Vedanta Washery & Logistic Solutions Pvt. Ltd. [1.2 MTPA Iron beneficiation unit] Kunkuni Village, Kharsia Tehsil Raigarh District, Chhattisgarh PRE-FEASIBILITY REPORT Iron ore beneficiation Pre-feasibility Report Chapter - 1 EXECUTIVE SUMMARY 1.1 ABOUT PROJECT PROPONENT Vedanta Washery & Logistic Solutions Pvt. Ltd. [here in after referred as VWLSPL] is incorporated with Registrar of Companies. The company is promoted by Shri. Surya Agrawal engaged in various businesses and having good reputation in the market, which was gained with good business experience. Looking forward in prospects of utilization of washed coal and Beneficiated iron ore, VWLSPL propose to establish an Iron ore Beneficiation & Coal Washery in Raigarh District of Chhattisgarh State. 1.2 ABOUT THE PROPOSED PROJECT Vedanta Washery & Logistic Solutions Pvt. Ltd. proposed to establish 1.2 MTPA Iron Ore beneficiation along with 4.0 MTPA wet type Coal washery in same premises at Village: Kunkuni, Tehsil: Kharsia, District: Raigarh, Chhattisgarh. Total land envisaged for the entire project is 33.87 acres and same is in possession of management. Khasra no. of the total land are 483, 490, 493, 480/1, 480/3, 480/4, 481/1, 481/10, 481/3, 481/4, 481/5, 481/6, 481/7, 481/8, 481/9, 482/1, 482/2, 482/3, 482/4, 484/1[485/2], 484/2, 485/1, 485/2, 486/1, 487/2, 487/3, 488/1, 488/2[489/1], 488/3, 488/4[489/3], 489/2, 489/4, 489/5, 489/6, 489/7, 489/8, 491/1, 491/2, 491/3, 494/1, 494/2, 494/3, 494/4, 495/1, 495/2, 495/3, 495/4, 495/5, 495/6, 497/1, 497/4, 498/2, 498/5, 499/1, 499/2, 499/3, 499/4, 499/5, 499/6, 500/1, 500/2, 500/3, 500/4, 500/5, 500/6, 500/7-k, 500/7-kh, 500/8, 501/1, 501/2, 502/1, 501/3, 499/8, 502/2, 502/3, 506, 507/1, 507/3, 508/1. Total project cost envisaged for the entire project is Rs. 45.0 Crores. Railway siding is envisaged for the proposed coal washery to be served from Roberston Railway Station. 1 Iron ore beneficiation Pre-feasibility Report Chapter - 2 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION 2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT Vedanta Washery & Logistic Solutions Pvt. Ltd. [here in after referred as VWLSPL] is incorporated with Registrar of Companies. The company is promoted by Shri. Surya Agrawal engaged in various businesses and having good reputation in the market, which was gained with good business experience. Looking forward in prospects of utilization of washed coal and Beneficiated iron ore, VWLSPL propose to install a Coal Washery & Iron ore Beneficiation in Raigarh District of Chhattisgarh State. 2.2 BRIEF DESCRIPTION OF NATURE OF PRODUCT Vedanta Washery & Logistic Solutions Pvt. Ltd. proposed to establish 1.2 MTPA Iron Ore beneficiation along with 4.0 MTPA wet type Coal washery at Village: Kunkuni, Tehsil: Kharsia, District: Raigarh, Chhattisgarh. Total land envisaged for the proposed project is 33.87 acres and same is in possession of management. 2.3 NEED FOR THE PROJECT Need for processing Any ore in general, seldom occurs in its purity and form required by the industry and iron ore is no exception to it. In many cases, presence of deleterious impurities like silica, alumina, sulphur & phosphorus beyond desired limits render the ore unsuitable for use in iron making (blast furnace) or adversely affects its productivity and quali ty both. Efficient and economic production of pig iron in blast furnace depends to a very large extent on the input of appropriate quality of raw materials. There has been a change, over the years in the nature of the feed particularly for iron ore i.e., from a totally lump oriented feed to use of higher sinter & pellet in the blast furnace burden. Therefore, the requirement of fines has gone up considerably. Hence, the emphasis on enriching the quality of fines through techno-economically viable beneficiation process has become more and more essential. High-grade lumpy ore reserves are limited and hence optimum utilisation of locked-up valuables in sub-grade/marginal grade iron ore resources and fines are essential for 2 Iron ore beneficiation Pre-feasibility Report survival of the Industry & growth that can be achieved only through implementation of appropriate beneficiation technology. In most of the iron ore deposit of banded iron formation (BIF), almost all the different types of iron formations (massive, laminated, lateritic ore, blue dust etc.) are encountered and it is not always possible to mine it selectively for obvious reasons. Therefore, during commercial exploitation, two or more types of iron formations are mixed together thereby diluting the high-grade ore with lower grade one and vice versa. Therefore, run-of-mine (r.o.m.) iron ore also needs appropriate beneficiation in its totality. The overall characterization (physical, mineralogical & chemical) of the various types of hematite iron ore formations indicated that massive iron ore as well as blue -dust formations which are invariably very high in iron content (Fe >65%) at times contain impurities of silica & alumina beyond the required stipulations. Therefore, it needs consideration for beneficiation for rejection of silica & alumina. In view of the above M/s Vedanta Washery & Logistic Solutions Pvt. Limited has proposed establish Iron Ore Beneficiation at Village: Kunkuni, Tehsil: Kharsia, District: Raigarh, Chhattisgarh. 2.4 DEMAND – SUPPLY GAP Iron ore beneficiation plant in India Iron ore beneficiation facilities in the country are highly inadequate i.e., only 52 concentrators cater to the need for iron ore production of about 220 MTPA (mines -316). Of this around 50% of the concentrators are exclusively in Goa region (production 33 MTPA; mines 72) dedicated solely for export and not meant for domestic consumption. In most of these concentrators, beneficiation process technology is limited to sizing, washing and classification to meet the size requirement with nominal rejection of silica and alumina impurities. Such washing facility was basically successful on accou nt of selective mining of medium to high-grade iron ore at a cut-off grade of 60% Fe. However, such practice of processing may not be of any help once low-grade ores are mined at the threshold value i.e., 45% Fe to augment production. Major beneficiation plants in the country are owned by M/s SAIL, NMDC, TISCO, OMC, JSW Steel Ltd, M/s V.M.Salgaoncar Pvt. Ltd, Sesa Goa Ltd, Socedade de Fomento, Goa etc. 3 Iron ore beneficiation Pre-feasibility Report 2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT) PHYSICAL INFRASTRUCTURE Once the proposed activity is commissioned, the socio-economic status of the local people will improve and there by infrastructure facilities like communication systems will improve. Most of the villages at present do not have protected water supply. After the implementation of the project, the affordability of the public to spend on water treatment, supply & distribution will more along with the aid from the state government. EMPLOYMENT POTENTIAL The proposed project creates employment to 100 people during construction and 50 people during operation of the proposed Coal washery & Iron ore beneficiation unit. SKILLED Total skilled employment in the proposed plant will be around 15. SEMI-SKILLED Total Semi-skilled employment in the proposed project will be around 15. Priority will be given to local people for semi -skilled jobs. UNSKILLED Total Unskilled employment in the proposed project will be around 20. Top priority will be given to local people for unskilled jobs. 4 Iron ore beneficiation Pre-feasibility Report Chapter - 3 PROJECT DESCRIPTION 3.1 TYPE OF THE PROJECT Vedanta Washery & Logistic Solutions Pvt. Ltd. proposed to establish 1.2 MTPA Iron Ore beneficiation along with 4.0 wet type coal washery at Village: Kunkuni, Tehsil: Kharsia, District: Raigarh, Chhattisgarh. Total land envisaged for the proposed project is 33.87 acres and same is in possession of management. 3.2 LOCATION OF THE PROJECT Project is located at Village: Kunkuni, Tehsil: Kharsia, District: Raigarh, Chhattisgarh . Topographical location of project site is shown below: 5 Iron ore beneficiation Pre-feasibility Report 3.3 SIZE OR MAGNITUDE OF OPERATION 1.2 MTPA Iron ore Beneficiation. 3.4 MANUFACTURING PROCESS 3.4.1 IRON ORE BENEFICIATION PROCESS Beneficiation process is a combination of crushing, screening, washing, grinding, classifying by gravity separation, magnetic separation, floatation p rocesses. The final concentrate slurry is filter pressed to get a dry enriched ore quality with Fe >65% and moisture ~10%. The water is recycled in the process. The tailings are settled in a thickener and a large amount of water is recovered and circulated in the process. The discharge from the thickener is of low value with Fe <45% and moisture content ~25%. The Iron Ore beneficiation plants comprise of the following sections: (i) Screening, crushing and washing section (ii) Grinding Section (iii) Concentration Section Major Equipment and Facilities: The major equipment and facilities for the iron ore beneficiation pla nts are briefly described below: Screening, Crushing and Washing Section: It has been envisaged that the crusher fines and low/sub-grade iron ore will be fed in a proportion of 4:1 into a receiving hopper by means of trucks. One apron feeder will be equipped below the hopper to feed into a static grizzly, where the separation will take place at 100 mm to scalp out the +100 mm fraction and to deliver it to a reject stockpile via belt conveyor. The undersize of the grizzly will be further transported to screening and crushing section by means of a belt conveyor. 6 Iron ore beneficiation Pre-feasibility Report Scalper Screen:The iron ore will be fed onto a scalper screen having deck opening of 25 mm for separating -100+25 mm fraction to be fed directly into a cone crusher.