Expansion of Silica Sand Beneficiation Plant...Expansion of Silica Sand Beneficiation Plant At Village Momidi, Gudur, Andhra Pradesh Being Developed by M/s Mangalore Minerals Pvt

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,


a. Name Mr. Santhosh Mendon

b. Designation(Owner/Partner/CEO) Executive Director

c. Address Mineral House, Hampankatta,


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


confirmation


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)



confirmation


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)



confirmation


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:



confirmation


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:



confirmation


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.



confirmation


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.



confirmation


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


Beneficiation Plant


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.



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



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



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

*****



Pre Feasibility Report

For


Beneficiation Plant


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



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



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.



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



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



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



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.



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 (makeup 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%)



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.



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.



ANNEXURE-I

LOCATION MAP

ANNEXURE-II

LAYOUT PLAN

ANNEXURE-III

Documents

Expansion of Silica Sand Beneficiation Plant...Expansion of Silica Sand Beneficiation Plant At Village Momidi, Gudur, Andhra Pradesh Being Developed by M/s Mangalore Minerals Pvt