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
Expansion of “Silica Sand 1. Name of the Project Beneficiation plant”
2. S. No. in the schedule 2(b)
Existing Capacity- About 6 Lakh MT/Year Existing Capacity- About 6 Lakh Proposed Capacity/area/ Length/tonnage to be 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
Yes it attract general condition Does it attract general conditions? If yes, Please
7. as the production s more than
Specify.
0.1 Million TPA.
Does it attract the specific condition? If yes, please
8. NA
specify.
Momidi, Andhra 9. Location Pradesh
a. Plot/survey/Khasra No. 302 & 302B1
b. Village Momidi
Chillakur Mandalam, c. Tehsil Gudur
d. District Nellore
e. State Andhra Pradesh
Gudur Railway station (30
km) Nearest Railway station/ airport along with distance
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
distrit Headquaters at a distance Nearest Town, city, district Headquarters along with of 65 km and the plant is 30 km off Main Gudur – Nellore
12. Highway
distance in kms.
M/s Mangalore Mineral Pvt. 13. Ltd. Name of the applicant Mineral House, Hampankatta,
14. Registered Address Mangalore – 575001
Mineral House, Hampankatta,
15. Address for correspondence:
Mangalore – 575001
a. Name Mr. Santhosh Mendon
b. Designation(Owner/Partner/CEO) Executive Director
Mineral House, Hampankatta,
c. Address
Mangalore – 575001
d. Pincode 57001
e. E-mail [email protected]
f. Telephone No. 0824-2428028
g. Fax. No. O827-2422076 Existing land for Silica Sand
Details of alternative Sites examined, if any. 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
Whether separate application of interlinked project
18. 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
be given.
21. NA
(a) The forest (conversation) Act, 1980 ?
(b) The wildlife (Protection) Act, 1972 ?
(c) The C.R.Z. notification, 1991 ? Whether there is any government order/ policy
22. 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.
1
(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.)
Details thereof (with approximate quantities
S.No. Information/Checklist 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)
Clearance of existing land, 1.2 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 investigations
Yes Soil investigation will be carried out.
e.g. bore houses, soil testing? Plant will have some essential permanent
construction.
1.5 Construction works? yes
Demolition works? No No
1.6
Temporary sites used for
construction works or housing of Yes Approx 20 temporary sheds shall be provided. 1.7
construction workers?
Above ground buildings,
structures or earthworks 10 nos. single room houses and 1 canteen will
1.8 NO
including linear structures, cut be provided for workers.
and fill or excavations.
N.A.
Underground works including No 1.9
mining or tunneling?
NA.
1.10 Reclamation works? No
NA
1.11 Dredging? No
NA 1.12 Offshore structures? No
Mineral beneficiation will be carried out in the Production and manufacturing
1.13 Yes following phases.
processes? Details are given in EIA report.
Sand purchased from the local mines and Facilities for storage of goods or
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 %. Facilities for long term housing 10 nos. single room houses will be provided
1.16 Yes of operational workers? for workers.
No new rail, will be expected during
New road, rail or sea traffic 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
other transport infrastructure construction & operation, however there will 1.18 Yes
including new or altered routes be a formation of new road.
and stations, ports, airports etc?
Closure or diversion of existing Noclosureordiversioninexisting
transport routes or infrastructure transportation.
1.19 No
leading to changes in traffic
movements?
No transmission line or pipeline will be made.
New or diverted transmission 1.20 No lines or pipelines?
Beneficiation Plant will not impact on surface
Impoundment, damming,
culverting, realignment or other hydrology.
1.21 No
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
the natural valleys. Bunding of plants shall be
Changes in water bodies or the 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
Finished goods are dispatched by road operation or decommissioning? transport.
Long-term dismantling or NA
1.25 decommissioning or restoration No
works?
Ongoing activity during NA
decommissioning which could
1.26 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.
None
1.29 Introduction of alien species? No
No species exist at the site. Therefore, no such
loss is anticipated. Loss of native species or genetic
1.30 No
diversity?
NA
1.31 Any other actions? No
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):
Details thereof (with approximate S.No. Information/Checklist
Yes/No quantities /rates, wherever possible) with
confirmation
source of information data
The land is Patta Land under ownership of Land especially
MMPL. It has been converted into industrial
2.1 undeveloped or Yes
agricultural land (ha) use by the collectrate.
The company has water recycling plant and
is only using minimum water as make-up
Water (expected source water. Water requirement for process is 200 2.2 & competing users) unit: Yes
KLD and domestic water requirement
KLD
will be 8 KLD.
Silica Sand is the only raw material required
2.3 Minerals (MT) Yes 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)
NA Forests and timber
2.5 No
(source – MT)
Energy including
Power requirement is 700 KW.
electricity and fuels 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
resources (use
2.7
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.
Details thereof (with approximate
S.No. Information/Checklist 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
hazardous (as per
3.1 No
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
Affect the welfare of employees are tribal labours being trained to
3.3 Yes
people e.g. by changing do plant operation. The direct (63) and
indirect (150) employment will enhance the living conditions? the
income level hence will lead to civilization of local people.
People of local/neighboring village will be
Vulnerable groups of benefitted.
people who could be Yes
3.4 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)
Details thereof (with approximate
S.No. Information/Checklist Yes/No quantities /rates, wherever possible) with
confirmation
source of information data
NA Spoil, overburden or
4.1 No
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
facility. The used oil will be sold to vendors
Hazardous wastes (as per
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
Earth Clay from Silica Sand. This will come Other industrial process
4.4 yes as under flow from the water recycling plant wastes
and is used in Landfilling. Waste process clay
will be 3%.
Surplus product NA
4.5 No
Sewage sludge or other Sewage Sludge generated will be
Yes sludge from effluent biodegradable.
4.6 treatment
Construction or NA
4.7 No demolition wastes
Redundant machinery or After the completion of life of Beneficiation
4.8 yes equipment Plant it will be sold as second hand.
Contaminated soils or Some traces of waste water generated is
4.9 Yes other materials taken back to circuit and recycled.
NA
4.10 Agricultural wastes No
NA
4.11 Other solid wastes No
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
Details thereof (with approximate S.No. Information/Checklist
Yes/No quantities /rates, wherever possible) with confirmation
source of information data
Emissions from The combustion from fossil fuel will be from
combustion of fossil use of diesel operated machinery/DG sets, 5.1 yes
fuels from stationary or only during the hours when electric supply
mobile sources will not be there.
Crushing and transfer points of dry material
will produce dust. Dust extraction system for
Emissions from 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
transportation for which regular sprinkling of
Emissions from materials
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
construction activities from construction activities. Stored water 5.4 Yes 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.
Emissions from No incineration will be done.
5.6 No
incineration of waste
Emissions from burning No such activity will take place.
of waste in open air (e.g.
5.7 No slash materials,
construction debris)
None
Emissions from any other
5.8 No sources
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
Details thereof (with approximate
S.No. Information/Checklist 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
equipment e.g. engines, will be of highest standard of reputed make
6.1 Yes 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.
From industrial or similar
6.2 No None processes
From construction or
6.3 No NA demolition
6.4 From blasting or piling No NA
Noise and vibration will be there during
From construction or construction but it will be for temporary
6.5 Yes
operational traffic period. Also, noise will come during
incoming and outgoing of trucks.
None
From lighting or cooling
6.6 No systems
None
6.7 From any other sources No
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:
Details thereof (with approximate S.No. Information/Checklist
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
Soak pits will be used to discharge the
From discharge of
sewage or other effluents sewage generated from the workers during
operational phase.
7.2 to water or the land Yes (expected mode and
place of discharge)
By deposition of Fugitive Dust is likely to be generated for
pollutants emitted to air which water sprinkling to be done and proper
7.3 No 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.
NA
7.4 From any other sources No
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.
Details thereof (with approximate
S.No. Information/Checklist
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.
Used oil from engines will be carefully stored
From explosions,
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.
Details thereof (with approximate S.No. Information/Checklist
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
site, which could have an green belt at the periphery of the plant.
9.2 Yes
impact on the
environment
Set a precedent for later
9.3 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 boundary 1 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. 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.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 2 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd. 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:
Per Hour Per Hour Per Annum Drying Capacity (Existing) (Expansion) (Expansion) Capacity Capacity for Washed Silica 300000 100MT 660,000 MT Sand (3 shift operation) 20 MT 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 Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 3 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd. 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 Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 4 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd. 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 *****
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 5 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
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
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 6 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd. 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
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 7 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
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.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 8 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
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 Raw Silica Sand Water-washed Constituents Quartz (%) (%) Silica Sand (%)
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 0.5% to 3% Nil Nil impurities
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 9 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
BLOCK DIAGRAM OF BENEFICIATION PROCESSES
RAW SAND STOCK
FEED HOPPER 100 TPH
DILUTION TANK
1MM SCREEN ROD MILL
SCREW CLASSIFIER I
ATTRITION I
SUMP PUMP
SCREW CLASSIFIER II
ATTRITION II
SCREW CLASSIFIER III LINE-2 DESLINE CYCLONE MULTISIZER
Dewatering ‐600 SCREEN Dewatering Dewatering Dewatering Dewatering
SPIRAL CONCENTRATOR
MAGSEP
DEWATERING STOCK STOCK REJECT PRODUCT
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 10 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd. BLOCK DIAGRAM OF LEACHING PROCESSES
SAND STOCK
FEED HOPPER RECIRCULATION WAT E R MAKEUP WAT E R ‐ TANK BORE WELL ACID WAT E R CONVEYOR
BUCKET ELEVATOR WAT E R RECOVERY LAGOON
WEIGH BELT FEEDER
PLASTIC LINED LAGOON SAND PREHEATING
REACTOR HYDRATED LIME DOSING
QUENCH TANK
BULK FRESH PUMP ACID WATER STORAGE TANK TANK HYDROSIZER
Over flow DEWATERING
CONVEYOR
STOCK
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 11 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
Capacity: The proposed capacity is given below:
Per Hour Per Hour Per Annum Drying Capacity (Existing) (Expansion) (Expansion) Capacity Capacity for Washed Silica 300000 Sand (3 shift operation) 100MT 660,000 MT MT 20 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.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 12 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd. 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%)
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 13 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
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. Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 14 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
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.
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 15 Expansion of Silica Sand Beneficiation Plant at Village Momidi, Gudur, A.P. By M/s Mangalore Minerals Pvt. Ltd.
ANNEXURE-I
Prepared By: M/s Perfact Enviro Solutions Pvt. Ltd. 16
LOCATION MAP
ANNEXURE-II LAYOUT PLAN
ANNEXURE-III