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Comprehensive Industry Document on Iron Ore Mining

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Comprehensive Industry Document on Iron Ore Mining COMPREHENSIVE INDUSTRY DOCUMENT SERIES COINDS/__/2007-08 COMPREHENSIVE INDUSTRY DOCUMENT ON IRON ORE MINING CENTRL POLLUTION CONTROL BOARD (Ministry of Environment and Forests, Govt. of India) Parivesh Bhawan, East Arjun Nagar, New Delhi – 110032 Website : www.cpcb.nic.in e-mail : [email protected] August, 2007 The Cover Photographs used are Controlled Blasting in Bailadila, NMDC, Sluury disposal of KIOCL, Excavation & Loading in KIOCL, Dump stabilization & Dust suppression at Bailadila, NMDC (clockwise from top left) FOREWORD The series of publication entitled under “Comprehensive Industry Document Series” (COINDS) is designed to cover the status of each specific type of industry in the country in detail, covering all environmental issues. These documents facilitate the concerned units in the sector to improve environmental performance and compliance with the National Environmental Standards. The Comprehensive Industry Document on Iron Ore Mining Industry is one in the series that the Central Pollution Control Board has taken up for publication. The main objective of this document, apart from giving an overall view of iron ore mining industry, is to develop the National Environmental Standards, to provide cleaner technologies and to specify Guidelines / Code of Practice for Pollution Prevention & Control. The report has been finalized after a series of discussions with the industry representatives, industry associations, State Pollution Control Boards and other statutory bodies associated with the mining industry. This study was taken up by the Central Pollution Control Board through the Steel Authority of India Limited (SAIL), Environment Management Division (EMD), Kolkata. The help and assistance extended by the State Pollution Control Boards, Indian Bureau of Mines, Iron ore mining Industries, iron ore mining Industry Associations etc. during the study is gratefully acknowledged. I would like to express my sincere appreciation for the work done by the SAIL, EMD’s team headed by Dr. R. K. Agrawal, Executive Director, EMD and comprising Er. T. K. Bhowmick, Assistant General Manager, Er. Malla Srinivasu, Manager. I commend the efforts made by my colleagues Er. R. C. Kataria, Senior Environmental Engineer for co-ordinating the study and finalizing the report under guidance of Dr. B. Sengupta, Member Secretary, CPCB. The contribution of Shri Mahendra Kumar Gupta, Data Entry Operator, in preparing the typed manuscript deserves due acknowledgement. We, in CPCB, hope, that the document will be useful to the Industry, Regulatory Agencies, the Consultants and others interested in pollution control in Iron Ore Mining. (J. M. Mauskar) August 29, 2007 REPORT Development of Clean Technology for Iron Ore Mines and Development of Environmental Standards Prepared for Central Pollution Control Board (Ministry of Environment and Forests, Govt. of India) Parivesh Bhawan, East Arjun Nagar, New Delhi – 110032 September 7, 2007 TABLE OF CONTENTS EXECUTIVE SUMMARY ES-i 1. Chapter ONE Introduction ...................................................................................... 1-1 1.1 Background .........................................................................................1-1 1.2 Scope of the Project.............................................................................1-1 1.3 Study Methodology .............................................................................1-2 2. Chapter TWO Iron Ore Mining in India..................................................................... 2-1 2.1 Principal Ores of Iron..........................................................................2-1 2.1.1 Haematite ................................................................................2-1 2.1.2 Magnetite ................................................................................2-2 2.1.3 Goethite and Limonite ............................................................2-2 2.1.4 Siderites...................................................................................2-2 2.2 Description of Important Iron Ore Formations in India......................2-3 2.2.1 Pre-Cambrian ..........................................................................2-3 2.2.2 Gondwanas..............................................................................2-3 2.2.3 Deccan Traps...........................................................................2-3 2.3 Iron Ore Deposits and Resources / Reserves in India .........................2-3 2.3.1 Iron Ore Deposits ....................................................................2-3 2.3.2 Iron Ore Resources/Reserves and Distribution in India..........2-5 2.4 Status of Exploitation ..........................................................................2-9 2.5 Future Demand..................................................................................2-16 2.5.1 Iron Ore requirement during 2006-07 and 2011-12..............2-16 2.5.2 Future Development Programme ..........................................2-17 2.6 Present Mining Practices in India......................................................2-18 2.6.1 Manual Mines .......................................................................2-18 2.6.2 Mechanised Mines................................................................2-19 2.7 Present Iron Ore Processing Technology in India.............................2-23 3. Chapter THREE International Scenario ................................................................... 3-1 3.1 World Statistics on Iron Ore Mining...................................................3-1 3.1.1 World Resource.......................................................................3-1 3.1.2 Production ...............................................................................3-2 3.1.3 Consumption ...........................................................................3-3 3.1.4 Trade & Transportation...........................................................3-4 3.1.5 Mergers and Acquisitions .......................................................3-4 3.2 Major Iron Ore Producing Countries...................................................3-6 3.2.1 China .......................................................................................3-6 3.2.1.1 Present Status............................................................................................. 3-7 3.2.1.2 Development of Heavy Duty and High Efficiency Mining Equipment ... 3-7 3.2.1.3 Development of High Intensity and Low Loss Mining Technology........ 3-7 3.2.1.4 In-Pit/Crushing/Conveying System........................................................... 3-8 3.2.1.5 Blasting Technology.................................................................................. 3-8 3.2.1.6 Pit slope stability........................................................................................ 3-9 3.2.2 The CIS (Former USSR).......................................................3-10 3.2.2.1 General Information................................................................................. 3-10 3.2.2.2 Mining Machinery ................................................................................... 3-11 3.2.3 Sweden..................................................................................3-13 3.2.3.1 The Kiruna Mine...................................................................................... 3-13 Page No. i TABLE OF CONTENTS 3.2.4 Australia ................................................................................3-14 3.2.4.1 Overview of Iron Ore Mining in Australia.............................................. 3-14 3.2.4.2 Geological background............................................................................ 3-16 3.2.4.3 Operations ................................................................................................ 3-16 3.2.4.4 Technology trends.................................................................................... 3-17 3.2.5 Brazil.....................................................................................3-21 3.2.5.1 Over View of Iron Ore Mining................................................................ 3-21 3.2.5.2 Mining Companies................................................................................... 3-21 3.2.5.3 Technology Trends .................................................................................. 3-22 3.3 Technological Developments in Iron Ore Mining ............................3-22 3.3.1 Drilling ..................................................................................3-22 3.3.2 Blasting .................................................................................3-23 3.3.3 Excavation.............................................................................3-25 3.3.4 Haulage and Transportation System .....................................3-26 3.3.5 Ore Crushing & Screening....................................................3-28 3.3.6 Ore Beneficiation ..................................................................3-28 3.3.7 Slurry Transportation of Iron Ore .........................................3-28 4. Chapter FOUR Environmental Impact of Iron Ore Mining..................................... 4-1 4.1 Environmental Impacts – Open Cast Iron Ore Mining ......................4-1 4.1.1 Impact on Land .......................................................................4-3 4.1.2 Impact on Ecology ..................................................................4-3 4.1.3 Impacts on Water Regime.......................................................4-4
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