed and Size Grading is done as per customer Spec Requirement.
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 3
Beneficiation Plant Objectives: The main objectives of sand beneficiation are concerned with the industrial uses, where sand is required in pure form and its size is graded to exact specifications. Sand, though abundant, is seldom in pure form. It is contaminated with clays (silicates), metal oxides and various other minerals. Further it is not available in grain size as required.
Beneficiation process consists of:
Washing with water to make sand free of clay and separate the heavy mineral oxides. It needs magnetic separation to make it free of ferric oxides and free Iron
Size wise gradation of sand grains to get product which will have the desired composition sand grain of pre-determined percentage of each size.
Silica Sand Beneficiation Process: Raw sand purchased from the local mines & loaded to the plant site storage yard of the MMPL. Later on through hopper raw sand passes through conveyor & then washed (Simple Water) in multiple stages and forward for separator for separating different sizes. It is stock in different stock pile & ready to dispatch for the foundry grade. Glass Grade Silica Sand: Though silica sand is superior to quartz in glass making, the use of quartz increased due to the depletion of good silica sand mines and increase in the transportation cost. But silica sand is always superior, because it saves 5% to 7% in fuel cost in glass making and comparatively lower temperatures required in the furnace life. Thus, if silica sand with low iron content is available with reasonable transportation cost, the glass industry would always prefer silica sand in the place of quartz. Capacity: The proposed capacity is given below:
Capacity Per Hour (Existing)
Per Hour (Expansion)
Per Annum (Expansion)
Drying Capacity
Capacity for Washed Silica Sand (3 shift operation) 20 MT
100MT 660,000 MT 300000
MT
3. Site Analysis
Location and Connectivity: Mangalore Minerals Pvt.Ltd. is located in Momidi village, Gudur having Mandalam : Chillakur & district: Nellore. The Project Site is well connected to Nellore (Head
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 4
Quaeters) at a distance of 65 km and to Gudur at a distance of 30 km. The Ore is transported by road as the plant is located adjacent to the mines. Nearest Railway station are Gudur Railway station (30 km). Villages nearby Momidi Village are Yeruru ( 2.5km ) , Varagali (3 km ), chintavaram (8 km). Sensitivity of Location: There is 1 natural drain in S.W. direction at a distance of 1.5. Certain mining activities are occurring in nearby areas. There is a possibility of cyclone. Proper control measures will be taken for this. Existing Infrastructure: Physical: The plant is 30 km off main Gudur- Nellore highway. The Ore is transported by road as the plant is located adjacent to the mines. It is running project. Roads, electricity and drinking water is available. Process water is obtained through tube well. Social: School nearby Momidi: Govt School. Banks near by Momidi : Vijaya Bank Temple near by Momidi: Shiv mandir Landform, Land-use and Ownership: Landform: The land is Patta Land under owner ship of the MMPL. It has been converted in to Industrial Use by the collectrate. It is barren land. Planning Brief:
Green Belt/Afforestation: The length of preriphery is about 800 m. 2 rows of tree will be planted along the periphery with an tree spacing of about 5 m. Thus about 300 trees will be planted along the boundary, besides this strip plantation, about 200 hundred trees have been planted in the vacant spaces. Drinking Water Management (Source & Supply of Water): The maximum strength of workers will be: 63 directly employed & 150 indirect personnel. Drinking water requirement will be within 8 KLD for workers. The drinking water will be provided through Tube-well/Hand-pump. The water requirement for process in plant will be 200 cubic meter. The company has water recycling Plant and is only using minimum Water as Make-up water
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 5
Sewerage System: The maximum strength of workers will be: 63 directly employed & 150 indirect personnel. Septic tank and soak pits will be provided for waste thus generated. Some traces waste water generated is taken back to circuit and recycled. Solid Waste Management: The domestic waste shall be disposed off in vermin-composting site within the plant area and waste clay shall be reused in land filling and plantation purpose. Power Requirement: The power requirement for beneficiation plant will be 700 KW and 600 KVA capacity DG set shall be used as power back-up. APSTDCL Substation is 8 km from the location and has direct Dedicated Power Line. Air Quality Management: Dust and emission are likely to be generated from handling of Silica Sand and transportation, for which regular sprinkling of water and alternatives like closed conveyors, closed silos, direct loading of closed vehicles to transport dusty material etc. will be used to reduce the emission. Rehabilitation and resettlement (R & R) Plan There will be no rehabilitation and resettlement involved with the project. Project Cost along with analysis in terms of Economic Viability of the Project: The project cost of the plant is about Rs 15 core. The detail of project cost is given ahead: Analysis of proposal (Final Recommendations) Employment has been generated to the local Villagers and neighboring Villages, Most of the Employes are Tribal labours Being Trained to Do Plant operation. There will be direct and indirect employment at the first instance. About 85% of the total employment will be given to locals. Finally, the after-use of the site will be the development of Green Belt around the periphery of the plant and retained water will be used by surrounding people after the completion of the life of the beneficiation plant. Sheds will be used for community. In essence, comparison to gains the harms are negligible
*****
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 6
Pre Feasibility Report
For
Expansion of Silica Sand
Beneficiation Plant
At Village Momidi, Gudur, Andhra Pradesh
Being Developed by
M/s Mangalore Minerals Pvt. Ltd. Mineral House, Hampankatta,
Mangalore-575001
Prepared By Environmental Consultant
M/s Perfact Enviro Solutions Pvt. Ltd. (NABET Registered wide list of accredited consultants organizations/ Rev 11/ 5th August,
2013 at S.No-113) (An ISO 9001:2008 &ISO 14001:2004 Certified Company) 5th Floor, NN Mall, Sector 3, Rohini, New Delhi-110085
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 7
1. Introduction of the project / Background information
The project is being promoted with view to serve Indian glass and ceramic industries in particular and chemicals, paints and refractory industry in general, with supply of high grade processed silica sand. Promoters experience over 3 Decades in the similar field has been the main driving force behind conceptualizing this project. Silica sand is the main raw material for glass industry and one of the major raw materials for ceramic, chemicals, paints and refractory industry. Silica Sand is found in abundance in the States of A.P, U.P., Bihar, M.P., Rajasthan and parts of Kerala. Silica sand in its original form contains impurities like clay, iron, small quantities of lime etc. Particularly for glass industries, silica purity must not be less than 99.0%. However, for specialty glasses Silica purity is required to be as high as 99.8%. Similarly for rest of industries using Silica Sand as one of the Raw materials, presence of clay, calcium and iron is most detrimental for usage. Of these Iron content is the most un-desirable element for glass and ceramic industry. Any quantity above 0.1% makes the raw material unusable. Unfortunately in India, there is no industry in the organized sector to process the sand with means of sophisticated water washing equipment, leave aside chemically treated silica. Therefore, the consumer industry has to rely on existing supplies which contain above impurities and therefore the quality of end product leaves much to be desired. There are rare instances of sand being washed particularly sheet glass industry for removal of clay and other silt materials. The best quality of sand comes from the states of Andhra Pradesh, Uttar Pradesh, Bihar, West Bengal, Madhya Pradesh, Rajasthan and Karnataka where some effort is made by the miners to wash the sand with water. Elsewhere, the sand washing is done very rarely; therefore, entire bulk consumers are dependent upon supplies from U.P. The mineral property selected belongs to M/S Mangalore Minerals Private Limited (MMPL). MMPL identified Several Silica Sand Sites in Andhra Pradesh and Shortlisted Gudur area of Nellore district as a potential Site to Setup Silica Sand Washing Plant for its Foundry Requirements for the State of Andhra Pradesh. MMPL purchases silica sand from local mines in Momidi, Siddavaram, Karlapudi areas of Kota and Chillakur Mandalam, Nellore district. Need of the Project: As informed earlier that in India, there is no industry in the organized sector to process the sand with means of sophisticated water washing equipment; hence there is necessity of this project
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 8
2. Project Description
MMPL identified Several Silica Sand Sites in Andhra Pradesh and Shortlisted Gudur area of Nellore district as a potential Site to Setup Silica Sand Washing Plant for its Foundry Requirements for the State of Andhra Pradesh. MMPL purchases silica sand from local mines in Momidi, Siddavaram, Karlapudi areas of Kota and Chillakur Mandalam, Nellore district.. MMPL project is linked to the Development of Foundries and Glass industries in and around the Andhra Pradesh area. The Sand purchased from local mines is Prewashed and latter scrubbed and Size Grading is done as per customer Spec Requirement. Beneficiation Plant
Objectives: The main objectives of sand beneficiation are concerned with the industrial uses, where sand is required in pure form and its size is graded to exact specifications. Sand, though abundant, is seldom in pure form. It is contaminated with clays (silicates), metal oxides and various other minerals. Further it is not available in grain size as required.
Among several industries, float glass and high tech foundry industry are growing at extremely fast rate due to the rapid industrialization in the country. These rapid developments of float glass and foundry industries are based on high purity silica sand. The industries of the state are dependent upon high purity silica sand supply from suppliers of outside the state like Karnataka, Maharashtra and Uttar Pradesh to meet the stringent quality norms to manufacture casting from cold box, hot box, shell sand and various other resin binder processes. As these places are at far away from Andhra Pradesh, the landed cost of the silica sand to these plants becomes very high which increases the cost of their product making them less competitive. But as the transportation costs have increased, the landed costs to the foundries in and around Andhra Pradesh and Tamilnadu have also increased substantially. Our company has been trying its best to reduce the cost of raw material to the industries in and around Andhra Pradesh. To achieve the goal, it has carried out R&D and has developed a flow sheet for utilization of silica sand available in Andhra Pradesh for production of high purity silica sand for glass industries as well as foundry industries in and around Andhra Pradesh & Tamilnadu.
So in total the objectives of sand beneficiation are:
1. providing sand for industrial use in readymade form 2. eliminating the wastages and providing quality sand 3. providing sand in the grain size as required and 4. In order to maintain the quality of sand.
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 9
Beneficiation process consists of:
Washing with water to make sand free of clay and separate the heavy mineral oxides. It needs magnetic separation to make it free of ferric oxides and free Iron
Size wise gradation of sand grains to get product which will have the desired composition sand grain of pre-determined percentage of each size.
Silica Sand Beneficiation Process: Raw sand purchased from the local mines & loaded to the plant site storage yard of the MMPL. Later on through hopper raw sand passes through conveyor & then washed (Simple Water) in multiple stages and forward for separator for separating different sizes. It is stock in different stock pile & ready to dispatch for the foundry grade. Glass Grade Silica Sand: Though silica sand is superior to quartz in glass making, the use of quartz increased due to the depletion of good silica sand mines and increase in the transportation cost. But silica sand is always superior, because it saves 5% to 7% in fuel cost in glass making and comparatively lower temperatures required in the furnace life. Thus, if silica sand with low iron content is available with reasonable transportation cost, the glass industry would always prefer silica sand in the place of quartz. Chemical Comparative Chart of our Chemical Analysis of Silica Sand & Quartz Sample A B C
Constituents Raw Silica Sand
(%) Water-washed Silica Sand (%)
Quartz (%)
SiO2 98.52 99.2 99.40 Al2O3 0.50 0.15 0.15 Fe2O3 0.24 0.12 0.04 TiO2 Tr. Tr. Tr. CaO 0.15 0.10 Tr. MgO Tr. Tr. Tr. Na2O3 0.05 0.04 0.04 K2O 0.02 0.02 0.02 I.O.I. 0.44 0.28 0.26 Total 99.92 99.91 99.91 Color Dark Red Light Red White Size 10 to 120 mesh 10 to 120 mesh 10 to 120 mesh Clay & other impurities
0.5% to 3% Nil Nil
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 10
BLOCK DIAGRAM OF BENEFICIATION PROCESSES
RAW SAND STOCK
FEED HOPPER
DILUTION TANK
1MM SCREEN
SCREW CLASSIFIER I
ATTRITION I
SUMP PUMP
SCREW CLASSIFIER II
ATTRITION II
SCREW CLASSIFIER III
DESLINE CYCLONE MULTISIZER
‐600 SCREEN
SPIRAL CONCENTRATOR
MAGSEP
DEWATERING
PRODUCT
Dewatering Dewatering Dewatering DewateringDewatering
STOCK REJECT
STOCK
ROD MILL
100 TPH
LINE-2
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 11
BLOCK DIAGRAM OF LEACHING PROCESSES
SAND STOCK
FEED HOPPER
CONVEYOR
BUCKET ELEVATOR
WEIGH BELT FEEDER
SAND PREHEATING
REACTOR
QUENCH TANK
PUMP
HYDROSIZER
DEWATERING
CONVEYOR
STOCK
HYDRATED LIME DOSING
PLASTIC LINED LAGOON
WATER RECOVERY LAGOON
RECIRCULATION WATER TANK
Over flow
MAKEUP WATER‐BORE WELL
WATERACID
BULK ACID
STORAGE TANK
FRESH WATERTANK
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 12
Capacity: The proposed capacity is given below:
Capacity Per Hour (Existing)
Per Hour (Expansion)
Per Annum (Expansion)
Drying Capacity
Capacity for Washed Silica Sand (3 shift operation) 20 MT
100MT 660,000 MT 300000
MT
The company has developed unique process and has standardized it to perfection to get pure silica sand in bulk scale. The nearness to the source of raw material will help to attain this projected capacity utilization from first to sixth year operation. PLANT LAYOUT: The planned placement of equipment will be made in logical sequence for production process, with adequate space for storage, material handling, equipment repairs, stores and effluent processing. We foresee no bottlenecks in process flow. Expansion of capacity at same site can be considered in near future. Site Analysis Location and Connectivity: Mangalore Minerals Pvt.Ltd. is located in Momidi village, Gudur having Mandalam : Chillakur & district: Nellore. The Project Site is well connected to Nellore (Head Quaeters) at a distance of 65 km and to Gudur at a distance of 30 km. The Ore is transported by road as the plant is located adjacent to the mines. Nearest Railway station are Gudur Railway station (30 km). Villages nearby Momidi Village are Yeruru ( 2.5km ) , Varagali (3 km ), chintavaram (8 km). Sensitivity of Location: There is 1 natural drain in S.W. direction at a distance of 1.5. Certain mining activities are occurring in nearby areas. There is a possibility of cyclone. Proper control measures will be taken for this.
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 13
Existing Infrastructure: Physical: The plant is 30 km off main Gudur- Nellore highway. The Ore is transported by road as the plant is located adjacent to the mines. It is running project. Roads, electricity and drinking water is available. Process water is obtained through tube well. Social: School nearby Momidi: Govt School. Banks near by Momidi : Vijaya Bank Temple near by Momidi: Shiv mandir Landform, Land-use and Ownership: Landform: The land is Patta Land under owner ship of the MMPL. It has been converted in to Industrial Use by the collectrate. It is barren land. Planning Brief:
The maximum strength of workers will be: 63 directly employed & 150 indirect personnel.
The most of the workers are hired from local/neighboring village. Accommodation will be provided to those employees coming from out
side due to statutory requirement. Approx 20 temporary sheds will be provided.
The ultimate land use will be development of Green Belt around the periphery of the plant and retained water will be used by surrounding people after the completion of the life of the beneficiation plant. Sheds will be used for community.
PARTICULARS QUANTITY
Power requirement (for both the circuits) 700 KW
HSD for Loaders, Generators & Trucks 600 KL per annum
Fuel Oil for Drying Plant 1200 KL per annum
Generator 600 KVA
Daily water requirement for processing (make- up water) 200 cubic meter
Quantity of water recirculation 94%
Daily water requirement for domestic use 8 KL
Daily solid waste/ Clay generation 19800 MT per Annum (3%)
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 14
93% water will be circulated & 7% will be absorbed during the process. Proposed Infrastructure: Physical: The plant is 30 km off main Gudur- Nellore highway. The Ore is transported by road as the plant is located adjacent to the mines. It is running project. Roads, electricity and drinking water is available. Process water is obtained through tube well. Green Belt/Afforestation: The length of preriphery is about 800 m. 2 rows of tree will be planted along the periphery with an tree spacing of about 5 m. Thus about 300 trees will be planted along the boundary, besides this strip plantation, about 200 hundred trees have been planted in the vacant spaces. Water Management (Source & Supply of Water): The maximum strength of workers will be: 63 directly employed & 150 indirect personnel. As far as drinking water is concerned, it can be seen that drinking water requirement will be within 8 KLD for workers. The drinking water will be provided through Tube-well/Hand-pump. The water requirement for process in plant will be 200 cubic meter. The company has water recycling Plant and is only using minimum Water as Make-up water Sewerage System: The maximum strength of workers will be: 63 directly employed & 150 indirect personnel. Septic tank and soak pits will be provided for waste thus generated. Some traces waste water generated is taken back to circuit and recycled. Solid Waste Management: The domestic waste shall be disposed off in vermicomposting site within the plant area and waste clay shall be reused in land filling and plantation purpose. Power Requirement: The power requirement for beneficiation plant will be 700 KW and 600 KVA capacity DG set shall be used as power back-up. APSTDCL Substation is 8 km from the location and has direct Dedicated Power Line. Air Quality Management: Dust and emission are likely to be generated from handling of Silica Sand and transportation, for which regular sprinkling of water and alternatives like closed conveyors, closed silos, direct loading of closed vehicles to transport dusty material etc. will be used to reduce the emission.
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 15
Rehabilitation and resettlement (R & R) Plan There will be no rehabilitation and resettlement involved with the project. Project Cost along with analysis in terms of Economic Viability of the Project: The project cost of the plant is about Rs 15 core. The detail of project cost is given ahead: Analysis of proposal (Final Recommendations) Employment has been generated to the local Villagers and neighboring
Villages, Most of the Employes are Tribal labours Being Trained to Do Plant operation. There will be direct and indirect employment at the first instance. About 85% of the total employment will be given to locals. Further, the share of indirect employment like increased purchasing power, dhabas and retail shops etc. is largely shared by local residents. Finally, the after-use of the site will be the development of Green Belt around the periphery of the plant and retained water will be used by surrounding people after the completion of the life of the beneficiation plant. Sheds will be used for community. In essence, comparison to gains the harms are negligible.
Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 16
ANNEXURE-I
LOCATION MAP
ANNEXURE-II
LAYOUT PLAN
ANNEXURE-III