3. final pfr 2.6environmentclearance.nic.in/writereaddata/online/tor/0_0_06_sep_2… · existing...

NMDC Limited, 10-3-311/A, Khanij Bhavan, Castle Hills, Masab Tank, Hyderabad -500 028 Tel: 91-040-23538713-21, 23, Fax: 91-040-23538711

PRE-FEASIBILITY

REPORT FOR OBTAINING PRIOR ENVIRONMENTAL CLEARANCE

FOR CONSTRUCTION OF

10 MTPA CAPACITY SCREENING &

BENEFICIATION PLANT – II,

SLIME DISPOSAL PIPE LINES &

13.4MT CAPACITY TAILING DAMS

FOR DIOM & KIOM

AT DONIMALAI, KARNATAKA (In terms of the provisions of EIA notification,2006)

Rev 1, June 2014

NMDC LIMITED

PRE FEASIBILITY REPORT FOR CONSTRUCTION OF SCREENING & BENEFICIATION PLANT-II,

SLIME DISPOSAL PIPE LINES AND TAILING DAMS FOR DIOM & KIOM, DONIMALAI JUNE – 2014

NMDC Limited, Hyderabad

CONTENTS

Chapter Description Page No.

1 Executive summary 1

2 Introduction of the project/ Background information 7

3 Project Description 10

4 Site Analysis 12

5 Planning Brief 14

6 Proposed Infrastructure 15

7 Rehabilitation and Resettlement (R & R) Plan 17

8 Project Schedule & Cost Estimates 18

9 Analysis of proposal (Final Recommendations) 21

ADDITIONAL TECHINICAL DETAILS OF FEASIBILITY REPORT

10 Ore Geology & Reserves 23

11 Plant Design & Layout 27

12 Civil & Structural Works 37

13 Electrical & Controls 44

14 Environmental Measures 52

15 Manpower Planning 56

16 Annexures 58

17 List of Plates 65


SLIME DISPOSAL PIPELINES AND TAILING DAMS FOR DIOM & KIOM, DONIMALAI JUNE – 2014

NMDC Limited, Hyderabad Page 1

1. Executive Summary

1.1 General

NMDC Limited is a Public Sector Company under the Ministry of Steel, Government

of India. Primarily engaged in the business of exploring minerals and developing

mines to produce raw materials for the industry, it is also expanding its activities

towards steel making and other value added products. It has been conferred

“NAVARATHNA” status by Government of India. Incorporated in 1958, NMDC has

been actively contributing to the development of the nation for five decades and

grown from, strength to strength during its journey.

NMDC is India’s single largest iron ore producer and exporter, presently producing

about 27 million tons of iron ore per annum from 3 fully mechanised mines viz.,

Bailadila Deposit – 14/11C, Bailadila Deposit – 5, 10/11A (Chhattisgarh State) and

Donimalai Iron Ore Mines (Karnataka State) which are awarded ISO 9001-2000

`certification.

NMDC Limited is presently engaged in iron ore mining at Donimalai with a

production capacity of about 7 million tons per annum. NMDC is also operating

another mine in Kumaraswamy hill range i.e., Kumaraswamy Iron Ore Project,

which has a reserve of about 130 million tons of hematite ore. Construction of

Kumaraswamy Mine facilities for processing 7 MTPA of ROM is already on and

expected to be commissioned by end of 2013. Earlier, it was envisaged to utilize

existing Screening & Beneficiation plant of Donimalai mine for Kumaraswamy mines

also, as iron ore reserves in Donimalai were getting depleted. Subsequently, based

on the exploratory core drilling operations, additional iron ore reserves of 95.5 MT

have been established. The combined production of both the mines is proposed to

be about 14 MTPA.

1.2 Plant Capacity

Existing Screening & Beneficiation Plant of Donimalai was originally constructed to

process 4 MTPA of ore and subsequently many equipment were added and one

more screening line was installed to process up to about 7 MTPA. Existing Plant

cannot process iron ore beyond 7 MTPA. Moreover, it has outlived its life, resulting

in frequent break-downs which lead to considerable loss in the availability of

equipment and hence production. To sustain production without interruption due

to frequent breakdown of the existing plant, it is proposed to set-up a Screening &

Beneficiation Plant-II, which can handle/treat ore from either Kumaraswamy mine

or Donimalai mine or both the mines. Hence, it is prudent to construct a new

Screening & Beneficiation Plant of installed capacity for processing ore up to 7

MTPA in Phase-1, which will be augmented to 10 MTPA in Phase-2 in future.

Necessary provisions for additional 2 lines will be made in the plant building.

1.3 Proposed Scheme




Overall plant layout of the proposed scheme is shown in Plate No. 3 and description

of the proposed Screening & Beneficiation plant-II (Refer Plate No. 4.1 & 4.2) is as

follows:

1.3.1 Screening & Crushing

• The Run of Mine (ROM)[(-) 100mm] of Kumaraswamy mines or Donimalai

mines or both the mines is stored in silos of about 4000 tons (each) storage

capacity. The ore is extracted through apron feeders and fed to double deck

primary screens (with 30mm & 20mm apertures) through belt conveyor.

• The oversize material of primary screens is fed to tertiary crusher to crush (-)

100mm ROM to (-) 30mm. The middle fraction and the under size material of

primary screen are fed to Calibrated Lump Ore (CLO) conveyor and secondary

screens respectively.

• The crushed ore of tertiary crusher is fed to double deck tertiary screen (with

30mm and 6mm apertures), wherein the oversize material (+ 30mm) is re-

circulated to tertiary crusher. The middle fraction of tertiary screen (-) 30 (+)

6mm and under size fraction (- 6mm) of tertiary screen are fed to CLO product

conveyor and fines product conveyor respectively.

• Under size of secondary screen is fed to classifier of wet circuit system.

Suitable gate arrangement is envisaged at the bottom of under size chute of

secondary screen, which diverts material to launder leading to classifier circuit

when operating on wet mode. Under dry mode the gate will be lifted /

opened to divert the material to fines conveyor.

• Conveyor receiving middle fraction [(-) 10 mm (+) 6 mm] of secondary screen

is envisaged with reversible operation to feed the material either to fines

conveyor or CLO conveyor based on the requirement.

1.3.2 Wet Circuit

Classifier overflow is fed to dewatering screen and the underflow to hydro-

cyclones. The overflow of dewatering screen is fed to fines conveyor and the

underflow is fed to cyclones. The cyclones (with separation size of 150 microns)

overflow is diverted to thickener and the underflow to filtrate unit to recover some

fines, which in turn is fed to fines conveyor.

1.4 Technological Facilities

The new Screening & Beneficiation plant shall have the following major facilities

• Feeder to receive ore from Kumaraswamy downhill conveyor

• Tripper conveyor

• Storage silos

• Apron feeders

• Belt conveyors

• Double deck primary screens




• Double deck secondary screens

• Tertiary crushers

• Double deck tertiary screens

• Spiral classifiers

• Dewatering screens

• Hydro-cyclones

• Horizontal Belt Filters (HBF)

• Tailing thickeners

• Tailing disposal system

• Tailing dam

• Water storage tanks

• Water reclamation and distribution

• Suitable material handling facilities (such as EOT cranes, hoists, etc.)

• Dust control systems

1.5 Land

The proposed Screening & Beneficiation Plant – II is planned to be set up towards

southern side of the existing Screening & Beneficiation Plant-I on the hillock

between existing fine ore belt conveyor number BC 411 and existing lump ore

conveyor number BC 501. The location of the proposed facility considered is in

between N78200 & N78600 and E81600 & E82000 and in the outside lease area.

Tailing thickener facility is considered on eastern side of the proposed Screening &

Beneficiation plant-II near the co-ordinate N78500 & E81800. About 13.0 Ha of land

is required for construction of Screening & Beneficiation plant-II.

1.6 Water

The source of water for the Project is from Water Treatment Plant (WTP) which

draws water from Narihalla Dam. WTP is at Donimalai base camp located about

1km from the proposed plant site. Water from this WTP is pumped to storage tank

of about 5000 m3 located adjacent to the plant site. From this point water is

brought to Screening & Beneficiation Plant by gravity and then distributed to

different equipment. Make up water requirement for processing 7 MTPA ore is

estimated at about 370 m3/hr (2451 m

3/hr is required for operation, out of which

make-up water is 370 m3/hr).

1.7 Power

The incoming power supply for the proposed Screening & Beneficiation Plant- II is

planned to be tapped from existing Valley sub-station through over head line

(11kV)/ underground HT cable (11kV), which is about 2 km distance.

Estimated power requirement of the proposed plant is as follows:

Maximum Demand (Crushing & Screening) : 1.5 MVA (Mega Volt Amperes)

Annual Energy Consumption : 7.2 MU (Million Units)




1.8 Man-power Plan

The overall manpower requirement has been estimated at 10 executives and 71

non-executives. Apart from operation and running maintenance (mechanical and

electrical), the proposed manpower also caters to preventive maintenance and shut

down operations.

1.9 Capital Outlay

The capital outlay estimated for the scheme is about Rs. 399.75 crores. The capital

cost includes for Mechanical equipment & works of Rs. 148.32 crores (including all

taxes & duties and E&C), Civil & Structural works of Rs. 108.53 crores, Tailing Dam

works of Rs.51.81 crores and Electrical & Control works of Rs. 25.02 crores. Other

costs considered in the outlay are design, engineering, consultancy services

administration during construction (@ 5% on the Project basic cost), contingencies

(@ 5% on the Project basic cost) and Turnkey Package Concept, overheads and

contractor's profit margin (@ 15% on Project basic cost).

Sl.

No. Description

Approx. Basic Cost

Estimate (Excludes

Spares, E&C, Taxes &

Duties) (Rs. In Cr)

Approx. Cost Estimate

including all taxes,

duties and E & C

(Rs. In Cr)

I Mechanical Equipment & Works 94.12* 148.32**

II Electrical & Controls 17.85 25.02

III Civil & Structural Works 103.10 108.53

IV Tailing Dam 49.22 51.81

V Sub-total (A) 264.29 333.68

VI

Design, Engineering, Consultancy

services and administration during

construction (@ 5% on Project Basic

Cost)

13.21

VII Contingency (@ 5% on Project Basic

Cost) 13.21

VIII

Turnkey Package Concept, overheads

and contractor's profit margin

including local conditions prevailing

in the region (@ 15% on Project Basic

Cost)

39.64

IX Total (V + VI + VII + VIII) - 399.75

* Comprises FC component of Rs. 23.89 Cr and Rs. 70.23 Cr for indigenous items.

** Comprises FC component of Rs. 43.67 Cr (for supply of equipment, spares and

supervision charges during E &C) and Rs. 104.65 Cr for indigenous items.




1.10 Production Cost Analysis

Because of the additional capital investment for construction of the proposed

Screening & Beneficiation Plant – II for processing ROM from both Donimalai and

Kumaraswamy Mines, there will be hike in the cost of production as furnished

below:

Capital outlay : Rs. 399.75 crores.

Depreciation : Rs. 22.21 crores per year.

Cost involved due to additional manpower : Rs. 8.10 crores per year

Therefore, increase in cost of production = (22.21+8.10) / 0.7

= Rs. 43.3 per MT at 100%

capacity utilisation.

The increase in cost of production is primarily due to considering ‘Screening &

Beneficiation Plant’ on standalone unit. However, it is an essential unit required for

getting the final product.

1.11 Project Implementation Plan

1.11.1 An EPCM Consultant shall be appointed for Engineering, Procurement, Project

Management, Construction Supervision and Inspection Services, who will be

responsible for executing the Project through the Lump Sum Turnkey (LSTK)

contractor(s).

1.11.2 The total project is proposed to be executed largely on LSTK basis and includes the

following:

i) Site levelling

ii) All the facilities including tertiary crushing and screening – Dry circuit

iii) Wet circuit including process water system

iv) Tapping the power from existing 33/11 kV Substation and the power

distribution facilities at plant site

v) Auxiliary facilities including construction of office building, Stores, Internal

roads, etc.

However, the above packaging philosophy shall be reviewed after engagement of

EPCM consultant.

1.11.3 Statutory clearances: Following clearances are required for establishment of this

Project:

(i) Clearance from MOEF for diversion of forest land for construction of

Screening & Beneficiation Plant, Tailing Dam.




(ii) Environmental clearance for the Project.

(iii) Consent for establishment from Karnataka State Pollution Control Board

(KSPCB).

Of the above, Forest clearance for diversion of forest land is most critical.

Subsequent to receipt of this only other clearances can be obtained.

The time period required for commissioning of the Screening & Beneficiation plant

including Performance Guarantee (PG) test of 3 months is 27 months from the date

of receipt of the last statutory clearance, assuming that the LSTK contractors are in

place by that time. Refer Plate No. 16 for the time schedule for implementation of

the scheme.

1.12 Advance actions: Following actions are to be taken prior to Award of LSTK

contracts.

• Clearances to be obtained from the statutory authorities for construction of

Screening & Beneficiation Plant, tailing dam, laying of overhead electric line

and pipe line for slime disposal to tailing dam.

• Survey the plant site area

• Soil investigation to be done in the plant site area

• Enabling works i.e. construction water & construction power

1.13 Recommendation

Towards sustaining overall system efficiency and for processing of ores from both

Donimalai Iron Ore Mines (DIOM) & Kumaraswamy Iron Ore Mines (KIOM), the

installation of this Screening & Beneficiation Plant is inevitable and hence

recommended for immediate implementation.




2. Introduction of the project/ Background information

(i) Identification of project and project proponent.

NMDC has started production of iron ore from the Donimalai Iron Ore Mines from

the year 1977. The mine is capable of operating at a capacity of 7 million tons per

annum (MTPA). At present the ore is being treated in the existing Screening &

Beneficiation Plant-I of Donimalai. It is estimated that about 95.5 million tons of

additional ore reserve is proved in Donimalai Mines. The other mine in the area

with NMDC is Kumaraswamy Iron Ore Mine. Kumaraswamy Mine is estimated to

have a reserve of about 130 million tons of hematite ore. Construction of

Kumaraswamy Mine facilities for processing 7 MTPA of ROM is already on and

expected to be commissioned by end of 2013.

Existing Screening & Beneficiation Plant-I at Donimalai was originally designed to

process 4 MTPA ore with a provision of 3 lines. Subsequently additional equipment

and one more line were added to process 7 MTPA ore. Further enhancement of

capacity of existing Screening & Beneficiation Plant is not possible and therefore, a

proposal for construction of new Screening & Beneficiation Plant-II of capacity-10

MTPA was proposed.

(ii) Brief description of nature of the project.

The iron ore processing in the plant mainly involves Iron ore crushing, Screening

and Beneficiation.

(iii) Need for the project and its importance to the country and or region.

The existing Screening & Beneficiation plant is operating since 1977, which is about

36 years old. Initially the Screening & Beneficiation plant was installed with 3 lines

only to process 4 MTPA ROM but at later stage one more line (fourth line) was

installed to treat ore up to 7 MTPA. Out of four (4) lines in the Screening &

Beneficiation plant, any three lines would be in operation and one under

maintenance. In order to handle the enhanced production, there is a requirement

of additional screening lines. Considering plant layout, creation of additional

screening line(s) in the existing Screening & Beneficiation plant is not feasible.

Limitations / constrains of the existing & Plant for capacity expansion

a) Congested due to addition of equipment subsequent to Plant construction.

b) Material jamming in many chutes due to inadequate height of fall of material

between equipment.

c) Wet circuit needs augmentation.

d) Impossible to augment capacity more than 7 million tonnes per annum due to

space constraints within the Plant and around it.




e) In the ‘Technical Report on Production enhancement of Iron Ore Mines’, Vol-1

(Donimalai Iron Ore Mine), submitted by Mecon in 2007, it is stated that - “The

Equipment of the Plant are worn out and the existing Screening Plant would

have outlived its life till the commissioning and start of the production from

Kumaraswamy Mine. Therefore, it is proposed to erect a new Screening Plant of

matching capacity to commensurate with the production from Kumaraswamy

and Donimalai Mines.”

Considering the above limitations / constrains of the existing Screening &

Beneficiation Plant for capacity expansion, it is proposed to construct a new

Screening & Beneficiation Plant-II consisting of 4 Screening lines (3 working & 1

standby) with installed capacity for processing ore up to 7 MTPA. Provision of

additional 2 lines is proposed for handling additional 3 MTPA for future

requirement.

(iv) Demand-Supply Gap.

The demand for steel in India is projected to grow in the years to come and this in

turn would call for increased demand for iron ore. In this segment, M/s NMDC

Limited (NMDC) is gearing up to meet the expected increase in demand by

enhancing production capabilities of existing mines, by opening up new mines, by

setting up new integrated steel plants and by expanding capacity of existing plants.

(v) Imports vs. Indigenous production.

NA

(vi) Export Possibility.

NA

(vii) Domestic / export Markets.

Prime customers of NMDC are the following:

1 Rashtriya Ispat Nigam Ltd., (VSP)

2 KIOCL Ltd.,

3 Essar Steels Ltd.,

4 JSW Steel Ltd.,

5 Ispat Industries Ltd.,

6 CG based Sponge Iron Units

7 Welspun Max Steel Ltd.,

8 Visveswaraya Iron & Steel Plant

9 Aparant Iron & Steel Co. Ltd.,

10 Tata Metalliks Ltd.,

11 Southern Iron & Steel Co. Ltd.,




12 MMTC Ltd.,

13 Vikram Sponge Iron Ltd.,

Iron Ore is also exported to Japan & South Korea on a smaller scale.

(viii) Employment Generation (Direct and Indirect) due to the project.

Direct employment is estimated at about 81 persons which includes Executives: 10

Nos. and Workmen/Non-executives : 71 Nos. and indirect employment is

estimated at about 400 people.

The Executives would be placed during the construction of the project itself, as they

have to get acquainted with the plant and equipment for efficient running of the

concerned units.

Some of the construction personnel can progressively be absorbed with the

tapering of the construction work, particularly in the maintenance and services

areas of the plant. A certain portion of junior executives and supervisory staffs may

have to be recruited during the construction stage itself as acquaintance with

equipment erection will be very much beneficial for them in running the units later.




3. Project Description

(i) Type of project including interlinked and interdependent projects, if any.

The proposed Plant is interlinked with existing Donimalai Iron Ore Mine (DIOM),

upcoming Kumaraswamy Iron Ore Mine (KIOM).

(ii) Location (map showing general location, specific location, and project boundary &

project site layout) with coordinates.

Donimalai iron ore deposits are covered in the Survey of India topo-sheet No. 57

A/12 between Lat. 150

02’ 0” and 150

06’30” and Longitude 760

36’ 0” and 760

38’30”. The deposits are situated in Bellary district of Karnataka.

Donimalai deposits are situated on the southern half of the eastern range of hills

flanking Sandur valley. Sandur valley, which is about 40 km long and about 4 – 5 km

wide is surrounded by a long range of hills both on the eastern and western flanks,

giving an elliptical shape to the valley with its long axis running NW and SE. The two

ranges of hills close in towards the southern end and therefore the main opening of

the valley is towards the north.

(iii) Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

The most suitable site for the proposed plant is near to existing loading plant,

product conveyors (fines & lumps), KIOM downhill conveyor, Thickener and

proposed Tailing pond.

(iv) Size or magnitude of operation.

The Plant will process Iron ore up to 7 MTPA in Phase-1 with 3 operating lines and a

standby line. In Phase -2 the plant capacity will be augmented to 10 MTPA by

addition of another 2 lines.

(v) Project description with process details (a schematic diagram/ flow chart showing

the project layout, components of the project etc. should be given)

The ROM of Kumaraswamy mines or Donimalai mines or both the mines is stored in

silos of about 4000 tons (each) storage capacity. The lump ore [(-) 100mm] is

extracted through apron feeders and fed to double deck primary screens (with

30mm & 20mm apertures) through belt conveyor.

The oversize material of primary screens is fed to tertiary crusher to crush (-)


primary screen are fed to CLO conveyor and secondary screens respectively.

The crushed ore of tertiary crusher is fed to double deck tertiary screen (with





circulated to tertiary crusher. The middle fraction of tertiary screen (-) 30 (+) 6mm

and under size fraction (- 6mm) of tertiary screen are fed to CLO product conveyor

and fines product conveyor respectively.

Under size of secondary screen is fed to classifier of wet circuit system. Suitable

gate arrangement is envisaged at the bottom of under size chute of secondary

screen, which diverts material to launder leading to classifier circuit when operating

on wet mode. Under dry mode the gate will be lifted / opened to divert the

material to fines conveyor.

Conveyor receiving middle fraction [(-) 10 mm (+) 6 mm] of secondary screen is

envisaged with reversible operation to feed the material either to fines conveyor or

CLO conveyor based on the requirement.

(vi) Raw material required along with estimated quantity, likely source, marketing area

of final product/s, Mode of transport of raw Material and Finished Product.

Finished products fines & lumps are transferred through conveyors to loading plant

and despatched through railway wagons using mechanised loading facilities.

(vii) Resource optimization/ recycling and reuse envisaged in the project, if any, should

be briefly outlined.

About 85 % of process water is recovered from Tailing pond & thickener. About 4 to

5 % of slimes generated will be stored in tailing pond.

(viii) Availability of water its source, Energy/ power requirement and source should be

given.

Source of water is from water treatment Plant which gets water from nearby

Narihalla dam. Make up water requirement for processing 7 MTPA ore is estimated

at about 370 m3/hr (2451 m

3/hr is required for operation)

Estimated power requirement of the proposed plant is as follows:

Maximum Demand (Crushing & Screening) : 1.5 MVA (Mega Volt Amperes)

Annual Energy Consumption : 7.2 MU (Million Units)

(ix) Quantity of wastes to be generated (liquid and solid) and scheme for their

Management/disposal.

About 4 to 5 % of slimes generated will be stored in tailing pond.

(x) Schematic representations of the feasibility drawing which give information of EIA

purpose.

Proposed Screening & Beneficiation plant facilities and tailing dam locations are

shown in the drawing 3-2-148 in the feasibility report




4. Site Analysis

(i) Connectivity.

The Plant is located at 50 km from Bellary, district head quarters and 38 km from

Hospet town. The area is connected by road as well rail to Bangalore & Hyderabad.

The Plant area is approachable by a fair-weathered metal road from Toranagallu

town. Toranagallu is well served by the National Highway and Trunk rail/roads. The

distances to important places are as follows:

• Donimalai to Bengaluru - 350 km

• Donimalai to Hyderabad - 460 km

• Donimalai to Toranagallu - 28 km

The nearest rail head is Toranagallu Railway Station, which is 28 km from the plant

site. Chennai port is about 600 km by rail line from Ranjithpura railway station and

is connected to western coast via Sanvardom by about 389 km.

(ii) Land Form, Land use and Land ownership.

Forest land, open mixed jungle

(iii) Topography (along with map).

Proposed Screening & Beneficiation Plant facilities are shown in drawing no. 3-2-

148 & 3-2-131.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies

(including area under CRZ)), shortest distances from the periphery of the project to

periphery of the forests, national park, wild life sanctuary, eco sensitive areas,

water bodies (distance from the NFL of the river), CRZ. In case of notified industrial

area, a copy of the Gazette notification should be given.

Forest Land, open mixed jungle

(v) Existing Infrastructure.

No facilities exist.

(vi) Soil classification

The rock formations of the region consist of phyllites (locally designated as shales),

the well known Banded Hematite Jaspers and Quartzites (BHJ & BHQ) and

quartzites and basic igneous rocks (green stones) which have been generally

metamorphosed to the “Green Schist facies. According to Fermor, it is a folded




synclinorium in which the apparently large number of hematite-quartzite bands is

due to repetition by folding.

(vii) Climatic data from secondary sources.

The area receives an annual rainfall ranging from 600 mm to 800 mm. The

predominant rainy season in this area is between July and October. Rain also occurs

occasionally in the months of November and January due to northeast monsoon.

The maximum temperature is around 400 C in summer while minimum temperature

is around 150 C in winter, which occasionally goes to as low as 12

0 C.

(viii) Social Infrastructure available.

Well developed township/colony exists in Donimalai.




5. Planning Brief

(i) Planning Concept (type of industries, facilities, transportation etc) Town and

Country Planning/Development authority Classification.

Only Iron Ore Process Plant is proposed

(ii) Population Projection

Roughly about 15000 populations exist.

(iii) Land use planning (breakup along with green belt etc).

NA

(iv) Assessment of Infrastructure Demand (Physical & Social).

NA

(v) Amenities/Facilities.





6. Proposed Infrastructure

(i) Industrial Area (Processing Area).

Total area required for Screening & Beneficiation Plant-II & associated facilities is

39.32 Ha which includes – Screening & Beneficiation Plant-II (13 Ha), Tailing Dam-I

(16.2 Ha), Tailing dam-II (9.0 Ha), Pipe line-I (0.06 Ha), Pipe line-II (0.34 Ha) and OHE

line (0.72 Ha)

(ii) Residential Area (Non Processing Area).

NA

(iii) Green Belt.

Afforestation measures shall be taken-up through developing barrier platforms all

around the plant. To maintain ecological balance in the area, plantations of suitable

species of ever green/locally grown trees shall be made. Adequate tree plantations

shall substantially abate dust pollution, filter the polluted air and ameliorate the

plant environment without any hazards in public health.

The Screening & Beneficiation Plant includes development of a green belt that is

expected to reduce noise levels, limit the propagation of fugitive dust and produce

a better occupational / aesthetic environment. The implementation of a green belt

around the plant and side of the roads and the selection of plant species will be

carried out in co-operation with Horticulture Department.

(iv) Social Infrastructure.


(v) Connectivity (Traffic and Transportation Road, Rail/Metro/Water ways etc)

Existing road adjacent to the Proposed Plant will be used for connectivity. Internal

roads will be layed inside the Plant premises for man & material movement.

(vi) Drinking Water Management (Source & Supply of water)

The source of water for the Project is from existing Water Treatment Plant (WTP) at

Donimalai base camp located about 1km from the proposed plant site.

(vii) Sewerage System.

Sewerage system is already available at the adjacent plant which is at 300m

distance.

(viii) Industrial Waste Management.

NA




(ix) Solid Waste Management.

The slimes stored in tailing pond will be used as raw material for upcoming Pellet

Plant.

(x) Power Requirement & Supply / source.

The estimated power requirement of the proposed plant is as follows:

T

The incoming power supply for the proposed Screening & Beneficiation Plant-II is

planned to tap from existing Valley sub-station through over head line (11kV) /

underground HT cable(11kV), which is about 2 km distance.

• Maximum Demand (Screening &

Beneficiation Plant - II)

: 1.5 MVA

• Annual Energy Consumption : 7.2 MU




7. Rehabilitation and Resettlement (R & R) Plan

(i) (Policy to be adopted (Central/State) in respect of the project affected persons

including home oustees, land oustees and landless laborers (a brief outline to be

given).

There is no settlement of Human population at the proposed Plant location.




8. Project Schedule & Cost Estimates

(i) Likely date of start of construction and likely date of completion (Time schedule for

the project to be given).

Clearances to be obtained from the statutory authorities for construction of

Screening & Beneficiation Plant, tailing dam, laying of overhead electric line and

slime disposal pipe line to tailing dam. Thereafter an EPCM Consultant shall be

appointed for Engineering, Procurement, Project Management, Construction

Supervision and Inspection Services, who will be responsible for executing the

Project through the Lump Sum Turnkey (LSTK) contractor(s).

Implementation schedule

By initiating advance action for some of the activities, considering some are parallel

actions and based on minimum time period required for certain activities like

appointment of EPCM consultant, supply of long lead item such as cone crusher

etc., setting up of the proposed system will require 45 months from the date of

approval of TEFR (TEFR approved on 05.11.2013). The time frame required for

construction of the Plant is 24 months after obtaining forest clearance. An

indicative time schedule is presented in the form of ‘Bar Chart’, placed at Plate No.

16.

(ii) Estimated project cost along with analysis in terms of economic viability of the

project.

The capital cost estimated for creation of additional facility by construction of

Screening & Beneficiation Plant – II, is Rs. 399.75 crores. The detail of the break-up

is as below:

Sl.

No. Description

Approx. Basic Cost

Estimate (Excludes

Spares, E&C, Taxes &

Duties) (Rs. In Cr)

Approx. Cost Estimate

including all taxes,

duties and E & C

(Rs. In Cr)

I Mechanical Equipment & Works 94.12* 148.32**

II Electrical & Controls 17.85 25.02

III Civil & Structural Works 103.10 108.53

IV Tailing Dam 49.22 51.81

V Sub-total (A) 264.29 333.68

VI

Design, Engineering, Consultancy

services and administration during

construction (@ 5% on Project Basic

Cost)

13.21




VII Contingency (@ 5% on Project Basic

Cost) 13.21

VIII

Turnkey Package Concept, overheads

and contractor's profit margin

including local conditions prevailing

in the region (@ 15% on Project Basic

Cost)

39.64

IX Total (V + VI + VII + VIII) -

399.75

* Comprises FC component of Rs. 23.89 Cr and Rs. 70.23 Cr for indigenous items.

** Comprises FC component of Rs. 43.67 Cr (for supply of equipment, spares and

supervision charges during E &C) and Rs. 104.65 Cr for indigenous items.

Cost of Production

Because of the additional capital investment for construction of the proposed

Screening & Beneficiation Plant – II for processing ROM from Kumaraswamy and

Donimalai Iron Ore Mines, there will be hike in the cost of production as furnished

below:

Capital outlay : Rs. 399.75 crores

Depreciation : Rs. 22.21 crores per year

Cost involved by additional manpower required : 81 X 10 lacs

= Rs. 8.10 crores per year

Increase in cost of production : (22.21+8.1) / 0.7

= Rs. 43.3 per ton at 100%

capacity utilization

Notes

1. Depreciation is considered for 18 years of life for Kumaraswamy Mines.

2. Only manpower cost towards fixed cost of production cost is considered keeping

variable cost for producing 7 MTPA of CLO & Fines unchanged. Increase on Rs.

43.3/- per ton is at 100% utilisation and will vary according to the utilisation of the

facility.

3. The environment and forest clearances are yet to be obtained. In case of delay in

obtaining the same, the calculation may also need to be revised.

4. Considering the production target of Donimalai complex, the level of production

may sustain at about 10 MTPA for few years from 2016-17, as more reserves are

proved in Donimalai Mines. Hence, to sustain the continuity of production from

both mines and for better working environment with better maintenance facility, it

is required to consider construction of Screening & Beneficiation Plant – II. At later




date, the Screening & Beneficiation plant – II will be augmented with by installing

additional two lines to process ore up to 10 MTPA. Equipment of existing Screening

& Beneficiation plant in serviceable conditions can be used for augmentation of

Screening & Beneficiation -II in phased manner. However, the increase in cost of

production due to this Screening & Beneficiation Plant is Rs. 43.3/ton, which is

primarily due to depreciation and additional manpower considered.




9. Analysis of proposal (Final Recommendations)

(i) Financial and social benefits with special emphasis on the benefit to the local

people including tribal population, if any, in the area.

• Direct employment of about 81 people (Executives & non executives).

• Indirect employment of about 400 people.

• Uninterrupted production of Iron ore products to supply Steel industries.

• Increased level of production to match with future increased demand of Iron

Ore.

Towards sustaining overall system efficiency and for processing of ores from both

Donimalai Iron Ore Mines (DIOM) & Kumaraswamy Iron Ore Mines (KIOM), the

installation of this Screening & Beneficiation Plant-II is inevitable and hence

recommended for immediate implementation.




ADDITIONAL TECHNICAL

DETAILS OF

FEASIBILITY REPORT




10. ORE GEOLOGY & RESERVES

10.1 Geology of Deposits of Donimalai & Kumaraswamy

10.1.1 Donimalai Iron Ore Deposit

(1) Location

Donimalai iron ore deposits are covered in the Survey of India topo-sheet

No. 57 A/12 between Lat. 150

02’ 0” and 150

06’30” and Longitude 760

36’ 0”

and 760 38’30”. The deposits are situated in Bellary district of Karnataka.

Donimalai deposits are situated on the southern half of the eastern range of

hills flanking Sandur valley. Sandur valley, which is about 40 km long and

about 4 – 5 km wide is surrounded by a long range of hills both on the

eastern and western flanks, giving an elliptical shape to the valley with its

long axis running NW and SE. The two ranges of hills close in towards the

southern end and therefore the main opening of the valley is towards the

north.

(2) General Geology

The rock formations of the region consist of phyllites (locally designated as

shales), the well known Banded Hematite Jaspers and Quartzites (BHJ &

BHQ) and quartzites and basic igneous rocks (green stones) which have been

generally metamorphosed to the “Green Schist facies. According to Fermor,

it is a folded synclinorium in which the apparently large number of

hematite-quartzite bands is due to repetition by folding.

(3) General description of the Deposit

The iron ore range in Donimalai constitutes prominent ridges extending over

a total strike length of about 7.0 km having trend of NW to SE following

general strike of the country rocks with steep (700) to vertical beds

dominantly towards the east.

The deposit is conveniently divided in to two blocks, namely North Block

and South Block. In South block, one ore zone followed NNW for about 2.6

km after which it splits into two, one limb following the original trend for

another 0.6 km and the eastern limb making a small angle with the main

zone and traceable for about 0.8 km. These two limbs do not join up and are

separated by a small band of shale. The main western ore zone has been

designated as Deposit 1 and the small eastern limb as Deposit 1A. The south

block ends to the south against a private lease hold in which the main ore

body is found to extend for about 100 m.

Further north, the continuity of Deposit 1 and 1A is lost and outcrops of

lateritised shale and BHJ are found. This break in the continuity of ore has




been taken as the boundary between the North and South Blocks of

Donimalai.

In the general strike continuity of Deposit 1 further north, two isolated ore

bodies are observed. Those ore bodies have been designated as 2W and

3W. Similarly, in the general strike continuity of Deposit 1A further north

and occurring to the east of Deposit 2Wand 3W, two isolated ore bodies are

found. These have been designated as Deposit 2E and 3E.

10.1.2 Kumaraswamy Iron Ore Deposit

(1) Location:

Kumaraswamy Iron Ore deposits situated at the southern closure of the hill

ranges of Bellary – Hospet sector. The Kumaraswamy deposits in turn

consists of 5 iron ore blocks namely, A,B,C,D & E. Out of which ‘B’ & ‘C’

blocks are within the mining lease of NMDC Ltd. covers an area of 647.50

ha.

The ore bodies ‘B’ & ‘C’ of Kumaraswamy are covered in the survey of India

topo-sheet No. 57A/12 and lie between latitude 1500’10” to 15

00’50” and

Longitude 76034’5” to 76

036’20”.

(2) Geology of the Ore Deposits

Kumaraswamy ‘B’ and ‘C’ blocks lie on the Southern flank of Sandur Basin,

which is grouped under Dharwarian schist belt. The range forms the eastern

continuation of the Ramanadurg Range. “B’ Block is contiguous to ‘C” Block

on eastern side except for the small patch of non-mineralised valley portion.

The general strike of the ore body is WNW – ESE which is almost parallel to

the trend of Kumaraswamy range i.e., East-West. The dip is towards North

with an angle varying from 150 to 16

0. All along the strike length of the ore

body the foot wall is characterised by Ferrugenous shale / tuff. Cherty

quartzite and banded hematite quartzite occur on the Northern flanks.

(3) Ore Types

NMDC has grouped all the ore types into 5 individual ore types, viz., Hard

ore (Type-1), Limonitised Laminated ore (Type-2), Soft Laminated Ore (Type-

3), Powdery Ore (Type-4) and Lateritic ore (Type-5). NMDC conducted

laboratory tests at R&D Laboratory on individual ore types.

10.2 Mineable Reserves

Estimation of Ore Reserves and Grade of Donimalai & Kumaraswamy Deposits




Mineable ore reserves have been computed within the pit limits of drawn on each

of the slice plans. Ore reserves following within the pit limits thus designed are

considered mineable reserves for mechanized operations.

(1) BLOCKWISE MINEABLE RESERVES, GRADE AND LUMP

RECOVERY OF DONIMALAI BLOCKS

AS ON 01.04.2013

Sl.

No. Block

Reserves in

Million

Tons (MT)

Grade % Lump

Recovery

(%) Fe

1 South Block 56.02 66.00 32.50

2 3E Deposit 12.52 65.34 25.30

3 2W Deposit 3.81 61.83 26.20

4 3W & 2E

Deposit 1.77 63.76 28.10

5 Beyond MM

Cross Section 21.37 65.86 31.51

Total 95.48 65.68 31.00

(2) BLOCKWISE MINEABLE RESERVES, GRADE AND LUMP RECOVERY OF

KUMARASWAMY

‘B’ & ‘C’ BLOCKS AS ON 01.04.2012

Sl.

No. Block

Reserves

in MT

Grade % Lump

Recovery

(%) Fe SiO2 Al2O3 P

1 Kumaraswamy

- ‘B’ Block 29.559 65.00 1.55 1.92 0.070 35.70

2 Kumaraswamy

- ‘C’ Block 100.421 63.85 1.85 3.15 --- 30.72

Total 129.980 64.11 1.78 2.87 0.070 31.85

10.3 Ore Characteristics

It is conceptualised that the feed material to the proposed Screening &

Beneficiation plant is (-) 100 mm, either from Kumaraswamy deposit or from

Donimalai or from Kumaraswamy and Donimalai deposits together. To generate

data in respect of:




(i) Physical & Chemical properties of Lump ore (-) 100 mm size

(ii) Product studies of proposed sized material (-) 30 (+) 6 mm size.

(iii) Product studies of proposed sized material (-) 6 mm

(iv) Product characterization and material balance

Representative samples of Kumaraswamy Mines were collected and mineralogical

tests conducted by R&D. Relevant data from test results have been considered for

the purpose of preparation of this Report.

Based on the test results of composite samples of Kumaraswamy Mines, Material &

Water Balance Diagrams are prepared (Refer Plate No. 1.1 & 1.2).




11. PLANT DESIGN AND LAYOUT

11.1 Layout considerations

o The proposed Screening & Beneficiation plant is planned to ensure best

possible interconnection with minimal disturbance to the existing facilities.

o The new Screening & Beneficiation plant-II is planned to make best use of

contours between existing lump ore Conv. 501 and fine ore Conv. 411 from EL

722m to EL 690m.

o Considering the topography, storage silos are envisaged instead of open

stockpile in order to have more live volume, clean & safe storage and easy

retrieval of material, which are eco-friendly.

11.2 Process flow sheet development

NMDC has adopted the screening, crushing and wet screening facilities based on

the results of the following tests conducted on composite sample of Kumaraswamy

ore.

o Mineralogy and liberation studies

o Chemical analysis

o Characterisation studies

o Settling studies

o Filtration studies

Based on the above, a conceptual process flow diagram (Refer Plate No. 2.1 & 2.2)

along with material and water balance is prepared by NMDC, which forms basis for

the design of plant and selection of equipment.

11.2.1 Material Balance

a) ROM input : 1800 TPH

b) CLO production rate : 819 TPH

c) Fines production rate : 938 TPH

d) Tailings / Slimes : 43 TPH

11.3 Feed Ore Characteristics

The Screening & Beneficiation plant is designed to handle ROM from Kumaraswamy

mines or Donimalai mines or both the mines and the specifications of feed material

are as follows:




a) Size of ROM : (-) 100mm

b) ROM Bulk density : 2.2 to 2.5 T/m3

(approx.)

c) Specific gravity : 4.5 to 5.2

d) Compressive strength : 4500 kg/cm2

e) Angle of repose : 350

f) Surcharge angle : 200

g) Bond work index : Up to 11

h) Moisture content : about 5%

i) Quality : Fe-63%, SiO2-2.74%, Al2O3-3.23% & LOI – 3.8%

j) Typical size analysis of feed

to the proposed plant : (+) 100 mm - 2.49 %

(-) 100 mm (+) 80 mm - 3.33 %

(-) 80 mm (+) 50 mm - 4.75 %

(-) 50 mm (+) 30 mm - 8.19 %

(-) 30 mm (+) 6 mm - 26.25 %

(-) 6 mm (+) 3 mm - 11.38 %

(-) 3 mm (+) 1 mm - 8.67 %

(-) 1 mm - 34.94 %

(The above size analysis may vary by 3 to 5 % points at each size)

11.4 Product Specification expected:

Products & Size CLO

(-) 30 mm (+) 6 mm

Fines

(-) 6 mm

Fe 64.29 % 62.44 %

SiO2 + Al2O3 6.0 (max.) 7.00 % (max.)

Over size (+) 30 mm – 5 % (max.) (+) 6 mm - 5 % (max.)

Under size (-) 6 mm – 15 % (max.) (-) 100 mesh - 25 % (max.)

11.4.1 As per the present scenario in the iron ore market and recent Government

directives for selling of iron ore products, the product size of calibrated lump ore

(CLO) shall be ( - ) 40 ( + ) 10mm and fines size shall be ( - ) 10mm. Though the test

works for the scheme was carried out and results were analyzed considering the

product size of CLO as ( - ) 30 ( + ) 6mm and fines as ( - ) 6mm, some tests were

redone and analyzed for product size of CLO as ( - ) 40 ( + ) 10mm and fines as ( - )

10mm. Accordingly, the recovery rate of CLO, fines, slimes, chemical analysis such

as %Fe, Al2O3, SiO2, apertures of the primary screen and secondary screen are

estimated. For change in specifying the product size, there will not be any change in

the process, whereas layout & design care is taken while developing the proposed

scheme. An indicative comparative statement for the different products size is as

below:




CLO Fines

(-) 40 (+) 10

mm

(-) 30 mm (+) 6

mm (-) 10mm (-) 6mm

Primary screen

aperture size (mm) 40 & 20 30 & 20

Secondary screen

aperture size (mm) 10 & 3 10 & 6

% Fe 63.75 64.29 62.26 62.44

% SiO2 1.65 1.08 2.73 2.91

% Al2O3 2.88 3.53 4.08 3.31

% Weight recovery 41.00 45.50 51.00 52.12

While preparing Tender Document for implementation of the Project, the above

aspect needs to be taken care in finalizing the specification of above screens

including tertiary screens.

11.5 Design Criteria

The total estimated available quantity of iron ore reserve available as on

01.04.2012, from Kumaraswamy Deposit and Donimalai Deposit is about 225

million tons. Therefore, new Screening & Beneficiation plant-II processing capacity

has been considered to be 7 MTPA in Phase-1 similar to the existing Screening &

Beneficiation plant-I and matching with capacity of Kumaraswamy Project.

Hence, to take feed @ 2000 TPH (design) from Kumaraswamy downhill conveyor,

Screening & Beneficiation Plant-II is envisaged with 4 lines (3 working and 1

standby) for processing ROM of 7 million tons per annum (MTPA) for reliable &

continuous trouble free operation. Each screening line is envisaged to operate at

650 TPH rated capacity with design capacity of 750 TPH.

Taking a view of in-built operational allowance, it has been considered that the

Screening & Beneficiation Plant will be operating at rated capacity of 1800 TPH to

achieve projected target of 7 MTPA ROM handling.

The Plant capacity will be augmented to 10 MTPA in Phase-2 in future by adding 2

more lines for which required provision would be made.

11.6 Scheme Proposed

Overall plant layout of the proposed scheme is shown in Plate no. 3 and description

of the proposed Screening & Beneficiation plant (Refer Plate No. 4.1) is as follows:

11.6.1 Screening & Crushing

• The ROM of Kumaraswamy mines or Donimalai mines or both the mines is

stored in silos of about 4000 tons (each) storage capacity. The lump ore [(-)




100mm] is extracted through apron feeders and fed to double deck primary

screens (with 30mm & 20mm apertures) through belt conveyor.

• The oversize material of primary screens is fed to tertiary crusher to crush (-)


primary screen are fed to CLO conveyor and secondary screens respectively.

• The crushed ore of tertiary crusher is fed to double deck tertiary screen (with


circulated to tertiary crusher. The middle fraction of tertiary screen (-) 30 (+)

6mm and under size fraction (- 6mm) of tertiary screen are fed to CLO product

conveyor and fines product conveyor respectively.

• Under size of secondary screen is fed to classifier of wet circuit system.

Suitable gate arrangement is envisaged at the bottom of under size chute of

secondary screen, which diverts material to launder leading to classifier circuit

when operating on wet mode. Under dry mode the gate will be lifted /

opened to divert the material to fines conveyor.

• Conveyor receiving middle fraction [(-) 10 mm (+) 6 mm] of secondary screen

is envisaged with reversible operation to feed the material either to fines

conveyor or CLO conveyor based on the requirement.

11.6.2 Wet Circuit

• Process water after washing of iron ore contains high concentration of

suspended solids (iron ore fines) and is called as slurry, which is collected from

underflow chute of secondary screens in a ore processing plant for

beneficiation to attain the following objectives:

(i) To minimise slime loss by more fines recovery

(ii) To recover process water for recirculation

(iii) To deposit less tailings (iron ore bearing) in tailing dam

• Classifier overflow is fed to dewatering screen and the underflow to hydro-

cyclones. The overflow of dewatering screen is fed to fines conveyor and the

underflow is fed to cyclones. The cyclones (with separation size of 150

microns) overflow is diverted to thickener and the underflow to filtrate unit to

recover some fines, which in turn is fed to fines conveyor.

11.7 Technological Facilities

The plant shall comprise of tertiary crushing, screening, classifying, filtering and

conveying facilities to be set up in an integrated manner and consists of the

following technological units. The description of the technological facilities specified

in this chapter is as proposed for this plant and as per the drawings enclosed.




11.7.1 Travelling Tripper & Tripper Conveyor

Ore conveyed either from KIOM or DIOM or both is extracted from a storage

bunker at the discharge of downhill conveyor BC 723 of KIOM and feed to a

1200mm wide tripper conveyor (@ 2500 rated capacity with 10% design margin)

provided with travelling tripper, which feeds to silos.

11.7.2 Silos

Four numbers - RCC silos of about 8m square (inner dimension) and about 40m

height for storage of 4,000 tons (each silo) of ROM ore from secondary crushers of

either KIOM or DIOM or both are envisaged.

11.7.2.1 Functional Design of Silos/Bins of Reliable Gravity Flow

The extraction of the ore from the silos is based on gravity flow. The problems

associated with the silos/bunkers, hoppers and transfer chutes while handling Iron

ore are numerous particularly when the bulk solid contain a significant portion of

fines at higher moisture levels. The typical flow problems include “No flow”,

“Reduced live capacity”, “Segregation” etc., which significantly affect the

performance of the plant in general.

A properly designed silo system results in better capacity utilization, better flow

rate control and an improved uniformity in the extraction of the ore. For this,

proper geometrical configuration of silos suitable for specific iron ore application is

important, in order to minimize or avoid the flow problems.

The functional design of proposed silos/bins shall conform to IS 9178 (Part 3) for

reliable gravity flow. The flow properties of Iron ore proposed to be handled in the

silos at different moistures is to be established in the laboratory by using the Jenike

shear tester. The parameters like Internal angle of friction, wall angle of friction and

flow function thus established form the inputs to arrive at the silo design

parameters like minimum slope and outlet dimensions. The minimum slope and

outlet dimensions of the silo vary with the geometry and the wall liner used for

specified flow regimes like Mass Flow or Expanded Flow. Normally, an abrasive ore

like iron ore shall be stored in a silo designed to promote Expanded Flow (bottom

portion Mass Flow and top self emptying Funnel Flow).

The trouble free movement (flow) of ore from the silos/bunkers/hoppers and

transfer chutes play a vital role in the productivity of the screening plant. It is also

required to exercise due care while designing the transfer bin / transfer chutes in

order to avoid plugging and excessive wear. The minimum wall inclination to

initiate flow after impact depends on the ore moisture content as well as the

friction between the liner used and ore.

The outlet size and slope of the bins envisaged in this report are largely in order for

the envisaged application based on flowability tests conducted (May, 2012) by R&D

Centre on Kumaraswamy composite sample. However, fine tuning of functional




design of silo/bin and transfer chute shall be carried out based on flow properties

of combined sample of Kumaraswamy & Donimalai Deposits after required test

works at NMDC R&D Centre during further course of engineering.

11.7.3 Apron Feeders

Apron feeder - one number for each line for extracting ore from silo to feed primary

screen feed conveyor. The design capacity of apron feeder and belt conveyors

(1200mm wide) is 800 TPH.

11.7.4 Primary Screen

The double deck vibrating screen of circular motion/linear motion vibrating screen

of 2400mm x 6100mm size is considered in each line. The screen is mounted on

rigid structural support in the screen building. The rated capacity of the screen is

650 TPH. The design capacity of the screen is 750 TPH.

11.7.5 Secondary Screen


of 2400mm x 6100mm size is considered in each line. The screen is mounted on

structural trolley in the screen building. The design capacity of the screen is 550

TPH.

11.7.6 Tertiary Crusher

Two Nos. (1 working & 1 standby) 7’ cone crushers for crushing (-) 100mm ROM to

30mm are considered with operating capacity of each about 750 TPH (500 TPH

fresh feed & about 250 TPH recirculation load). The crusher foundation is designed

for dynamic loading and is isolated from main building foundations.

11.7.7 Tertiary Screen


of 2400mm x 6100mm size. The decks are of 30 mm & 6 mm aperture panels for

screening the material. The screen is mounted on rigid structural support in the

screen building. The rated capacity of the screen is 650 TPH. Two nos. screens (One

working and one standby) are envisaged. The design capacity of the screen is 750

TPH.

11.7.8 Classifiers

Secondary screen underflow is diverted to classifier (4 Nos. - 72” dia. and 37’ long)

for separation of 150 microns. The raking capacity of each classifier is considered as

350 TPH. The raked sand is diverted to fines product conveyor and the overflow is

fed to hydro-cyclone.




11.7.9 Dewatering screens

4 Nos. Dewatering screens of 2400mm X 6100mm are envisaged to dewater the

classifier sand.

11.7.10 Hydro-cyclones

Classifier overflow and dewatering underflow is fed to cluster of hydro-cyclones for

separation size of 150 microns. The underflow of cyclone is fed to filter circuit. The

overflow of hydro-cyclone is fed to tailing thickener. Two circuits of cyclones are

considered in series, one circuit of desliming cyclone and one circuit of densifying

cyclone.

11.7.11 Tailing Thickener

The overflow from the cyclone is fed to φ35m hi-rate thickener (1 number) for

thickening. The capacity to handle feed is approximately 150 TPH solid. The

thickener is of civil construction and it consists of flocculent system for faster

settling.

The under flow is pumped to the tailing dam by slurry pump provided below the

thickener. A stand-by pump is also considered. The slurry is transported through

rubber lined MS pipeline of approximately 200m & 1110m length into Tailing dam-1

& 2 respectively. Density meter and flow meter is provided in the discharge line for

measuring the density of the slurry. The pump suction is provided with

automatically operated knife gate valve for isolation. Flush water is provided in the

suction line for cleaning the pipeline before starting and after stopping of pump.

11.7.12 Slurry Pumps and Sumps

The sumps are fabricated with MS plate and rubber lined for abrasion resistance.

The sumps are provided with ultrasonic level sensor for measurement of level.

Make-up water line with automatic modulating valve is provided for each sump.

The level measurement from ultrasonic level sensor is interlocked with the

automatic modulating valve to ensure the sump level is maintained within the pre

determined level to avoid starving of the pump.

The slurry pumps are of heavy duty abrasion resistance centrifugal pumps. The

impeller and casing are rubber lined / hard metal for handling abrasive slurry. The

slurry pumps are driven through Variable Frequency Drive (VFD).

The suction lines are of MS pipe with rubber lined and provided with automatic

knife gate valves for isolation purpose. The flush water line is provided to clear the

slurry, if any before starting and after stopping of the pumps. A drain valve is

provided for draining out slurry from the pipeline. All discharge lines are of MS pipe

with rubber lined and provided with the magnetic flow meter to measure the flow

rate. Nucleonic type density meter is provided in tailing disposal pipe line.




11.7.13 EOT Cranes

EOT cranes and suitable handling facilities at various locations are considered in the

Plant for servicing and maintenance of equipment and facilities.

11.7.14 Belt Conveyors

All belt conveyors are 1200mm wide provided with skirt-boards, chutes, safety

switches, scrapers, take-up units etc. Skirt-board shall be suitably lined with liner

plates (preferably chrome-carbide liners) while chutes with Mn-steel liners at

impact/abrasive zones. The belt conveyors running at out-door are provided with

covered structural gallery with maintenance walk-ways on both sides.

11.7.15 Horizontal Belt Feeders (HBF)

Horizontal belt filters are considered to recover some iron values and also to

recover some water in the process, from under flow of densifying cyclones. Slurry

from densyfying cyclone underflow is passed on to a moving perforated belt

conveyor, which allows filtrate (water) to drain through the perforations on the belt

and collected suitably by vacuum principle. Filter cloth fastened on the belt top of

perforated belt conveyor retains slurry at the feeding end and as it moves towards

discharge it holds the cake to be discharged at the head end. Three units are

considered in the circuit with two operating and a standby.

11.8 Service & Common Facilities

11.8.1 Process Water Circulation System

The process water requirement for Screening & Beneficiation Plant-II is as follows:

Sl. No. Consumer Qty. (m3/hr)

INPUT

1 Process water for Primary screen 1440

2 Process water for Secondary screen 1011

Total 2451

OUTPUT

1 CLO 55

2 Fines 156

3 Thickener underflow 64

4 Thickener overflow 1117

5 Cyclone overflow 736

6 HBF Filtrate 322

Total 2451

MAKE UP WATER

1 Products 276

2 Extra for floor washing , dust control etc., 90

366




A recirculation water tank of 5000 m3 capacity is envisaged to receive the cleaned

water from the tailings thickener and the size of tank is 35m dia. & 5.5m height.

The makeup water requirement for the process will be brought by a pipe line from

the Donimalai filter house / WTP to make up water storage tank located at +745.00

m level near the Screening & Beneficiation plant-II. Water balance for the plant is

indicated in Plate no. 1.2.

11.8.2 Make-up Water Supply System

The make-up water required for the project is pumped from the water treatment

plant at Donimalai base. 2nos. (1W+1S) pumps of capacity 500 m3/h with a head of

about 700m are envisaged to pump water from Sump at WTP to 5000 cu.m

recirculation tank near the Screening & Beneficiation plant-II. A pump room is

envisaged to accommodate make-up water pumps adjacent to the water storage

sump at WTP.

Currently the sanctioned quantity of water from Narihalla dam is 745 cum/hr.

Presently Project is withdrawing water @ 350 cum/hr. The proposed augmentation

of water supply from Narihalla dam for another 400 cum/hr (total 745 cum/hr) is

under progress.

11.8.3 Dust Control System

Dry Fog Dust Suppression System is considered for various material transfer points

at Screening & Beneficiation Plant-II. The fugitive air borne dust generated during

material transfers at conveyors, crushing, screening, etc., will be suppressed by

superfine atomization of water droplets produced with the help of compressed air

to form a blanket of extremely fine fog to entrap the fugitive air borne dust such

that the suppression is achieved due to agglomeration by impact of dust particles

with water droplets until mass becomes heavy enough to cause the particle to

settle on the main material without wetting the product being handled.

The system shall comprising of MS water tanks, pipe work, nozzles, solenoid valves,

manual shut-off valves, pumps (one working and one stand-by), air compressor

(one working and one stand-by), all necessary electrics with MCC and

instrumentation required for operation of the system through PLC etc.,

11.8.4 Fire Fighting

Fire fighting extinguishers will be suitably located in transfer towers and buildings in

their respective maintenance and operating floors.




11.9 Tailing Reservoirs

The locations of the proposed tailing ponds of 8 MT & 5.4 MT capacity are indicated

in the Plate No. 14 will be used for storage of tailings of the new Screening &

Beneficiation plant-II. Area of tailing dams considered is about 9 Ha (initial stage)

and 16.2 Ha (second stage).

11.10 The final products Fines & CLO are proposed to be carried to stockyard through

existing fine ore conveyor and CLO conveyor systems. To meet the increased

production rate, a proposal for augmentation of BC 411 is ready and is to be

implemented appropriately. In a similar manner augmentation of CLO conveyor

systems should be taken up appropriately.

Existing stocking and loading facilities are proposed for the utilization of dispatch of

the products. However, a proposal for additional fine ore stockpile for increased

production fines and a loading line is in pipeline. This additional loading line will

take care of the increased production rate of CLO, fines and other products like

pellets, etc.

11.11 The requirements / facilities described / envisaged here are indicative and may

undergo change for design improvement, process and layout optimization, if any,

during further engineering stage.




12. CIVIL AND STRUCTURAL WORKS

12.1 The following facilities are envisaged for the subject work

1. RCC Silos 4000T cap. each-4 nos., with lift & staircase,

2. RCC Silos for future provision- with foundation & walls up to plinth,

3. Primary & Secondary Screening Plant buildings with EOT crane of 30/5 & 15/3T

capacity

4. Tertiary Crusher House (TCH) building with EOT crane of 30/5T capacity,

5. Tertiary Screening House (TSH) ,

6. Conveyor galleries nos. 801, 806, 810, 812, 813, 814, 819, 823, 829 & 832.

7. Junction Houses nos. JH-1 to JH-4,

8. Horizontal Belt Filter Building,

9. Thickener – 1 no. of dia. 35m,

10. Ground Level Reservoir (GLR) of 5000 cu.m capacity,

11. Plant office, Canteen & Rest shelter buildings,

12. Service roads (2.0 km) to all facilities with drains, culverts, metal crash barriers

on Valley side at turnings,

13. MCC Buildings – 2 nos., size 18m x 10m.

12.2 For the above facilities, the following civil & structural works are considered

A. Civil Works

1. RCC Silos of 4 nos. each 4000T capacity of size 8m x 8m with top elevation fixed

at RL (+) 762.25 (approx). Accordingly, earthwork, RCC quantities etc. have been

worked out. Further, for future provision, 2 nos. of silos kept and foundation &

walls up to plinth level has been considered for easy vertical rising of

superstructure only, if required, later. 25mm thick Mn steel liners are suitably

considered in the walls and hopper area of silos.

2. Earthwork excavations in over area and in foundations are considered including

back-filling. An average lead of 5 km considered for disposal of 280,000 cu.m

excavated earth. This is proposed to be dumped in an area to be identified by

project, later.

3. RCC M25 grade (conforming to IS: 456-2000) are considered in RCC silo,

Screening & Beneficiation plant, TCP, TSP, Junction houses, MCC buildings,

Office building, Canteen, Rest shelter building etc. Design mix for RCC in silo

structure shall be used.

RCC M20 grade (conforming to IS: 456-2000) is considered in retaining walls,

drains, cross drainage works etc. All steel reinforcement shall be of Fe-415

grade conforming to IS: 1786 (latest version).

In Junction houses, RCC floor slabs (M25 grade) supported on structural beams

are considered to support machines/equipment. CC flooring above hard soling




at ground levels of junction houses is considered including CC apron around

with drains all-round.

Mud mat PCC (1:4:8) below foundations.

4. Service roads of 10m wide (7m bitumen carpet width & 1.5m shoulders width)

with 1 in 16 longitudinal gradient and 1 in 20 on curves are considered for

access to all plant facilities and connecting to existing road. Double W-Beam

metal crash barriers on valley side of roads are considered with RCC drains &

culverts.

In the construction stage, only soling and metalling works in roads shall be

carried out with proper consolidation. The bitumen carpet work shall be done

after opening to traffic and after one rainy season.

5. Automatic Fire Detection and Suppression System (FDSS) is considered for

conveyor between down-hill conveyor system of KIOP and Tripper Conveyor.

6. NMDC shall carry out preliminary soil investigation works in the plant areas for

inclusion of the sub-soil test results in tender documents, which will serve as a

general guidance to tenderers about the sub soil type and strength in the area.

However, turnkey contractor shall carry out both detailed survey and soil

investigation works in the plant areas for doing engineering of plant structures

and their design of foundations; earth cut slopes and benches etc.

B. Structural Works

1. Supply, fabrication and erection of all structural steel works in plant buildings,

junction houses, conveyor galleries & supporting trestles, HGTU’s/VGTU’s are

considered.

2. The structural steel shall be of Grade Fe-410WA & Fe-410WB as required

conforming to IS: 2062.

Pre-coated colour galvalume sheeting (Steel grade 550 Mpa, Zn coating not less

than 120 gsm, 0.50mm TCT) in both roof and side sheeting of all houses and

galleries are considered.

FRP translucent sheeting of 2mm thick (conforming to IS: 12866 having

matching corrugations to galvalume sheets) are also considered on side

sheeting only. The quantity of FRP sheeting shall be 15% of total sheeting in

both roofing and cladding put together.

3. Both primer and finish paintings (total DFT of 205 microns) to structural steel

surfaces are considered.




4. Necessary modification/dismantling works at interfacing areas of new galleries

with existing conveyor nos. 504 & 411 are considered.

5. Clearance of 6m (min.) below structural conveyor gallery at road crossing points

is considered. Muck tray plates below galleries at these crossing points are also

considered.

6. Monorails of sufficient capacity at all floor levels in Junction houses / Plant

buildings to handle machine / equipment are considered. Doors of sufficient

size in all buildings / houses are considered towards approach road side.

C. Enabling Works

These works include construction of site office (semi-permanent) required

during survey, soil investigation works in the area. Construction water supply

required during construction shall be drawn from existing near-by sources.

Provision for enumeration of trees in the area is kept in the estimate.

Enumeration shall be done by project with local forest department.

12.3 Scope of Major Civil Work

The scope of major civil works includes, but not limited to, the following

• RCC Silos

• Screening & Tertiary Crushing Plant building foundation, platform slabs and

Equipment foundations

• Conveyor foundations

• Junction Houses

• RCC Elevated Thickener

• Makeup water pump house with pipe line (500 cum/hr)

• Filter water tank (63 m3/hr)

• Main water pump house with RCC recirculation tank of 5000 m3

/hr.

• Office building with store rooms

• Roads, Drains and Cross Drainage

• Electrical Substation and MCC / control room building etc.

12.3.1 General

The general specifications / details in respect of type of structures, grade of

concrete, materials, etc. for all major units have been assumed to be similar to

standard practice of civil works as per relevant latest Indian standard codes.

12.3.2 Site Grading/Plant Level Philosophy

The general topography of the site for Screening & Beneficiation-II is undulating

and surrounded by hills. Proposed plant area has been divided into number of sub-




areas. Finished ground levels of the unit and other non plant areas have been fixed

to minimize cut and fill. This has resulted in step formation due undulating area of

the site. Overall grading pattern is such that it facilitates good drainage.

12.3.3 Roads

The principal roads are 6 m wide whereas other roads are 4 m wide. Road width

covers carriage way and berm but excludes drain or bund. Generally the finished

road level is 300mm above FGL. Being hilly terrain, maximum permissible gradient

is limited to 1:20 and occasionally 1:16.

12.3.4 Drains

Concrete apron shall be provided around the Plant building with side drains. From

plant & non plant building area, the rain water is collected through drains in a

settling pond and finally discharged to existing Nala, as is the present practice at

Donimalai. A plant drainage system of trenches for collection and disposal of rain

water has been developed to meet environmental objectives. Drains are self

cleaning with a minimum slope of 0.2%.

Open trapezoidal and rectangular shape drains are provided along with pipe

culverts and box culverts are considered for drainage system. The sanitary waste is

collected and treated through septic tanks and soak pits. Existing network of water

supply is extended to cater to the proposed area requirements with suitable

storages, pumps and piping network.

12.3.5 Layout Plan

The overall Layout plan (Refer Plate No. 4.1) is developed keeping in view the

overall material flow and vacant areas available for locating new facilities. Efforts

were made to locate the new facilities within the land available with NMDC. The

Overall layout Plan shows all process & non process units and other Plant facilities.

12.3.6 Primary Screening Building

Primary & Secondary screening building is located on the adjoining hill near to the

existing Screening & Beneficiation plant. The arrangements of facilities are

indicated in the drawings enclosed.

12.3.7 Tertiary Crushing & Screening Building

Tertiary crushing plant building is located on the slope adjoining the Primary

Screening Building at a suitable distance to permit transfer of material to feeding

Tertiary Crusher and tertiary Screens.

12.3.8 Others




Outdoor switch yard is proposed for feeding the electrical loads of the new

facilities.

12.3.9 Foundation system

Open cast foundations are envisaged for all plant structures. The costing for this

Report is based on the assumptions that open foundations will be used for all

structures.

12.3.10 Water proofing for underground RCC basement structures

All underground basement structures like sumps, etc. in contact with earth shall

have standard water proofing treatment mainly consisting of the following:

� Water proofing paint to be provided in outside faces of walls and base raft in

contact with soil.

� Pressure grouting through perforated and threaded nozzles (to be inserted

during concreting) along the constructions joints only.

� All underground RCC basement structures (base raft, walls, etc.) have been

assumed to be designed as cracked section. However, water retaining

structure like underground/partly underground/on ground water reservoirs/

sumps etc. have been assumed to be designed as uncracked section as per

relevant Indian standard codes.

12.3.11 Concrete grade

In general the following concrete grades will be adopted for RCC & PCC works.

• RCC works

M – 25 RCC works for all foundation works, substructures, superstructure

elements of all plant buildings

M – 20 RCC works for drains, base slab of grade floors and intermediate

floor slab and roof slab supported on steel superstructures and

cable trenches, etc.

• PCC works

M – 10 Lean concrete below foundations, etc.

M – 15 For PCC works in drain, screed concrete, etc.

12.3.12 Building material

• Cement

In general cement shall be ordinary Portland cement conforming to latest IS

standards.

• Reinforcement steel for RCC

For all RCC work, reinforcement bars shall be TMT bars of Fe415/500 grade with

strength requirement conforming to IS 1786-1985.

• Brick/ solid concrete block masonry work




Brick/solid concrete block shall be of locally available best quality conforming to

the architectural requirements.

12.4 Design of steel structures

o Steel structures will be designed to meet the technological requirements and

general conditions of the projects on totality basis.

o In order to achieve maximum economy in the use of steel, the frames will be

designed as rigid portals.

o Design of steel structures will be carried out as per IS: 800-2007and/ or any

other recognized standards approved/ accepted by the agencies concerned.

Adequate ventilation will be provided in the buildings for successful operation

of the plant & equipment installed therein.

o All staircases will have a minimum width of 800 mm formed from chequered

plates or Open grid panels. The slope of staircases will be preferably within 36

to 40 degrees.

o Hand rails of platforms will be of tubes. The top rail will be 1.1 m above

platforms level. The top rail, knee rail and the posts will be tubes and toe

guards will be of steel plates (i.e. skelp plate).

o The thickness of structural elements will not be less than 6 mm (except for

webs of rolled Sections). An allowance for corrosion is kept for structures

exposed to outside atmosphere. In case of load bearing welds the thickness of

fillet welds shall not be less than 6 mm.

12.4.1 Loading

Superimposed loads to be considered in the design of steel structures are as per IS:

875-1987 in addition to technological loads, if any. Live loads for platforms, stairs,

etc. are 300 kg/m2 unless other-wise specified.

Design of buildings and structures for the effect of wind load shall be carried out as

per IS: 875 (Part-3)-1987. Design of buildings and structures for the effect of seismic

loads shall be carried out as per IS: 1893-2002.

12.4.2 Method of construction

All steel structures are generally of welded construction. However, structural

members like roof purlins and side runners will be of bolted construction.




12.4.3 Material of construction

o All structural steel sections and plates up to and including 20 mm thick shall

conform to IS: 2062-2006 Grade A and plates of thickness more than 20 mm

thick shall conform to IS: 2062-2006 Grade B.

o Crane rails shall conform to IS: 3443-1980.

o Non designed sections such as walkways shall be of steel conforming to IS:

977-1995 and Handrail tubes shall conform to IS: 1161-1198 and toe guard

skelp plate shall conform to IS: 1079-1994.

o Roofing and Side sheeting shall be of 0.68 mm thick Industrial Troughed

Colour Coated Steel Sheets.

o Electrodes shall conform to IS: 814-2004

o Black hexagonal bolts, nuts shall conform to IS: 1363-1992.

o Primer paints conforming to IS: 2074-2002 and Finish paints conforming to IS:

2932-1993 will be used.

12.5 Standard and codes of practices

Standard and codes of practice referred to do this job shall be as per Indian code of

practice.

12.6 Basis of Working of Quantities & Rates

The Civil & Structural works have been worked out based on the scheme layout

and site contour drawings.

The earthwork quantities for all plant buildings and service roads are calculated

based on the contours and finished floor levels shown in the scheme drawings. The

RCC and structural steel quantities have been worked out based on the geometry of

plant sizes and general sizing of various civil & structural members arrived in similar

works of Dep.10&11A, Dep.11B, Kumaraswamy Project etc.

12.7 The works and requirements listed above are indicative and may undergo change

for improvement / optimization of the scheme if any, during further engineering

stage.




13. ELECTRICAL & CONTROLS

13.1 Power Required

The estimated power requirement of the proposed plant is as follows:

13.2 Source of Power Supply

The incoming power supply for the proposed Screening & Beneficiation Plant-II is

planned to tap from existing Valley sub-station through over head line (11kV) /

underground HT cable(11kV), which is about 2 km distance. 3.3kV HT supply shall

be considered for the equipments whose power rating is 160kW and above. One

number 11kV HT switch board (Incomer, Power Transformer feeder & Lighting

transformer feeder and one no. of 3.3kV HT switch board, 14 feeders app.) is

envisaged. As the number of LT equipments are more, two number of intelligent LT

MCCs (80 feeders of various ratings) are envisaged. One number of 2.5 MVA,

11kV/3.3kV Power transformer, one no. 2.0 MVA, 3.3kV/440V distribution

Transformer, one no. 125 kVA, 11kV/230V Lighting Transformer is considered.

13.3 Power distribution system

The 11 kV over head power line / underground HT cable at proposed Screening &

Beneficiation plant-II from the proposed 33/11 kV substation shall be terminated in

a DP structure. For further power distribution it is envisaged to provide one number

11/3.3 kV transformer of suitable rating, 11kV & 3.3 kV switch boards, 3.3/0.433

transformer of suitable rating 125kVA, 11kV/230V, Ph-Ph for, lighting transformer,

LTMCC, MLDBs, LDBs & other equipment as required. All connections from the DP

structure onwards are foreseen by means of cables.

13.4 Design Considerations

o The design of power distribution system and selection of equipment shall be

based on the main considerations of reliability, ease of operation &

maintenance, simplicity, safety and as well as convenience of future

expansion.

o The equipment shall conform to relevant IS/IEC specifications and code of

practice to meet the operational requirements and to ensure reliable and

trouble free service in the plant.

o Electrical switchgear rooms shall be of ventilated design maintaining slight

positive pressure to exclude dust from entering. The enclosure class of

switchgears shall be IP42 or better.

• Maximum Demand (Screening &

Beneficiation Plant - II)

: 1.5 MVA

• Annual Energy Consumption : 7.2 MU




13.5 Basic Design Parameters

Incoming Power supply : 3.3 kV, 3 Ph, 50 Hz

Utilisation voltage : 3.3 and 415 V, 3 ph, 50 Hz

Motors rated above 160 kW : 3.3 kV, 3 Ph, 50 Hz

Motors rated 160 kW & below

and other LT consumers : 415V, 3 ph, 50 Hz

Illumination : 240 V, phase to phase, 50 Hz

Auxiliary supply : 240 V, 1Ph-Nuetral, 50Hz

Control power supply

AC : 240 V, 1Ph-Nuetral, 50Hz

DC : 110 V

System Earthing

- 3.3 kV : Resistance earthed

- 415 V : Solidly earthed

Maximum Symmetrical Short Circuit level considered for the system

- 3.3 kV bus : 13.1kA (rms) for 1 sec

- 415 V bus : 35kA (rms) for 1 sec

13.6 Major Facilities

13.6.1 HT Switchgear

11kV switch board with required incomer is also envisaged. The 3.3 kV switchgear

envisaged shall be indoor, sheet metal clad type with draw-out VCB circuit breakers

and shall be provided with necessary protection, control gear, metering and audio-

visual alarm annunciation system. The circuit breaker mechanism shall be

mechanically and electrically trip free. The circuit breakers shall be electrically

operated, stored energy type and shall be operated on 110 V DC control power

supply.

13.6.2 415 V Switchgear

The 415 V switchboard shall be sheet steel enclosed, non-draw out type in multi

tier formation. The switchboard shall be provided with incomer of draw-out type

and required number of outgoing motor and power supply feeders as per

requirement and shall include spare feeders of each type/rating. The air circuit

breaker shall be electrically operated and equipped with microprocessor based

direct acting releases for over load and short circuit as well as earth fault

protection.

The motor feeders shall be provided with MPCB/MCCBs with magnetic release,

thermal overload relay and contactor so as to provide Type 2 co-ordination. In

addition, motor feeders shall be equipped with CBCT and Earth leakage relay.

MCCBs shall be provided for outgoing power supply feeders. The MCCBs shall be

equipped with direct acting O/L, S/C releases and earth fault module with in-built




CBCTs. The 415V switchgear and control-gear shall conform to IS-8623 and IS

13947.

13.6.3 Transformers

The 11/3.3 kV transformer is envisaged at Screening & Beneficiation plant shall be

outdoor, ONAN, oil immersed, three phase, copper wound type as per IS-2026. The

3.3/0.433kV transformer envisaged at the Screening & Beneficiation Plant shall also

be of ONAN outdoor type’. Lighting transformer shall be of dry type with class H

insulation and temperature rise limited to class ‘B’. The rating of transformers shall

provide a design margin of 20%. Transformer magnetic core shall be made of low

loss CRGO silicon steel sheet of thickness not exceeding 0.3 mm.

The windings shall be made of electrolytic grade copper and shall be vacuum dried.

Inter turn and inter coil insulation shall be so designed that the di-electrical stress is

distributed uniformly throughout the winding under all operating conditions.

The transformers shall be designed to withstand short circuit on the secondary side

for duration of 2 seconds without any damage. Off circuit tap-changers shall be

provided for 11/3.3 kV transformer whereas for the 3.3/0.433 kV transformer, taps

with links has been foreseen. All the standard accessories such as conservator,

breather, Buchholz relay, OTI, WTI, oil level gauge, valves, explosion vent etc. shall

be provided for the 11/3.3 kV transformer. The dry type transformer shall be

provided with embedded RTDs and temperature scanner.

13.6.4 Cables

Power inside the plant shall be distributed through cables to various loads. Where

possible, cables shall be laid along wall/columns inside enclosed premises with

power cables being laid in ladder type GI cable trays and control cable laid on

perforated cable trays. Elsewhere, depending on constraints, cables may be buried

directly.

All 11 kV (UE) and 3.3 kV (UE) cables shall be heavy duty, XLPE insulated, PVC

sheathed, multi core, aluminum conductor, steel wire armoured suitable for

resistance earthed system.

Cables for 415 V systems shall be heavy duty, 1.1 kV grade, XLPE insulated, PVC

sheathed aluminum conductor, armoured / unarmoured as required. The control

cables shall be multi strand copper conductor, PVC insulated and PVC sheathed

with minimum cross section of 1.5 mm2 for control circuit and 4.0 mm

2 for power

circuit.

The HT cables shall conform to IS-7098 –1985, whereas LT power and control cable

shall confirm to IS-1554-1988 and IS-5831.




13.6.5 Shop Electrics

Power supply to all drives up to 160 kW and other loads operating at 415 V, 3

phase, 50 Hz system is envisaged through motor control centers (MCC). Motors

rated above 160 kW shall be supplied power from 3.3 kV H.T switchboard.

All motors shall be TEFC type and provided with class F insulation with temperature

rise limited to class B insulation, with enclosure class IP55. The motors generally

shall be squirrel cage type suitable for direct on line starting.

Slip ring induction motors is considered for cone crusher. Use of energy efficient

drive motors shall be preferred in general. Process building shall be provided with

100A, 415V interlocked receptacles as well as small power industrial socket outlets.

13.6.6 Illumination

Illumination for the Screening & Beneficiation Plant is foreseen through LDB, SLDBs

and appropriate luminaries. The LDB shall be fed from MCC through 415/230V dry

type lighting transformer LDBs shall supply power to the various sub-lighting

Distribution Boards (SLDBs) installed in various locations. The internal illumination

of process buildings shall be with HPMH light fittings. Average illumination inside

the shop building shall be 150 lux, wherever high colour rendering is required (low

colour distortion); metal halide lamp fittings shall be used.

Switchgear rooms/Control rooms shall be provided with decorative light fittings

employing CFL/LED lamps to attain illumination level of 300 lux.

All the approach roads shall have street lighting up to 100 m from plant. Area

illumination shall be provided with HPMH flood light fittings. The average

illumination level shall be 15 to 30 lux for outdoor illumination. 4 numbers of 25 m

height high mast towers are also envisaged for outdoor lighting with minimum of 8

numbers of 400 W HPMH lighting for each tower.

13.7 Instrumentation / Automation / Communication & Networking

13.7.1 Instrumentation and Automation

Instrumentation system has been envisaged with adequate measurement and

control and monitoring facilities with a view to attain efficient, reliable and trouble-

free operation of the plant and its facilities, safety of the plant, equipment and

operating personnel and user friendly man-machine communication.

For this purpose, hierarchical process control of the plant and equipment has been

envisaged. The automation equipment and devices have been identified by

different levels. The latest state-of-the art instrumentation and automation

equipment from product have been envisaged for the plant.

Instrumentation system shall generally consist of Micro-processor based two-wire

field instruments, Smart type (HART) transmitters. All the Instrumentation &




control equipment shall be new and supplied from the latest product-ranges of

reputed and approved manufacturers / vendors.

In addition to required measurements and controls, adequate sequential and safety

interlocks and logic functions, monitoring and display of all abnormal process

operating conditions have also been envisaged. Final control elements will be

pneumatically or electrically actuated types depending on specific application.

All Slurry pumps shall be VFD driven fitted with Flow indicating Transmitters for

better control of the operation.

Nucleonic type Density Transmitters shall be provided based on the critical

requirement.

Process Water Sumps shall be provided with Ultrasonic Level Transmitters.

Silos/Bins shall be provided with Radar type Level Transmitters along with paddle

Switch.

13.7.2 Control Hierarchy

The control and Automation system (PLC) shall be designed with geographical &

functional distribution of hardware in a multi-level hierarchy, via, Level-0, Level-1,

etc, as applicable, to meet specific plant requirements for monitoring, control,

process visualization & optimization of all the plants / shop units.

The instrumentation & automation system shall be structured in general,

considering the following hierarchical levels:

Level-0

This level is realized based on the primary sensing elements, transmitters, switches,

converters; microprocessor based intelligent systems and final control elements.

The components of this level shall be grouped and distributed geographically

around the plant as per main process equipment location.

Level-1

This level, also called supervisory level, is functionally responsible for supervision of

the individual process equipment & functions, monitoring, control, visualization and

regulation of process parameters to the desired level based on the signals

generated from the field level. This level is also responsible for processing of signals

for generating compatible control commands to control the process parameters by

activation of the final control elements.




Level-2

This level is realized based on the controllers & systems, input & output systems,

data base units, data communication, visualization system (HMI stations) and

interface units for connectivity to the other levels of the instrumentation &

automation system. In addition to routine PID functions, advanced process

optimization functions comprising special control algorithms, mathematical

computations etc. will be able to permit distribution of control and data acquisition

functions throughout the entire plant.

13.7.3 Appropriate Instrumentation & Automation is envisaged for the following:

a) Equipment: Storage Bins, Belt Weigh Scales, Tertiary Crusher, Screens, Metal

Detectors, Classifiers, Thickener.

b) Belt conveyors.

c) All sumps / pumping system are provided with measurements / controls for

flow, density, level, speed, pressure etc.

d) Screening & Beneficiation Plant and other units are controlled from the

Central Control Room (CCR).

Control instrumentation equipment will be microprocessor based Control System.

This will basically comprise of colored video monitors with keyboards, log, event

and alarm printers, colored hard copy units, field control stations, Input/output

Systems, power supply units, control and communication processors. Data High

Way and interfacing facilities for integrated operation with programmable logic

controllers. Suitable power supply and distribution network has also been

envisaged.

The PLC system shall be microprocessor based having functional distribution and

data base distribution sub-system wise. The system shall be modular construction

and expandable in future by adding additional modules. Programmable logic

controller (PLC) shall be with dual redundant cold standby CPU, power supply and

communication module and communication bus as minimum with additional

redundancy for I/O’s / Power supply for critical loops.

The proposed PLC system shall utilize latest and proven microprocessor-based

controller, which shall be configured to perform in real-time, such essential

functions as:

� Data acquisition / Control

� Transaction processing

� Operator interface

� Interactive graphic displays

� Database for data collection, achieving reporting and trending

� Process alarms and system diagnostics

One dedicated Control Room for controlling the operations of Screening &

Beneficiation Plant is envisaged.




13.7.4 Telecommunication facilities

Telecommunication system envisaged shall include:

� CCTV system.

� Public Addressing System( Loud Speaker Inter-Communication System)

13.8 Air Conditioning & Ventilation

13.8.1 General

Air-conditioning, Ventilation and Air pollution control facilities are considered for

the various electrical premises, equipment, service premises etc. of Screening &

Beneficiation Plant to ensure proper working environment both for men and

machines and to maintain necessary environmental conditions for proper storage /

working of equipment and materials.

The Air conditioning, Ventilation and Pollution control equipment to be provided

will be of industrial duty type suitable for continuous operation throughout the

year.

13.8.2 Design data

The selection of equipment / Systems is based on the following Climatic conditions:

i) Annual Max. Temp. : 45 deg C

ii) Annual Min. Temp. : 15 deg C

iii) Annual Rainfall : 416 – 865 mm

13.8.3 General Description of Facilities Provided

• Natural Ventilation

The main shop in general will be designed for Natural Ventilation with about 20 air

changes per hour. It will be ensured that the temperature in the working zones

does not exceed permissible limits during summer.

• Mechanical Ventilation

Exhaust Ventilation are envisaged with suitable fans in the areas like store rooms,

battery rooms, DG rooms, welding shop, repair shops, canteen, pump house,

compressor room, capacitor rooms and other areas as required.

• Air conditioning facilities

Suitable Air conditioners will be provided for Control rooms, VFD rooms, PLC/ RIO

Panel room, UPS rooms for heat removal and to maintain desired inside temperature




conditions for air conditioning. Some of the rooms in the office will be provided with

AC units for comfort air conditioning.

13.9 The requirements / facilities described / envisaged here are indicative and may

undergo change for design improvement, process and layout optimization, if any,

during further engineering stage.




14. ENVIRONMENTAL MEASURES

14.1 Forest Clearance

The proposed new Screening & Beneficiation plant-II is located in forest area near

existing tailing dam. About 13.0 ha of forest land is required for construction of

Screening & Beneficiation plant-II and allied facilities. On 11/9/2008, Donimalai

project has applied for obtaining diversion of 177.63 ha of forest land which

includes 10.00 ha for construction of new Screening & Beneficiation plant at

Donimalai and balance 167.63 ha pertains to un-diverted forest land of

Kumaraswamy ML area to Chief Conservator of Forests cum Nodal Officer,

Bengaluru. After processing the application in State Forest Department, Bengaluru,

Dy. Conservator of Forests, Bellary is directed to examine the proposal and submit

the proposal with full details. The survey and Demarcation work completed in the

month of April’10 and also tree enumeration by 30/9/10. On 18/2/10, Range Forest

Officer, Sandur submitted the detail inspection report to Asst. Conservator of

Forests, Bellary. The proposal is pending at office of ACF, Bellary for onward

submission to State Forest Department through DCF & CF, Bellary for obtaining

approval of State Government for forwarding the proposal to Ministry of

Environment & Forests (MOEF), New Delhi for seeking forest clearance.

The forest clearance may take considerable time as the application is required to

pass through various levels in State and Central Government.

14.2 Environmental Clearance

The proposed Screening & Beneficiation plant is going to adopt wet screening

operations for obtaining high quality grade ore. The wet operations include mineral

processing system such as spiral classifiers, de-watering screens, hydro-cyclones,

thickeners, etc. The wet screening operations at Screening & Beneficiation plant

attract EIA Notification 2006 which requires prior Environmental Clearance for

construction of project. The capacity of Screening & Beneficiation plant is 10 MTPA

and hence, it shall be categorised as “Category A” project requiring Environmental

Clearance from GoI, MoEF, New Delhi. As per MoEF’s circular no; J-

11015/200/2008.IA.II (M) dated 31/3/2011, MoEF will consider for issue of

Environmental Clearance only after obtaining 1st

stage Forest clearance of the area

involved in the proposal. The procedures involved in obtaining EC are given below.

1) Appointment of EIA Consultant duly accredited with Quality Council of India

for preparation of EIA reports for mineral processing plant sector for category

- A projects.

2) Submission of Form-I along with pre-feasibility report to MoEF, GoI, New

Delhi.

3) Attending Expert Appraisal Committee (Mining) for obtaining terms of

reference for preparation of EIA report.

4) Preparation of Draft EIA report and submission to Karnataka State Pollution

Control Board, Bengaluru for organizing Environmental Public Hearing.




5) Finalization of EIA report based on public hearing proceedings and submission

to MoEF, GoI, New Delhi.

6) Attending EAC meeting for presentation and clarifications

7) Obtaining Environmental clearance from MoEF.

The entire process may take minimum of one year time in getting EC. It is pertinent

here to mention that MoEF will consider for issue of EC only after receipt of 1st

stage Forest clearance for area involved for Screening & Beneficiation Plant.

14.3 Consent for Establishment (CFE)

During the process of Environmental clearance, application under Air (Prevention &

Control of Pollution) Act, 1981 and Water (Prevention & Control of Pollution) Act,

1974 are to be submitted to KSPCB, Bengaluru for obtaining Consent for

Establishment (CFE) for construction of the plant.

14.4 Environmental Control Measures

The proposed Screening & Beneficiation Plant mainly comprises of silos, apron

feeders, cone crushers, double deck screens, inter connecting conveyors, spiral

classifiers, cyclones, tailing thickeners, etc. The tertiary crusher will be operated in

dry condition and Screening & Beneficiation plant will be in wet condition. Hence,

an environmental management plan suitable to tackle air, noise and water

pollution arising from these plants is envisaged.

High capacity silos are envisaged as storage bunkers in the Screening &

Beneficiation plant instead of open stockpile in order to prevent dust generation

and which are eco-friendly.

A comprehensive environmental management plan as intended for the entire

Screening & Beneficiation plant is detailed below. In addition to the control

measures envisaged for primary pollutants like air, noise and water, house-keeping

is also addressed in this chapter to maintain the plant in an environmental friendly

condition.

14.5 Air Pollution control

To prevent air pollution in the plant, suitable integrated dust suppression systems

are to be adopted. Enclosures are to be provided for the conveyors & junction

houses and green barriers around the Plant shall be developed, similar to the

existing practice. Also, air pollution measuring shall be monitored regularly at all

such sources in plants.

Particulate matter (PM) generation at all dry material transfer points is expected to

increase suspended particulate matter (PM10 & PM2.5) in the surrounding

environment. The major sources of dust hazard in the Screening & Beneficiation

Plant are as follows:




� Feeding point of tripper conveyor

� Apron feeders, Cone crusher, conveyor feed points and discharge points

� Ore transfer points and operation of cone crusher

� Dust generation from conveyors while running

14.5.1 Proposed dust control system at crusher house

The iron ore transportation to crusher bound to generate dry fines while

transferring material into crusher. The generation of dry fines in the form of

particulate matter as respire-able dust is expected to travel some distance from the

crusher area and will suspend in the environment for longer time if it is not

controlled at the generation point itself. Since the proposed crusher house is a

covered area, dry fog system is envisaged at crusher house.

Fog based system is generally provided to limit water consumption used for dust

suppression at above dust generation points. In order to reduce plant water

requirement, dust suppression in particular dry fog system is envisaged.

In this system, compressed air and water based dual fluid works on the principle of

agglomeration. Dust particle generated from the material handling become air

borne and are made to pass through a blanket of extremely fine fog jet. The dust

particle and the fog jet collide and adhere to each other. This increases their mass

of the dust. After a series of such collisions the dust particles mass become heavier.

The system employs compressed air for atomization of water particle. Water at the

pressure of 1.5 ~ 2 kg/cm2 and compressed air at the pressure of 5 ~ 6 kg/cm

2 are

supplied at the atomizing spray point.

14.5.2 Following dust suppression system is suggested for other places of Screening &

Beneficiation Plant

For loaded belt conveyors (Starting and end point of the belt) and for screening

area, dry fog system is envisaged.

In addition to the above, pressurised filtered air supply system and mechanical

exhaust system will be provided at suitable places.

14.6 Water Pollution Control System

Water pollution in the form of iron ore tailings is expected from the plant. These

tailing are non hazardous in nature. The tailings will be impounded in new Tailing

dam. It is expected that about 85-90% of the Screening & Beneficiation plant’s

process water requirements will be met by recycled process water. A recirculation

tank with a live storage capacity of 5000 m3 is envisaged to receive the clean water

from tailing thickener. The make-up water requirement for the process will be

brought by pipeline from 5000m3 make-up water storage tank located at +745 m

level near to the Screening & Beneficiation plant. The make-up water demand for




the plant is expected to be about 370 m3/hr. However, the same will be about 500

m3/hr for treating 10 MTPA iron ore.

All unit operations in the Screening & Beneficiation Plant will be carried out in wet

mode. However, the tertiary crusher and screening unit will be working in dry

condition. Tailings will be generated from the Screening & Beneficiation Plant at a

rate 150 m3/hr. Tailings thickener overflow water about 2100 m

3/hr will be recycled

back to the process.

14.7 Noise control system

All the noise generating equipment like crusher, belt pulley, motors will be housed

or provided with acoustic barriers or isolating material capable of reducing noise to

desire level. To arrest and minimise the noise produced beyond acceptable levels

from running machinery in the plant, closed enclosures will be made for the plant

buildings / junction houses. Further, necessary measures to contain noise levels as

per IS/statutory rules will be ensured. Also, noise level measuring shall be

monitored regularly at all such sources in plants.

14.8 Green belt development

Afforestation measures shall be taken-up through developing barrier platforms all

around the plant. To maintain ecological balance in the area, plantations of suitable

species of ever green/locally grown trees shall be made. Adequate tree plantations

shall substantially abate dust pollution, filter the polluted air and ameliorate the

plant environment without any hazards in public health.

The Screening & Beneficiation Plant includes development of a green belt that is

expected to reduce noise levels, limit the propagation of fugitive dust and produce

a better occupational / aesthetic environment. The implementation of a green belt

around the plant and side of the roads and the selection of plant species will be

carried out in co-operation with Horticulture Department.




15. MANPOWER PLANNING

15.1 Organizational Structure

The proposed Screening & Beneficiation Plant shall be headed by one overall plant

in-charge. Each shift in-charge shall be directly reporting to the Plant in-charge.

15.2 Manpower

The requirement of manpower for the operation and maintenance of the proposed

Screening & Beneficiation Plant has been estimated by considering the following:

• Capacity of the Crushing & Screening & Beneficiation Plant complex

• Type of equipment to be installed

• Degree of automation envisaged

• Number of operating shifts to achieve the rated capacity

• Requirement of personnel as off and leave reserve etc.

The overall manpower requirement has been estimated at 81. In addition, there

will be some contract employees.

Apart from operation and maintenance (mechanical and electrical), the proposed

manpower also caters to preventive maintenance and shut down operations.

The summary & details of category-wise manpower requirement other than

contract employees is given below:

Production and Maintenance staff:

� Executives : 10 Nos.

� Workmen/Non-executives : 71 Nos.

�

15.2.1 Manpower Details – Executives

Sl.

No. Description

No. of

shifts

No. of

persons

per shift

Reserve Total Remarks

1 Overall In-charge 1 1 - 1 General Shift

2 Assistant 1 1 - 1 General Shift

3 Electrical/Electronics

Engineer 3 1 1 4 3 shifts

4 Shift In-charge 3 1 1 4 3 shifts

Total 10




15.2.2 Manpower Details – Workmen (Non-Executives)

Sl.

No. Description

No. of

shifts

No. of

persons per

shift

Reserve Total Remarks

1 Screening &

Beneficiation Plant

Operation

3 14 3 45 3 shifts

2 Maintenance crew 1 8 - 8 General Shift

3 Electrician &

control room 3 4 2 14 3 shifts

4 Truck driver 1 1 - 1 General Shift

5 Crane operator 1 1 - 1 General Shift

6 Misc./Stores 2 1 - 2 General Shift

Total 71

15.3 Recruitment

After the project is approved, plant in-charge and a few key personnel of different

categories shall have to be diverted from the existing DIOM to form the nucleus of

the Screening Plant for further development and to take necessary advance actions

for project construction.

The Executives would be placed during the construction of the project itself, as they

have to get acquainted with the plant and equipment for efficient running of the

concerned units.

Some of the construction personnel can progressively be absorbed with the

tapering of the construction work, particularly in the maintenance and services

areas of the plant. A certain portion of junior executives and supervisory staffs may

have to be recruited during the construction stage itself as acquaintance with

equipment erection will be very much beneficial for them in running the units later.

15.4 Training

All the Executives are suggested to be trained, mostly in the operation and

maintenance of plants of similar type. They in turn would share the technical

knowledge attained during the training with their subordinates. At least 3-4 months

before the commissioning of the project, these employees ought to complete their

training and be associated with the commissioning activities of the units.




16. ANNEXURES

Annexure Description Page No.

I.1 Mechanical cost estimate 59

I.2 Electrical cost estimate 61

I.3.1 Civil & structural cost estimate 62

I.3.2 Abstract of quantities of Civil & Structural works 63

I.4 Cost estimate of Tailing Dam 64

ANNEXURE I.1

Rs. In Lakhs

Conv. Tecnological structure, idler assys., pulleys, frames, counter

weight (as applicable), skirt boards, safety switches, LCS, drive unit incl.

motor etc.,

1 No. 246.02 Estimated as per Annexure-(i)



motor etc.,

4 Nos. 243.02 Estimated as per Annexure-(ii)



motor etc.,

1 No. 84.41 Estimated as per Annexure-(iii)



motor etc.,

1 No. 135.86 Estimated as per Annexure-(iv)



motor etc.,

1 No. 79.98 Estimated as per Annexure-(v)



motor etc.,

1 No. 88.36 Estimated as per Annexure-(vi)



motor etc.,

1 No. 158.36 Estimated as per Annexure-(vii)



motor etc.,

1 No. 131.64 Estimated as per Annexure-(viii)



motor etc.,

1 No. 38.15 Estimated as per Annexure-(ix)



motor etc.,

1 No. 130.33 Estimated as per Annexure-(x)



motor etc.,

1 No. 59.06 Estimated as per Annexure-(xi)



motor etc.,

1 No. 81.56 Estimated as per Annexure-(xii)



motor etc.,

1 No. 42.91 Estimated as per Annexure-(xiii)



motor etc.,

1 No. 69.11 Estimated as per Annexure-(xiv)



motor etc.,

1 No. 76.73 Estimated as per Annexure-(xv)



motor etc.,

1 No. 28.54 Estimated as per Annexure-(xvi)

17 Tripper conveyor Feeder 1 No. 150.12

As per HQMM/2050-09/11A049/2234

16.6.11 with Price escalation as per RBI

Index

16

Conveyor 826 (1200 mm wide X 6.5 m Length)

15



11


12


13


Conveyor 829 (1200 mm wide X 176 m Length)




9

10

Basic Cost at works

April ' 2013


Conveyor 801 including tripper (1200 mm wide X 432 m Length)





Sl. No.

MECHANICAL COST ESTIMATE FOR SCREENING & BENEFICIATION PLANT - II AT DONIMALAI

Remarks #Equipment Description Qty. Unit

2

3

A

5

4

1

6

7

8

14

* Annexures are with Mech. Engg. Dept.

mmanoj

Typewritten Text

mmanoj

Typewritten Text

Page 59

mmanoj

Typewritten Text

mmanoj

Typewritten Text

Rs. In Lakhs

Basic Cost at works

Conveyor 801 including tripper (1200 mm wide X 432 m Length)

Sl. No. Remarks #Equipment Description Qty. Unit

A

118 Apron Feeders 4 No. 400.00

As per HQMM/2050-09/11A049/2234

dt 16.6.11 with Price escalation as per

RBI Index

19 Vibrating Screens (Primary, secondary, tertiary & DWS) 14 Nos. 695.22

HQMM/1002-06/10C904; 908 &

910/1079 dt. 26.6.08 with price

escalation as per RBI Index

20 Vibrating feeders 2 Nos. 58.48HQMM/11057-07/10C 906 & 909/1119

dt 14.05.2009

21 Handling Facilities (EOT cranes & manual Hoists) 1 Lot 132.00 Estimated as per Annexure-(xviii)

22 Weightometers 7 Nos. 35.00 Lumpsum

23 Cross belt magnetic separator 2 Lot 80.00 Estimated as per Annexure-(xxii)

24 Classifiers 4 No. 220.00HQMM / 3019-06 / 16CN 36&44 /

Dt.30.03.11

25 Horizontal Belt Filters(HBF) 3 No. 1761.00Budgetary quote and price esclation as

per RBI Index

26 Cyclone feed tanks 2 Nos. 15.00 Estimated as per Annexure-(xix)

27 Centrifugal Slurry pumps 5 Nos. 475.00 Lumpsum

28 Hydro Cyclones 17 Nos. 192.27HQMM/3011-07/16CN61/ dt. 23.5.12

and price esclation as per RBI Index

29 Tailing Thickner 1 Nos. 106.00Budgetary quote dt. 14.10.10 and price

esclation as per RBI Index

30 Launders 1 Lot 50.00 Lumpsum

31 Chutes and Liners 1 Lot 410.32 As per Annexure - (xx)

32 Belting for all the above mentioned conveyors 1 Lot 348.62 As per Annexure-(xxi)

33Miscellanous (Tools & Tackles + Vulcanising machine & material + Dust

control system as required)1 Lot 200.00

34 Tertiary Crushers 2 No. 2389.01As per HQMM/2020-08/11X027/2189

Dt. 29.7.10 & esclation as per RBI index

35

a Spares (7.5% on Sl. No. 1 to 30) - Indigenous component - Lot 511.73

b Spares (25% on Sl. No.32) - Import component - Lot 597.25

36 Total Supplies and Spares - Indegenous (Sl. No. 1 to 33 & 35.a) - - 7534.80 -

37 Total Supplies and Spares - Imported (Sl. No. 34 & 35.b) - - 2986.26 -

38Total Supplies including Spares (Indegenous) + *Taxes & Duties on the

same (@20.14% on Sl. No.36)- - 9052.31 -

39Total Supplies including Spares (Imported) + *Taxes & Duties on the

same (@44.72% on Sl. No. 37)- - 4321.72 -

B 40TOTAL BASIC COST OF SUPPLIES (excluding spares and taxes & duties) (I

to 34)- - 9412.08 -

C 41 Provision towards system engineering by contractor (5% of Sl. No. 40) - - 470.60 -

D 42 Erection & Commissioning (10% on Sl. No. 40) - - 941.21 -

E 43 Supervision charges for E & C of Crusher & HBF 46.17 As per Annexure xxii

F 44 Total Mechanical Cost (38 + 39 + 41 + 42 +43) - - 14832.01 -

148.32 CRORES

Spares

-

COST ESTIMATE FOR PLANT EQUIPMENT (MECHANICAL) IS ABOUT Rs.

A

* Annexures are with Mech. Engg. Dept.

mmanoj

Typewritten Text

Page 60

ANNEXURE I.2

S.N Description Unit Qty Cost/ unit Amount in Rs.

1 Constuction of OH 11KVLine / Under ground cable

(3x300 sq.mm UE) from valley sub station to the

SP-2 switchyard

KM 3 3125000 9375000

2 One no. HT 3.3KV switch Boards (14no. including

incomer)

NO 1 11200000 11200000

3 One no. HT 11KV switch Board (three for incomer

& T/Former feeder)

NO 1 2400000 2400000

4 Intelligent LTMCC (app. 37+37 feeders of various

rating and etc.,) @1.05lakhs

Lot 8,400,000 8,400,000

5 Distribution Transformer with OLTC

2.0MVA,3.3KV/440V

NO 1 3000000 3000000

6 Power Transformer with OLTC

2.5MVA,11KV/3.3KV for HT

NO 1 3750000 3750000

7 Automation / PLC for the plant (750 I/O appr. ) Lot 24000000

8 Power cables ( HT , LT) of different sizes as per

requirement

Lot 30000000

9 Cable trays 5Km Km 5 450000 2250000

10 Instruments Lot 12000000

11 Instrumentation & Control cables Lot 18000000

12 IP based CCTV System app. 45cameras Lot 10300000

13 VVVF Drives for Vibrating feeders (4+1) and

Classifiers (4)

NO 9 1500000 13500000

14 UPS 12KVA, with batteries 150AH NO 1 1000000 1000000

15 110V Battery Charger(30A) with batteries (180AH) NO 2 2500000 5000000

16 Capacitor Bank HT Set 1 1200000 1200000

17 Lighting Transformer 11KV/230V ac, 125KVA NO 1 400000 400000

18 IP based PA system Lot 2000000

19 Illumination(Lighting fixtures, 25m High mast

towers 2no. etc)

LS 6000000

20 Earthing LS 3000000 3000000

21 3.3KV NGR Set 2 100000 200000

22 Utilities (AC, Exhaust fans etc.,) LS 500000

23 Enabling works

a Construction Power (app 300KVA, 11KV/440V

including cables, DB's etc)

NO 1 750000 750000

b Illumination LS 500000 500000

24 Miscellaneous 5% 8373750

A Total cost 177098750

A1Total cost with Esclation of 0.8% as per RBI Index 178550959.8

B

Provision towards system engineering by

contractor (5% of 'A1')

8927547.988

C Total Cost + Taxes & duties @ 20.15% on 'A1' 214528978.1

D Erection & Comissioning @15% of 'A1' 26782643.96

Total B + C +D 250239170.1

COST ESTIMATE FOR PLANT EQUIPMENT (ELECTRICAL) IA ABOUT RS.25.02 CRORES

ELECTRICAL COST ESTIMATE FOR SCREENING & BENEFICIATION PLANT - II AT DONIMALAI

mmanoj

Typewritten Text

Page 61

ANNEXURE I.3.1

April 2013

Cost estimate

during Sep. 2012.Remarks

(Rs. Ps)(1) (2) (3) (5)

1 CIVIL WORKS 613760037.30

2 STRUCTURAL WORKS 405684651.25

3Provision towards system engineering by

contractor (5% of '1+2')50972234.43

4

Automatic Fire Detection and Supression

System(FDSS) in connecting Down hill

Conveyor to RCC silo (L=0.5Km approx)

(Piping, civil, electrical, mandatory spares

etc.,)

12521000.00

Amount calculated on pro-rata

basis based on estimate for the

Dep-5 Conv no.28 & 29 (Rs

250.42Lakhs/KM) during May

2012.

5Enabling works. (Construction water & Site

office accommodation) -LS-1000000.00 Lumpsum

6 Survey works 200000.00 Lumpsum7 Soil Investigation work 500000.00 Lumpsum

8Enumeration of Trees for 1 hectares of

area @ 7 Lakhs per hectare.700000.00 Rate details from Env. Deptt.

9 Grand Total Amount = Rs. 1085337922.97

Say Rs. 108.53Crores

COST ESTIMATE FOR CIVIL & STRUCTURAL WORKS IS ABOUT Rs. 108.53 CRORES

FOR CIVIL & STRUCTURAL WORKS COST ESTIMATE FOR SCREENING & BENEFICIATION PLANT -II

AT DONIMALAI.

Refer Annexure I.3.2

Sl. No. Item Description

mmanoj

Typewritten Text

Page 62

April 2013

Sl. AmountNo. (Rs. Ps)(1) (2) (3) (4) (5)

1 Earthwork Cu.m 279794.47 56819933.25

2 PCC Cu.m 2824.66 11359895.03

3 RCC grade Cu.m 18292.20 116519600.12

4 Reinforcement Steel MT 2466.13 153516484.41

5 Anchor Bolts MT 27.58 1869938.57

6 Structural Steel MT 4486.05 296701703.21

7Galvalume Sheet 0.5mm TCT for both Roofing

& Cladding Sq.m 40844.34 34717688.75

8 FRP translucent sheeting-Cladding (2mm thk.) Sq.m 5094.89 8389841.32

9 Other civil works 133349100.89

10

Miscellaneous works (pipes, valves with

fittings for drinking water, process water,

pump house with Pumps & motors, service

water, finishing works,etc., (@ 5% of total

civil works) ( B)

40662209.28

853906394.84

Cost as on

Sep. 2012

Escalation

13.98 on 70%

material

SRNPP 9.60% Total

CIVIL WORKS (Sl. No.1+2+3+4+5+9+10) = 514097161.56 50309548.23 49353327.51 613760037.30STRUCTURAL WORKS (Sl. No.6+7+8) = 339809233.28 33253731.57 32621686.40 405684651.25

Annexure I.3.2

Total = Rs.

Abstract of Quantities of Civil & Structural works

Item Description Unit Quantity

mmanoj

Typewritten Text

Page 63

Annexure I.4

Item Rate Amountno. (Rs. Ps) (Rs. Ps)(1) (2) (3) (4) (5) (6)

Item rate analysis based prevailing market rate on April 2012 and DSR 2007- CPWD rate analysis.

1

EW in rough excavation & banking earth in

layars(20cm) Cu.m 287.40 783137.50 225073717.50

(Ref:Item no. 2.2.1/DSR '12)2 Transportation of Earth (Avg 3Km lead) Cum 125.92 783137.50 98612674.00

(Ref:Item no. 1.1.2/DSR '12)3 Extra for compaction of MDD 95% Cum 7.75 783137.50 6069315.63

(Ref:Item no. 16.2/DSR '12)

4Earth fill in core imprevious material & Cut of

trenches Cu.m 600.00 96702.00 58021200.00

(Ref:BHQ/TD Est /Aug 2012)

5 S/L of sand Cum 749.30 19740.00 14791182.00

(Ref: Item no.2.27/DSR'12)

6 S/S. of boulders 22.5cm thk….. Cu.m 607.55 705.00 428322.75

(Ref:Item no. 16.72/DSR' 12)

7 Jungle clearance sqm 4.82 70500.00 339810.00

(Ref: Item no.2.31/DSR'12)

8 Earth work in foundation & Trenches Cum 130.80 5640.00 737712.00

(Ref:Item no. 2.8.1/DSR '12)9 Earth work in stripping upto 300mm sqm 37.86 70500.00 2669130.00

(Ref:Item no. 2.1.1/DSR '12)10 Turfing in th D/S side Sqm 15.10 33370.00 503887.00

(Ref:Item no. 19.82/ BPWD SOR 2011)

11 Stone pitching sqm 336.50 940.00 316310.00

(Ref:Item no. 16.1/DSR '12)

Total Amount ( A ) 407563260.88

Miscellaneous works (Core, pipes, valves with

fittings, fillter works,etc., (@ 5% of total civil

works) ( B)

20378163.04

427941423.92With an esclation of 13.98% as per RBI index on (C ) 487767634.98

SRNPP factor @ 7.08% on (C ) 30298252.81Grand Total 518065887.80

Say Rs. 51.81Crores

Gross Amount (C)=(A)+(B) = Rs.

COST ESTIMATE FOR TAILING DAM FOR PROPOSED SCREENING & BENEEFICIATION PLANT-II

Item Description Unit Quantity

(Rate Analysis based on DSR 2012)AT DONIMALAI.

mmanoj

Typewritten Text

Page 64




17. LIST OF PLATES

SL NO PLATE

NO. DRAWING TITLE

DRAWING

NO.

1 1.1 Material & water Balance diagram (Sheet 1 of 2) 3-2-136

2 1.2 Material & water Balance diagram (Sheet 2 of 2) "

3 2.1 Equipment flow sheet (Sheet 1 of 2) 3-2-135

4 2.2 Equipment flow sheet (Sheet 2 of 2) "

5 3 Conceptual layout of proposed Screening & Benf. Plant-II 3-2-137

6 4.1 Screening & Beneficiation Plant-II layout (Sheet 1 of 2) 3-2-138

7 4.2 Screening & Beneficiation Plant-II layout (Sheet 2 of 2) "

8 5.1 GA of Silo & Tripper conveyor 801 (Sheet 1 of 3) 3-2-139

9 5.2 GA of Silo & Tripper conveyor 801 (Sheet 2 of 3) "

10 5.3 GA of Silo & Tripper conveyor 801 (Sheet 3 of 3) "

11 6 Silo, Screening & Beneficiation Plant-II Arrangement 3-2-140

12 7.1 GA of Screening & Beneficiation Plant-II (Sheet 1 of 5) 3-2-141

13 7.2 GA of Screening & Beneficiation Plant -II (Sheet 2 of 5) "




17 8 GA of TC Plant conveyors 3-2-142

18 9 GA of Tertiary Crushing Plant 3-2-143

19 10.1 Classifier & DWS Plan & Elevation (Sheet 1 of 2) 3-2-144

20 10.2 Classifier & DWS Plan & Elevation (Sheet 2 of 2) "

21 11 Plan of Horizontal Belt Filters (HBF) 3-2-145

22 12 GA of fine ore conv. 829 3-2-146

23 13 GA of lump ore conv. 832 3-2-147

24 14 Proposed Tailing dam location 3-2-148

25 15 Land required for proposed Screening & Beneficiation Plant-II 3-2-131

26 16 Time Schedule -

a) All dimensions and grid spacing are in millimeters unless specified otherwise.

b) All levels and contours are in meters unless specified otherwise.

c) All dimensions & elevations are indicative only and shall be reviewed during engineering stage.

d) Design & construction of all discharge chutes as shown are indicative.

e) Equipment/Conveyor’s drive location, its arrangement and type as shown is indicative only.

f) Minimum 1000mm clear passage shall be considered all around the equipment located in

buildings & Transfer House.

g) Trestles locations as shown are indicative only.

h) Maintenance hoists with monorail beams shall be considered, wherever required.

i) Staircase in all the buildings/houses shall be provided for access to all the floors and a good road

network for approaching all the buildings/transfer houses shall be planned suitably.

j) Dust suppression/ventilation/sampling units etc., are not shown in the drawing. However the

same shall be considered as per requirement.

k) Shall review the individual equipment / components / items / buildings / structures / system

during engineering stage for any improvements to ensure satisfactory working of the same for

the proposed application.

NMDC LIMITED

FOR TEFR PURPOSE & INDICATIVE ONLY

LUMPS

819.00 55.25

874.25 93.68

FINES

938.34 156.23

1094.57 85.73

NMDC LIMITED

1440

1116.90

736.38

321.58

1011

Input

Output

Make Up


NMDC LIMITED


801

806

804 805

808

811

813

810

814

824823822

821

820

829

802

832

837

835

836

813

805

809

812

825

826

838

851

852

854

ITEM NO DESCRIPTION QTY

1

1

1

1

1

1

ITEM NO DESCRIPTION QTY

857

NMDC LIMITED

841855848 843846

NMDC LIMITED

801

802

801

800

723

727

801

802

804

805806

801

NMDC LIMITED

801

805

802

804

806

801

801

805


NMDC LIMITED

808

809

810

811

812 813 814

815804

805

806


NMDC LIMITED

824

808

809

810

811

812 813 814

815

824

808

811


824.1 824.2 808.C808.D 808.B 808.A

809

810

811.C811.D 811.B 811.A

813

814

812

829

825826

NMDC LIMITED


829

814 813812 813 814

812

829

814

825

826

NMDC LIMITED


824.2

824.1

809

810

810

823

823

815

809

810

823

824809

829

825

826

NMDC LIMITED


809

812

NMDC LIMITED

813

809

832


813812

820

821.1821.2

822.1822.2

823

810

NMDC LIMITED

824.1824.2


NMDC LIMITED

820

821.1821.2

822.1822.2 823

810

827


811 814

837

835

836

841855

838

848

NMDC LIMITED

813

843846

835836

837

NMDC LIMITED

841

840

839

815

848

847

838

851

852

854

NMDC LIMITED

829

NMDC LIMITED


NMDC LIMITED

839

809

812

THIS DRAWING IS N.M.D.C.'S PROPERTY AND MUST NOT BE USED EXCEPT IN

CONNECTION WITH OUR WORK. ALL RIGHTS OF DESIGN OR INVENTION RESERVED

YEARMONTH J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J

1 Preparation & Finalisation of TEFR2 Approval of TEFR Start date of Project ‐ July 20133 Forest Clearance and Enviromental Clearance4 Appointment of agency for soil investigation5 Soil Investigation and submission of report6 Getting additional power supply (as required)7 Appointment of EPCM consultant8 Preperation of Tender document(s) for LSTK

package(s) for construction of Plant9 Invitation of bids and order placement for

package(s) for Plant construction 10 Engineering, manufacture, supply & construction

of Plant11 Trial Runs & Commissioning (Apr' 2017)

9Sl. no. Activity

3 6 3912 15 18 21 24 27 30 33 362012 20172013 2014 2015 2016

Plate No. 16Time schedule

6042 45 48 51 54 57

3. final pfr 2.6environmentclearance.nic.in/writereaddata/online/tor/0_0_06_sep_2… · existing...

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