M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.)

Executive Summary

1.0 Introduction M/s Madhya Bharat Agro Products Limited-Unit-II is the registered Public limited company having its head Office at Bhilwara (). The company is engaged in various industrial activities in Rajasthan and M.P. The Sagar/Chharatpur region is having very rich source of Rock Phosphate. Therefore company is going to setup a Rock Phosphate Beneficiation Plant at Saurai Industrial Area, village – Saurai, Tehsil Banda, District Sagar (M.P.). The proposed capacity of the plant is 300 TPD. The total land of 92,700 sqm is already acquired by the company for the proposed plant.

Very low grade rock phosphate converted into high grade rock phosphate by processing. It is a well known fact that has very low reserves of high grade rock-phosphate

(+30%P 2O5).though rock-phosphate reserves have been located in some States like Rajasthan, Madhya , , Andhra Pradesh, and , Rajasthan State Mines & Minerals ltd. is a main source of supply of indigenous rock phosphate, Approx over one million tonne per year of high grade rock phosphate is being manufactured.

Madhay Pradesh has estimated ore reserves of 45.6 million Tones (MT) of Low Grade rock-phosphate which makes it the second largest state in India in terms of rock phosphate, Mines account for 26.8 Million tones and 18.7 Million Tone at Hirapur. Out of these deposit, only 4.2 MT of Jhabua Rock and 2.1 MT of Hirapur, are of high grade (grater than 30% P 2O5). Madhya Bharat Agro Product Limited is one of the premier enterprises of the Private Limited Sector, primarily engaged in manufacturing of Single Super Phosphate in the State of M.P. The very objective of the company is to achieve cost effective technological innovations in the manufacturing of Beneficiated Rock Phosphate and to diversify into Beneficiated Rock Phosphate based downstream projects. With the technological know how available with KPL group Company. This company is professionally managed and remains focused towards increasing productivity and growth.

1.1 Identification of Project & Project Proponent

1 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.)

M/s Madhya Bharat Agro Products Limited-Unit-II is a Rock Phosphate based public listed company engaged in the business of exploring, economically exploiting and operating mines within the country and abroad.

The main objectives to be pursued by the company at Plant at Saurai Industrial Area, village – Saurai, Tehsil Banda, District Sagar (M.P.) is as follows:

 The company is going to setup Beneficiation of Rock Phosphate plant of less than one lac ton per annum capacity initially for processing rock-phosphate.  The land for setting up of the plant has already been purchased by the company.  The processing plant flow sheet has already been finalized and order has been released on company for supply of equipment and for creation and installation of the plant.  Approximately 30 persons may get initial employment. Nearby more than 80 persons may get indirect employment thereby generating employment opportunities for 110 persons.  Around 50 lacs revenue shall be generated by way of royalty and taxes.  The company will give maximum employment to the local residents only.  Project Detail Name of Company - M/s Madhya Bharat Agro Products Limited-Unit-II Managing Director - Mr. Pankaj Ostwal Installed Capacity - 300 TPD

2.0 Detail Of Project

1. Name of Project Rock Phosphate Beneficiation Plant

2. Location of the Project

Village Saurai

Tahsil Banda

District Sagar

State

2 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.)

3. Area Specific Detail

Proposed Project Area 92700 sqm.

Proposed Green Belt 32500 sqm.

Toposheet No. 54 l/16, 55 I/13

latitude 24 001’18 N

Longitude 78º53’31”E

4. Requirement

Total fresh Water requirement 300 kl/day

Total Power Requirement 1200 KVH

Total Manpower Requirement Approx-110

Environmental Protection Cost 79 Lacs

5. Detail of the Project Area

Nearest National Highway NH-86 (0.8 km)

Nearest Railway Station Makroria at 16 km

Nerset Town Sagar at 27 km

Neasrest Airport Khajuraho 163 km

National Park, Sanctuaries, Biosphere No National Park, Sanctuaries, Reserve, Wildlife corridors, Biosphere Reserve, Wildlife corridors, Elephant/Tiger Reserve within 10 km Elephant/Tiger Reserve within 10 km radius radius

Nerest River Bewas River at 9 km

2.1 Raw Material Consumption

Yearly Yearly Requirement Yearly Source

Requirement (MT) Requirement

3 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.)

(MT) (MT)

1. Low Grade Rock 99000 Hirapur/Chhatarpur Mine Phosphate

2. Sodium Silicate 180.0 Indigenous available

(SS) (Reagent)

3. Sodium Oleate 90.0 Indigenous available

(SO) (Reagent)

4. Grinding Media 75.0 Indigenous available

(SM) (Reagent)

Total 99345 MT

2.2 Process ROM ore is received from the Hirapur/Chhatarpur mines through trucks/dumpers in proposed plant site in the industrial area at Tehsil Banda, Dist Sagar M.P. Ore is stacked in stock piles after having been sampled and analysed. Ore is blended with the help of JCB to ensure constant grade/or quality before taking it for processing.

Ore is crushed in two stages from about 200 mm to (-) 6 mm using jaw Crusher, and Hammer Impactor. Tramp Iron Magnet removes any iron material to avoid damage to crushers. Belt conveyors are installed for transporting crushed ore from vibrating screen to next equipment. Dust extraction system is installed to remove dust at the place of generation and to limit the dust particles in the air within the permissible limit stipulated under the pollution control norms. Similarly Dust Suppression system is installed at the place of unloading ROM ore and Blending area. Ore crushed to < 6mm is stored in the Fine Ore Bin (FOB) for wet grinding in the Ball Mill. The ore is ground in a grate Discharge Ball/Rod Mill Operating in closed circuit with hydro cyclones to separate 80% -200 mesh particles. Hydro Cyclone over flow is fed to WHIMS -1 and WHIMS-II for the removal of iron bearing minerals. De-ferruginous slurry is taken to Slime Thickener. Slimes are removed and the slurry containing 35-40% solids is taken to Primary Conditioner.

4 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.)

Flotation circuit comprises Rougher and Scavenger Cells. Three stage cleaning has been provided to upgrade the concentrate to 31% P2O5. Tailings from the Cleaner Bank are recalculated back in the reverse order.

Beneficiated Rock Phosphate is finally pumped to Thickener for solid-water separation. Concentrate having solids >50% w/w is pumped to overhead slurry tanks for the gravity feeding to Horizontal Belt Press Filter. The concentrate in the form of cake is filtered which has moisture in the range of 20%.

BRP ponds have been provided to take care of large volume of concentrate slurry in the thickeners as a part of regular maintenance of thickener’s mechanism on monthly basis.

Plate Form for Drying

Concentrate cake needs further drying to <5% which is only accepted by the user’s of BRP. So, the concentrate cake is spread over on the Plat Form for drying. Techno-economic study does not favour drying through mechanized method as the product high manufacturing cost can not sustain high capital cost on the Rotary Dryers and high operating fuel and maintenance cost.

Tailings and Tailing Dam

Ore Beneficiation Plant produces tailing which is around 50-60% of total through put. Large volume of water is also trapped in tailing which has to be reclaimed for recycling in the process. Tailings are pumped to tailing thickener which is 40ft Dia x 10ft SWH. Tailings are thickened to about 40-45% solids w/w and are pumped to Tailing/Water Reclamation ponds for the storage of solids and water reclamation.

In view of environmental considerations and alarming water scarcity of water, large area is required for the storage of tailings so that maximum water could be reclaimed. With the proposed planning, it is expected to reclaim almost 50% water with the help of special designed De-cant wells. Further, solids in the tailing being slow settling material because of its fineness, more area is required for the effective settling of solids.

Reagent Preparation & Distribution

5 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.)

Sodium Silicate & Sodium Oleate are added with the help of specially designed Reagent Feeders at the pre-determined places for efficient results. Plant has sufficient covered area for the storage of bulk reagents. The reagents are dissolved in water and solution is prepared for the recommended strength. There are various reagent preparation tanks and storage tanks for meeting total daily requirement.

Beneficiation Plant Detail

 Capacity of Beneficiation Plant shall be 300 TPD.

 The overflow of hydro cyclone & stub cyclone will have low content and it will be allowed for settling in pond.

 The sludge settled at the bottom of pond i.e. Discards will be dumped in the plant premises.

 All the process water will be recycled back to process.

 Fugitive dust likely to generate from crusher & screen will be sucked and collected in bag filter

2.3 Equipment Detail

1. Vibrating Screen 1

2. Crusher 1

3. Impetor 1

4. Ball Mill 1

5. Hydrocyclone 4

6. Floatation Cell 24

7. Filter 1

8. Magnetic Separator 1

9. Thicker Mechanism 1

10. Pumps –Slurry 16 Pumps-Water reclaim 8 Pumps-dia form 4

6 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.)

11. weight bridge 1

2.4 Area required for beneficiation Plant

S. No. Particulars Area (sqm)

1 Total Land available 92700

2 Area for plant 2000

3 Raw material storage area 40,000 4 Finish good storage shad 2000 5 Thickner Area 1500 6 Tailing pond 8000 7 Green belt area 32500 8 Office building 500 9 Open area 6200

3.0 Meteorology

The climatic condition of this area is Semi arid. The maximum temperature goes up to 44ºC during summer in the month of May and the minimum temperature goes down to 4.5ºC during winter in the month of December- January. There are six rain gange stations in Sagar district. A heavier amount of rainfall occurs along the south western boundary of the district and decreases towards the north and slightly towards the east. In the southwestern parts of the district, Rehli gets a marked amount of low rainfall mainly due to its location in the valley on the leeward side of the hill range. The average annual rainfall is recorded to be 1134 mm. The normal annual rainfall of the district is 1134.8 m.m. About 90% of the annual rainfall takes place during the southwest monsoon period i.e. June to September only 5.5% of annual rainfall takes place during water and about 4.5% of rainfall occurs during the summer months. The winds in the area are light moderate during summer and winter. However the speed of the wind increases during the end of the summer season and monsoon season.

3.1 Ambient Air Quality The ambient air quality with respect to the study zone of 10 km radius around the project area forms the baseline information there are four mining lease are in the operation within 1

7 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.) km radius from the site. However, the project area is located close to NH-86 and vehicular traffic contributes to air pollution. The prime objective of the baseline air quality study was to assess the existing air quality of the area. This will also be useful for assessing the conformity to standards of the ambient air quality during the beneficiation plant.

This section describes the selection of sampling locations, methodology adopted for sampling, analytical techniques and frequency of sampling. The results of monitoring carried out for one season, from April 2010 to June 2010

Location of Stations The ambient air quality monitoring stations were set up at the following locations:

Table-3.4 Ambient Air Quality Monitoring Stations S. No. Location Direction Distance A1. Saurai Village SW 1.5 km A2. Mohanpur Village S 1.6 km A3. Delakhedi Village NE 2.3 km A4. Fatehpur Village SE 3.2 km A5. Panari Village NW 4.6 km

The baseline status of the ambient air quality has been assessed through a scientifically designed ambient air quality-monitoring network. Monitoring stations are both in leeward and wind ward direction. The design of monitoring network in the air quality surveillance program has been based on the following considerations: -Meteorological conditions on synoptic scale;

 Topography of the study area;

 Representatives of regional background air quality for obtaining baseline status;

 Representative of likely impact areas.

Samplings at five stations were carried out for one season i.e. summer during period April

– June 2010. The parameters monitored were SPM, RSPM, NOx and SO 2. The air samples are analyzed as per standard methods specified by Central Pollution Control Board, IS: 5184 and American Public Health Organization (APHA

The average concentrations of SPM for all the seven stations were found well within the

8 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.) limit. The variation of SPM level at different stations may be attributed to the local phenomenon such as vehicular movement, wind blow dust and agricultural activities etc. The Ambient Air Quality status around 5 km radius is given below:

9 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.)

Table 2.0 Conclusion of Ambient Air Quality Data

Location Parameter Min Max 98 Avg. Percentile A-01 SPM 98 204 181 139.6 RPM 52 78 69 58.3 NOx 10.7 22.6 17.5 16.3 SO 2 8.7 18.4 16.4 14.7

A-02 SPM 87 211 168 136.5 RPM 45 82 72 56 NOx 10.0 22.8 18 14.2 SO 2 9.2 18.7 12 14.2

A-03 SPM 102 198 171 148.6 RPM 37 76 69 56.6 NOx 8.0 18.6 16.8 14.2 SO 2 6.5 16.5 12.1 11.8

A-04 SPM 91 192 186 143.5 RPM 49 71 63 55.4 NOx 9.0 23.6 20.4 17.9 SO 2 6.3 19.5 16.2 12.4

A-05 SPM 95 190 180 147.2 RPM 51 74 61 57.6 NOx 10.2 21.3 20.8 17.4 SO 2 8.3 16.8 14.1 13.6

A-06 SPM 86 204 186 152.1 RPM 48 81 71 49.7 NOx 9.8 19.8 17.6 14.3 SO 2 7.9 21.4 15.2 17.4

3.2 Water Environment

The physical and chemical quality of water is important as the palatability of the water and its fitness for domestic purpose largely depends on its chemical quality. In view of the wide variations in the chemical quality of water available in different parts of the country, rigid limits cannot be laid down with regard to chemical constituents. Certain chemical substances, which may be present in natural waters, are toxic to human beings. These

10 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.) should not be permitted in drinking water in excess of the permissible limits. However, certain chemical substances render the water unpalatable and unfit for domestic use, if present in excessive amounts. For these substances, the highest desirable and maximum permissible levels have been prescribed. The limit designated as the highest desirable level applied to water that would generally be acceptable to consumers. Values in excess of this level will not be acceptable but may be tolerated in the absence of a better alternate source to the limit designated as the maximum permissible level. Above this level, the water source should normally be rejected.

3.3 Noise Pollution

Noise is known to produce various temporary changes in the physiological state of the human beings. Noises in an industry originate from the process causing impact, vibration or reciprocation moment, friction and turbulence in air or gas streams. Noise is one of the mentioned as one of the elements in the Environmental Protection Act 1986, giving the maximum allowable limits during day and night times. Ambient noise standards prescribed by Central Pollution Control Board are furnished

3.4 Biological Environment:

The biological environment mainly consists of flora and fauna and its relationship with surroundings. Biological environment includes species of native plants and animals and one may measures the degradation of environment by noting the decrease in the commonly species.

Shrubs and bushes can be seen in the plant area. And there is no well known rare, endangered species in this region. Hence there will be no considerable impact on the biological environment. The massive afforestation planned for the plant site shall generate a forest having.

3.5 Fauna According to Survey of India, the study area does not host natural wild life. There are also no zoos or bird sanctuaries in the study area. Rodents, monkeys, jackals and large birds constitute the natural fauna in the study area. Peasants, pigeon, peacock can be sighted

11 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.) occasionally along with the birds of common occurrence in the study area. Even forestland has only sparse row of trees and is not able to sustain much natural fauna. The fauna encountered are listed in table below.

Table – 2.0 List of Fauna in Study Area Bengal Monkey (Macasus rhesus) Jungle cat (Felischaus) Mongoose (Herpests mingo) Sambhar (Crevus unicolor) Kalmuha monkey Common haw cuckoo (Cuculus (Semnapthecus on lellccs) micropterces) House sparrow (Passer domesticus) House crow (carvus splendens) Common maina (Acrido tehras tristis)

3.6 Existing infrastructure facilities:

Education Within the study area there are only seven primary schools. But at Banda & Sagar have education facility with Collages & Higher Secondary Schools.

Medical and Health The project proponents shall provide facilities for medical check-up of its workers and employees through a visiting Physician. They will also provide first-aid facilities at plant time office. If necessary and in case of emergency, the medical aid can also be provided by hospitals situated at Sagar which is nearly 28 Kms. from Proposed plant.

Workers and Labour

The company shall employ a total number of more then 80-100 workers on regular basis. Out of these one or two will be at Managerial level. 18-19 other workers including casual workers will be employed according to the nature of work and need. The workers can be classified as skilled, semi skilled and non skilled.

12 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.)

Transport The National Highway no. 7 is connecting MP & Uttar Pradesh is 0.8 Kms away from site. All sorts of vehicles, viz. – Trucks, Mini-trucks, Buses, Jeeps, Cars etc. play day and night over this highway and instant conveyance is available even upto Sagar. Khajuraho is the nearest airport while Makronia is the nearest railhead about 16 kms Away from the site.

Communication The proposed site located at village Saurai which has more recent telecommunication system and has direct link with other parts of the country.

Methodology

The land use of the study area is studied by analyzing the available secondary data such as the District Primary Census Handbook of Sagar, 2001.

3.7 Soil & Geology

In the project area iron ore deposits is mostly exposed below the surface. Most of the Iron Ore deposit is in the form of mound and surface of the mound is plateau shape and the outcrops area is abundantly seen throughout the region. Proposed beneficiation Plant have a private land is also in plain agriculture land.

4.0 Green Belt Development An extensive green belt ultimately leads to the following: • Reclaim back filled areas • Screen fugitive dust • Control of noise • Increase vegetation cover and bio diversity • Provide a means of livelihood to local tribals by providing products after mine closure • Increasing aesthetic value

Efforts will be made to develop a full forest over the reclaimed area. Besides the reclaimed areas, green belt will also be developed on the area, which will not be mined, along roads, around office & building.

13 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.)

Green belt development should be carried out in planned manner in following areas: a) Along the haulage roads. b) All around the mining pits and worked out quarries, which has been carried out previously.

Plantation shall be carried out along the haulage roads at an interval of 5 m all along the haulage roads in three rows. The spacing between the rows should be 5 m. The species recommended for plantation along the roads are

1. Polyalthia longifolia (Ashok) 2. Azadirachta indica (Neem) 3. Terminalia arjuna (Arjun) 4. Cassia Fistula (Amaltas) 5. Schleichera trijuga (Kusum) 6. Butea sps. (Palash) 7. Mangifera indica (Aam)

This Rock Phosphate Beneficiation Plant Project has already been acquired 92,700 sqm land. Total area of the plant is 32500 sqm lands will be for green belt development.

5.0 Health and Safety

The Health and Safety of the employees shall be given first priority during the mining operation.

• Extensive publicity and propaganda related to safety • Provision of rest shelters for mine workers with amenities like drinking water, fans etc. • First aid facility shall be provided at mine site. • Training programme organize for First aid. • Periodical medical check up camps shall be organized for worker and staff.

6.0 Implementation of EMP and Monitoring

A large part of the sampling and measurement activities will be concerned with long term monitoring aimed at providing an early warning of any undesirable changes or trends in the natural environment that could be associated with beneficiation and associated activities.

In particular, monitoring strategy is required to ensure that all environmental resources, which may be subjected to contamination, are kept under review. Monitoring of the

14 M/s Madhya Bharat Agro Products Limited ––– Unit II Executive Summary Beneficiation of Rock PhosPhosphatephate ((Capacity: 300 TPD)))) Saurai Industrial Area ,Village Saurai, Tahsil Banda, Dist. Sagar (M.P.) individual elements of the environment is necessary.

To meet the above objective an Environment Management Cell shall be formed under supervision of consultant and involve Pollution Control Board for their valuable suggestion and guidance. The following items will be considered under the monitoring schedule:

 Re- Vegetation & Green Belt development  Washing  Loading  Air Quality Monitoring  Water Quality Monitoring  Occupational Health  Socio-Economic Development

7.0 Conclusion

Rock Phosphate Beneficiation Plant of M/s Madhya Bharat Agro Products Limited Unit-II at Saurai Industrial area vill. Saurai, Tahsil Banda, District Sagar (M. P.) will be environmental compatible to the surrounding due to the high standards of pollution control measures to be adopted during the operation activity. Considering the size and operation of beneficiation plant, if the proper environmental management plan is adopted.

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