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 (Rajasthan). 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 India 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 Pradesh, West Bengal, Andhra Pradesh, and Uttar Pradesh, 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, Jhabua 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 Madhya Pradesh 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.