pre-feasibility report for expansion of noamundi...

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PRE-FEASIBILITY REPORT For EXPANSION OF NOAMUNDI IRON ORE MINE (ML Area 1160.06 HA), FROM 10 MTPA TO 19 MTPA (ROM) WITH TOTAL EXCAVATION OF 27.0 MTPA AND ENHANCEMENT OF IRON ORE BENEFICIATION CAPACITY (Feed to Plant) FROM 18 MTPA TO 27 MTPA IN TOTAL PROJECT AREA 1230.42 HA OF NOAMUNDI at NOAMUNDI VILLAGE, PO: NOAMUNDI, WEST SINGHBHUM DISTRICT JHARKHAND STATE by: Noamundi Iron Mine Noamundi Village, West Singhbhum District, Jharkhand-833217 Submitted to: Ministry of Environment, Forest & Climate Change (MoEF&CC) New Delhi Environment Consultant: Vimta Labs Ltd. 142, IDA, Phase-II, Cherlapally, Hyderabad–500 051, Telangana State [email protected], www.vimta.com (QCI/NABET Accredited and ISO 17025 Certified Laboratory, Recognized by MoEF, New Delhi) October 2019

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  • PRE-FEASIBILITY REPORT

    For

    EXPANSION OF NOAMUNDI IRON ORE MINE (ML Area 1160.06 HA),

    FROM 10 MTPA TO 19 MTPA (ROM) WITH TOTAL EXCAVATION OF 27.0

    MTPA AND ENHANCEMENT OF IRON ORE BENEFICIATION CAPACITY

    (Feed to Plant) FROM 18 MTPA TO 27 MTPA IN TOTAL PROJECT AREA

    1230.42 HA OF NOAMUNDI

    at

    NOAMUNDI VILLAGE, PO: NOAMUNDI, WEST SINGHBHUM DISTRICT

    JHARKHAND STATE

    by:

    Noamundi Iron Mine

    Noamundi Village, West Singhbhum District, Jharkhand-833217

    Submitted to:

    Ministry of Environment, Forest & Climate Change (MoEF&CC) New Delhi

    Environment Consultant:

    Vimta Labs Ltd. 142, IDA, Phase-II, Cherlapally, Hyderabad–500 051, Telangana State

    [email protected], www.vimta.com

    (QCI/NABET Accredited and ISO 17025 Certified Laboratory,

    Recognized by MoEF, New Delhi)

    October 2019

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 1

    1.0 EXECUTIVE SUMMARY

    Tata Steel Limited (TSL) holds the Noamundi iron ore mine lease over an area of

    1160.06 ha located at Noamundi, West Singhbhum district of Jharkhand state and

    is being worked for winning of iron ore. Noamundi Iron ore mine was granted lease

    from 01.01.1922 for a period of 30 years over an area of 1160.06 ha. 1st Renewal

    for 30 years w.e.f. 01.01.1952 over an area of 1160.06 ha. 2nd Renewal over an

    area of 1160.06 ha granted by Govt of Bihar vide their memo no.4795 dated

    01.09.1984 and lease deed executed on 20.101985. Third Renewal of lease was

    applied on 17.12.2009. Express order vide letter no -286 dated 12.2.2015 issued

    by Government of Jharkhand for continuation of operation valid up to 31.03.2030.

    The total lease area of 1160.06 ha consists of forest land of 762.43 ha and non-

    forest land of 397.63 ha. The mining lease lies in Mahudi, Balijore, Korta,

    Noamundi, Sarbil, Barabalijori villages. The mine is captive for Tata Steel Limited,

    the entire ore produced from the mine is fed to the Company’s steel plant located

    at Jamshedpur and Kalinganagar along with its sister companies/subsidiaries like

    Tata Sponge Iron Limited, Tata Metalliks Limited TAYO ROLLS, Bhushan Steel

    Limited and other plants of the company.

    The Noamundi iron ore mine has obtained environment clearance vide letter No J-

    11015 /104 /2011-IA.II(M) dated 10.06.2013 for production of 10 MTPA of ROM

    and expansion of beneficiation plant from 10 MTPA to 18 MTPA with dispatch. The

    company has obtained CTO vide letter No JSPCB/HO/RNC/CTO-1162982/2017/779

    dated 13.06.2017 for production of 10 MTPA of ROM and Beneficiation of 13 MTPA

    of iron ore.

    The mine has applied for issuance of Corrigendum to Environmental Clearance of

    Noamundi Iron Mine of M/s Tata Steel Limited in view of the definition of Run of

    Mine (ROM), introduced in the recently notified Mineral (Other than Atomic and

    Hydrocarbons Energy Minerals) Concession Rules 2016, and the same has been

    recommended by 33rd EAC committee Meeting held during June 21st -22nd, 2018.

    The total project area is 1230.42 ha, which includes 1160.06 ha of mine lease and

    beneficiation plant. The expansion of Noamundi Iron Mine (Run of Mine) from 10

    MTPA to 19 MTPA with total excavation of 27 MTPA shall limit with in the same

    lease area of 1160.06 ha and as per approved mine plan from IBM vide letter no.

    RAN/WSB/Fe/MP-06/2019-20 dated 13th August, 2019. All the expansion of mineral

    processing plant / Iron ore beneficiation plant & mine from 18 MTPA to 27 MTPA

    (Feed to Plant) shall be restricted to project area only. The finished product from

    Noamundi shall be continued to be sent to the steel plant through railway siding

    either through Noamundi or through adjacent public siding along with public roads

    as per required.

    2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

    2.1 Identification of the Project & Project Proponent

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 2

    Tata Steel Limited was established in Jamshedpur, India in the year 1907. Tata

    Steel is part of the 150-year-old Tata group. Bringing to reality the vision of its

    founder, J. N. Tata, who inspired the steel and power industry in India, the Tata

    Steel Group is the 10th largest steel manufacturer in the world and is known to be

    the hallmark of corporate citizenship and business ethics. TATA Steel (based on

    capacity) is the 10th largest steel manufacturer in the world and amongst the top 3

    global steel companies. Tata Steel has been adjudged as the ‘Steel Industry Leader’

    globally by the Dow Jones Sustainability Index 2018 (DJSI). Tata Steel is also the

    only India-based company to emerge as a winner among all 60 sectors evaluated

    for DJSI 2018.

    With operations in 26 countries and commercial presence in 50 countries, the Tata

    Steel Group has a steel production capacity of 27.5 MTPA (as on March 31, 2018).

    Tata Steel India has manufacturing units at Jamshedpur, Jharkhand, with a

    production capacity of 10 MTPA and at Kalinganagar, Odisha, with a production

    capacity of 3 MTPA. In FY 2017-18, Kalinganagar unit received approvals for

    expansion to 8 MTPA. Tata Steel operates with a completely integrated value chain

    that extends from mining to finished steel goods. Therefore, the captive

    requirement of the iron ore will gradually increase from 35.6 Million tonnes in 2020-

    21 to 46.7 million tonnes in 2021-22, which would go up to ~ 59.9 million tonnes

    by 2029-30.

    The expansion of iron ore mines from existing capacity to future requirement is due

    to large organic and inorganic growth of company.

    The mining lease details are attached as Annexure-I.

    2.2 Brief Description and Nature of the Project

    Noamundi is a captive iron mine of m/s Tata Steel Ltd. and is been operational from

    last several decades. Currently, Noamundi has iron mine of 10 MTPA and

    beneficiation & dispatch of 18 MTPA. It is proposed to expand the capacity due to

    the captive requirement of iron ore to cater the need based on the requirement of

    Jamshedpur & Kalinganagar steel plants and other sister companies (Tata Metaliks

    Limited, Tata Sponge Iron Limited, TAYO, Bhushan steel Ltd). The iron ore mine

    shall enhance the production capacity from 10 MTPA to 19 MTPA along with

    beneficiation capacity from 18 MTPA to 27 MTPA (Feed to plant). All other support

    services are available to fetch the goal of the division.

    As per EIA Notification dated 14th September 2006, as amended on date, the

    production enhancement of Noamundi Iron Mine from (ROM) from 10 MTPA to 19

    MTPA and beneficiation (feed to plant) from 18 to 27 MTPA project falls under

    Category “A”, Project or Activity 1(a).

    2.3 Need for the Project and its Importance to the Country and Region

    India is the world’s third-largest producer of crude steel (up from eighth in 2003)

    and is expected to become the second-largest producer. The steel sector in India

    contributes nearly two per cent of the country’s gross domestic product (GDP) and

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 3

    employs over 6,00,000 people. The growth in the Indian steel sector has been

    driven by domestic availability of raw materials such as iron ore and cost-effective

    labour. Consequently, the steel sector has been a major contributor to India’s

    manufacturing output. The Indian steel industry is very modern with state-of-the-

    art steel mills. It has always strived for continuous modernization and up-gradation

    of older plants and higher energy efficiency levels. Presently, India’s crude steel

    capacity is around 126 Million Tonnes (MT) and Production of crude steel was 97.4

    MT during 2016-17.

    The Union Government has given its approval for National Steel Policy (NSP) 2017

    on 03.05.2017. The new Steel Policy enshrines the long-term vision of the

    Government to give impetus to the steel sector. It seeks to enhance domestic steel

    consumption and ensure high quality steel production and create a technologically

    advanced and globally competitive steel industry. The policy projects crude steel

    capacity of 300 million tonnes (MT), production of 255 MT and seeks to increase

    per capita steel consumption to the level of 160 Kg by 2030 from existing level of

    around 60 Kg and major segments of consumptions are infrastructure, automobiles

    and housing sectors. The policy also envisages to domestically meet the entire

    demand of high grade automotive steel, electrical steel, special steels and alloys

    for strategic applications and increase domestic availability of washed coking coal

    so as to reduce import dependence on coking coal from about 85% to around 65%

    by 2030-2031. The Union Cabinet has also approved the policy for providing

    preference to domestically manufactured iron & steel products on Government

    procurement. The policy provides preference to Domestically Manufactured Iron &

    Steel Products (DMI & SP), in Government Procurement for specified steel products

    having minimum value addition of 15%.

    Major projects of the Government of India like development of 100 smart cities,

    smart armed force stations, Delhi Mumbai Industrial Corridor, development of

    ports, expansion of Railways, National Solar Mission etc. are expected to increase

    demand of steel significantly in coming years.

    The Indian steel industry is very modern with state-of-the-art steel mills. It has

    always strived for continuous modernization and up-gradation of older plants and

    higher energy efficiency levels. Indian steel industries are classified into three

    categories such as major producers, main producers and secondary producers.

    TATA Steel, NMDC, SAIL, JSW, JSPL etc comes under major producers.

    India is expected to overtake Japan to become the world's second largest steel

    producer, and has envisaged achieving 300 MT of annual steel production capacity

    by 2030. Steel consumption is expected to grow 5.7 per cent year-on-year to 92.1

    MT in 2018.

    To achieve the 300 MT annual steel production, all the existing projects shall be

    expanded, new projects shall be installed, merger and acquisition shall take place,

    thus demand for raw material will increase.

    To meet the nation target of 300 MT annual steel production and merger and

    acquisition of new steel plant (Bhushan, Usha Martin) and increasing domestic steel

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 4

    demand, it is very important that all the iron ore mines of TATA Steel shall raise

    the production from current capacity.

    The captive requirement of the iron ore will gradually increase from 35.6 million

    tonnes in 2020-21 to 46.7 million tonnes in 2021-22 which would go up to ~ 59.9

    million tonnes by 2029-30.

    2.4 Demand-Supply Gap

    In 2016, the world crude steel production reached 1630 million tonnes (mt) and

    showed a growth of 0.6% over 2015. China remained world’s largest crude steel

    producer in 2016 (808 mt) followed by Japan (105 mt), India (96 mt) and the USA

    (79 mt). World Steel Association has projected Indian steel demand to grow by

    6.1% in 2017 and by 7.1% in 2018 while globally, steel demand has been projected

    to grow by 1.3% in 2017 and by 0.9% in 2018. Chinese steel use is projected to

    show nil growth in 2017 and decline by 2% in 2018. Per capita finished steel

    consumption in 2016 is placed at 208 kg for world and 493 kg for China by World

    Steel Association.

    In FY17, crude steel production in India was 97.42 MT, with the total crude steel

    production growing at a CAGR of 5.49 per cent over the last 6 years. As of March

    2017, the capacity utilization of steel producers is set to increase with strong export

    demand and signs of revival in domestic sales. Companies like TATA Steel, JSW

    and other Steel plants have experienced a sharp increase in steel manufacturing in

    the last few years. Steel manufacturing output of India is expected to increase to

    128.6 MT by 2021, accelerating the country’s share of global steel production from

    5.4 per cent in 2017 to 7.7 per cent by 2021. India’s steel output is expected to

    grow at a CAGR of 8.9 per cent during 2017-21 and India is expected to become

    top global steel producer.

    Due to large organic and inorganic growth of company along with expansion of

    Kalinganagar steel plant iron ore demand will raise. To fulfill the existing gap all

    iron ore mine of TATA Steel including Noamundi Iron Mine is going for production

    expansion from 32.6 Million tonnes in 2018-2019 to 46.7 million tonnes in 2021-

    2022 which would go up to ~ 59.9 million tonnes by 2029-30. In this line, Noamundi

    Iron ore mine has been undertaken for production expansion of 19 MTPA and the

    beneficiation & dispatch shall expand upto 27 MTPA. Also, other captive mines of

    tata steel such as Katamati, Joda East and Khondbond shall also under goes for

    expansion in future.

    2.5 Import Vs Indigenous Production

    Noamundi iron ore mine is a captive iron ore mine and beneficiation of Tata steel

    Ltd. thus import is not applicable, all the iron ore production made shall be used

    for captive purpose. The current production is restricted to as per statutory

    approvals.

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 5

    2.6 Export Possibility

    There is no proposal for direct export at present from this mine.

    2.7 Domestic Vs Export Markets

    All the produced iron ore shall be consumed in TSL own integrated steel plants of

    company.

    2.8 Employment Generation (Direct and Indirect)

    The existing operation of Noamundi Iron Mine has direct & indirect manpower

    potential as 1053 & 2237 respectively.

    After expansion the mine generates potentially direct employment and indirect

    employments of 1121 & 2596 respectively including the existing manpower.

    3.0 PROJECT DESCRIPTION

    3.1 Type of Project Including Interlinked and Independent Projects, If Any

    Noamundi Iron mine was started way back in 1925 with manual mining. After

    expansion of the steel works at Jamshedpur, the mine was partially mechanized in

    1953 after which it has been gradually developed into a fully mechanized and

    environment friendly mine over the past few decades mining operations have so

    far been confined to the Eastern & Western ridges separated by Balijhor nallah. The

    mine has been the major captive source for meeting demand of iron ore for tata

    Steels Jamshedpur Plant, Kalinganagar steel plant and its subsidiaries (Tata

    Metaliks limited, Tata Sponge Iron limited Tata Steel BSL, Usha Martin etc) and will

    continue to be in future.

    Currently, the expansion project includes production expansion from mines,

    installation of new beneficiation facility with dispatch and augmentation of other

    allied services such as building of new workshops, LG Plant, Briquetting, slime

    beneficiation, other pilot plant (SG beneficiation) water treatment plant, revamping

    of water supply line, conveying facility, mobile crushing, screening & washing

    facility shifting of colony etc..

    3.2 Location of the Project

    The Noamundi iron ore mine lease falls under six villages namely Mahudi, Balijore,

    Korta, Noamundi, Sarbil, Barabalijori under the Noamundi post office, West

    Singhbhum District, Jharkhand State. The location details are as follows:

    Mines : Boundary Pillar (TIS1) Coordinates Range of

    Mine Lease Area

    Latitude 22°08’14.465” N Between 22°05’N & 22°10’N

    Longitude 85°28’32.261”E Between 85°25’E & 85°35’E

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 6

    The project area is 120 km from Jamshedpur and 70 km from Chaibasa and falls in

    the toposheet 73 F/8 & 73 F/12.

    The area can also be approached from Noamundi Railway Station on Tatanagar –

    Gua /Barbil rail route of South Eastern Railways. The distance from Noamundi Iron

    mine to Noamundi railway station is about 5 km.

    The location of the project as Index map and study area map are given in Figure-

    1 and Figure-2 respectively.

    3.3 Details of Alternate Site Analysis

    No alternative site has been taken into consideration as this is an existing mining

    lease (site specific) and this proposal is for production expansion.

    3.4 Size or Magnitude of the Work

    The present rate of production of iron ore from the mine is 10 MTPA which will be

    increased to 19 MTPA during the expansion in successive years with total

    excavation of 27 MTPA. The beneficiation plant shall expand from 18 MTPA to 27

    MTPA.

    Noamundi iron ore mine has 150.74 million tonnes of proven reserves and ~157

    million tonnes of resources as on 01.04.2019. It is anticipated that the proposed

    ROM excavation will increase from 10 million tonnes to 19 million tonnes. Similarly

    processing capacity of the beneficiation plant will increase from 18 million tonnes

    to 27 million tonnes and will continue upto the end of life of mine.

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 7

    FIGURE-1

    INDEX MAP

    ANNEXURE-II

    STUDY AREA MAP

    Noamundi Mine Site

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 8

    FIGURE-2

    STUDY AREA MAP ON TOPOSHEET MAP

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 9

    3.5 Project description with process details (a schematic diagram / flow chart showing the

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

    A. OPEN CAST MINING

    Existing and Proposed Method of Excavation

    Noamundi iron ore mine was started way back in 1925 with manual mining. After

    expansion of the Steel Works at Jamshedpur, the mine was partially mechanized in

    1953 after which it has been gradually developed into a fully mechanized and

    environment friendly mine over the past few decades. Mining operations have so

    far been confined to the eastern and western ridges separated by Balijhor nallah.

    The mine has been the major captive source for meeting demand of iron ore for

    Tata Steel’s Jamshedpur plant, Kalinganagar steel plant and its subsidiaries (Tata

    Metaliks Limited, Tata Sponge Iron Limited, etc.) and will continue to be for Tata

    Steel’s Jamshedpur steel plant, Kalinganagar steel plant and its subsidiaries (Tata

    Metaliks Limited, Tata Sponge Iron Limited and Tata Steel BSL Limited, Usha Martin

    Limited etc) in foreseeable future.

    Mechanized method of open cast mining has been adopted for mining iron ore in a

    series of 12 m high benches with the help of shovel-dumper combination. The

    minimum bench width in the working benches is maintained at 25 m while in the

    ultimate stage, the bench width shall be reduced to 12 m thus having a final pit

    slope which is less than 45 degrees. Drilling is done using 150/165 mm diameter

    drills with 10% sub grade drilling. Rock breaker is utilized to break bigger size

    material into smaller fragments. Blasting is done by adopting the State of Art

    technology by using mostly SME (Site Mixed Emulsion Explosives). Nonel (non-

    electric initiation) and electronic detonators are used for blasting. The blasted

    material is excavated by shovels and loaded onto 100 tonne dumpers for

    transportation of the ore, subgrade or waste. Rigorous quality control procedure is

    adopted in the mine to avoid mixing of ore, subgrade and waste. Blast hole drill

    cuttings are sampled and analyzed in the laboratory using Inductively coupled

    plasma spectrophotometer (ICP) for determining iron and other elements.

    Depending upon the analysis results, mine face is demarcated as ore, subgrade

    and Waste zones and daily schedule for the material hauling is prepared

    accordingly. The subgrade is stacked separately at the earmarked place.

    Waste rocks encountered during the course of mining are handled separately and

    used for bench floor leveling, making berms etc. The ore is transported from

    different mining faces in a pre-determined proportion (for blending different

    qualities of ore), and deliver the same to the processing plant. The blending is

    aimed at maintaining the alumina content of ore at the desired range of 2.8% -

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 10

    4.3% in wet ore feed and 1.6% - 2.5% in dry ore feed. In the processing plant, the

    ore is crushed, washed and screened followed by classification and jigging to

    produce lumps and fines ore. The haul roads are maintained with a gradient of less

    than 1 in 16 except for short ramps, which have a maximum gradient of 1 in 10.

    The floor level of each bench is maintained by employing graders and dozers. This

    helps in easy, safe and efficient mobility of HEMM.

    Presently there are two waste dumps namely waste dump No 1 and waste dump

    No 2. During the plan period, there is proposal of two more waste dumps namely

    waste dump No 3, waste dump No 4. Total four number of waste dumps are

    proposed during the plan period. There is proposal of excavation of northern part

    of Hill 3 & 4 to its ultimate pit limit and the area would be backfilled by waste

    encountered during mining and will be named Waste dump No 3. Waste dump No

    4 is proposed towards south western side from the western pit and lies in the forest

    area for which the company has already sought for diversion.

    Mining operations had been confined to the eastern ridge and western ridge of the

    main block i.e Block- I. Presently, we are working in three pits namely Hill-3&4,

    Hill-5&6 and western pit .Present pits of main block are under operation since long

    time. Excavation of Hill 5 (In pit slime dam area) has been completed and it has

    been utilized for storing slime. Lot of low quality ore will be encountered in the

    already developed pits which requires good quality of ore for blending in order to

    feed into the processing plant. From mineral conservation point of view, along with

    the existing pit, the western pit and pit 7 will be developed in order to blend the

    good quality of ore from these areas with relatively low-quality ore from Hill- 5&6.

    This will help in supplying required quality and quantity of iron ore to meet

    increased requirement and quality of iron ore to our customers.

    The Noamundi Iron ore Mine is categorized as fully mechanized mine. Hydraulic

    drills are used for blast hole drilling. Excavation of ROM and overburden is

    undertaken through hydraulic shovels varying in capacities from 5.7 to 5.9 Cum

    and mining loader of capacity 9 Cum. Excavated material is hauled through bigger

    capacity dumpers of capacities ranging from 50 to 100 Tonnes. Taking into

    consideration to achieve higher production levels, increased lead distance due to

    excavation from the pits, the fleet will be upgraded & added gradually. The

    proposed loading equipment’s during the plan period consists of 4 shovels and 2

    loaders, one loader may be utilized for handling of temporary ore stockpiles. In

    addition of earlier more equipment’s will be utilized for setting up of new

    infrastructure facility of the upcoming projects which may vary based upon the

    requirement. The proposed fleet requirement consists of 100 tonne capacity

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 11

    dumper and shovel of 5.9 cum, however based upon the requirement and as per

    the ultimate pit design bigger fleet may be opted.

    The CIMFR (Central Institute of Mining & Fuel Research), Dhanbad has been

    engaged for conducting the rock fragmentation studies at Noamundi on quarterly

    basis. The recommendation of the study is being implemented for safe and scientific

    blasting in the mine. Blasting is done by drilling 150 mm dia holes with 10%

    subgrade drilling, for a bench height of 12 m.

    To sustain the above production rate from Noamundi Iron Mine, total ore required

    to feed the existing and upcoming plants will be around 201 Million tonnes till 2030.

    B. PROCESSING / BENEFICIATION OF ROM

    Noamundi processing plant, processes ore from Noamundi iron ore mine as well as

    from our TSL adjoining Katamati iron mine. One part of the ore is beneficiated by

    wet process while the other part of the ore is processed by the dry process. In the

    wet process, the feed constitutes hard ore, soft ore and flaky ore, which is fed in

    pre-determined proportion while in the dry process. The feed constitutes flaky ore

    and blue dust.

    WET BENEFICIATION:

    The mineral beneficiation process in the wet circuit has major change after

    introduction of jigging and hydro-cyclone facilities to improve the quality of the

    finished products and also ensuring further recovery of iron values from fines.

    The ROM is fed into the primary crusher having a capacity of 1800 tph (54-inch

    Gyratory crusher). The crushed ore (-200 mm) is then stored in two separate

    primary stockpiles. Primary crushed ore is then fed into two identical circuits, for

    secondary processing. Each secondary processing circuit consists of one secondary

    crusher which crushes the material to -40 mm. The crushed product is then

    screened on a double deck screen, with the top deck at 40mm and the lower deck

    at 10 mm. The oversize (i.e +40 mm) product from each of the secondary circuits

    is stored in a surge-pile from where it is fed to a tertiary crusher arranged in a

    closed loop, to ensure minimum generation of oversize in the sized ore. The -40

    mm + 10 mm fraction is recovered as Sized Ore. The -10 mm fraction of the

    secondary crushed product is sent to screw classifiers. The -10 mm fraction of the

    tertiary crushed product is recovered as Fines. In the screw classifier, the -10mm

    fraction from the secondary crushed product is classified to yield two products viz.

    -10 mm +0.15 mm (as underflow) and -0.15 mm (as overflow from classifier pool).

    The coarser fraction (i.e.-10mm +0.15mm) is then sent to a high frequency

    dewatering screen to drain off the excess moisture in the fines. The dewatering

    screens have a 0.20mm aperture, where the coarser fraction of the screw classifier

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 12

    (-10mm +0.15mm) output is screened. The -10mm +0.15mm product after

    screening is sent for jigging while the finer fraction (i.e -0.15mm) collected from

    each of the three circuits along with the classifier overflow and sent to the hydro

    cyclones for further processing.

    In the jigging plant, the fines (-10 mm +0.15 mm) are further beneficiated to yield

    Improved Quality Fines while the tailings are collected as solid rejects. In the hydro

    cyclones, the finer fraction (i.e. - 0.15 mm) is beneficiated to get improved yield &

    Quality Fines & hence an improved recovery, while the remaining slurry is sent to

    the thickeners. The slurry is thickened in the thickener and pumped to the slime

    dam. About 80% of the water is recovered and recirculated in the system.

    The company has future plans for total beneficiation, whereby a proportion of the

    higher alumina iron ore with lower iron values can also be beneficiated. In line with

    this and efforts towards mineral conservation, a Low-Grade Beneficiation Plant is

    also proposed to be installed for beneficiation of low grade ore. The Low-Grade

    Beneficiation Plant will consist of State of the Art beneficiation technology which

    includes Jigs.

    The steel company is also looking for beneficiation technology aiming to recover

    mineral values from the existing slime and Jig tailings. There are proposals for

    further pilot scale studies to finalize an economical beneficiation system like HGMS

    (High grade magnetic separator and through selective flocculation method), aimed

    towards mineral conservation.

    DRY BENEFICIATION

    Dry crushing plant comprises of primary gyratory crusher, screens, bins and

    conveyors. The ROM ore is transported by 50/60/100 tonne dumpers from the

    mines and dumped into the primary crusher. Primary crushed oversize product is

    conveyed to secondary cone crusher operating in open circuit with feed and product

    conveyors. Oversize product from the secondary cone crusher is conveyed to a

    tertiary cone crusher which is in closed circuit operation with a vibrating screen and

    conveyor system. Finally fines ore (-10 mm) is recovered after screening at every

    stage.

    In the dry crushing ore material is fed to the primary crusher. The crushed product

    (-220 mm) along with the undersize from the grizzly screen (i.e.- 100 mm) is sent

    to the double deck screen via apron feeder where oversize (+40 mm, -220 mm)

    goes to secondary crusher through surge hopper. The crushed product (-80 mm)

    along with the undersize from the double deck screen (i.e. -40 mm) is sent to surge

    bins (5 X 400 tonnes capacity). The -80 mm material is further screened and the

    oversize (+32 mm, -80 mm) is sent to tertiary crusher and the undersize (-32

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 13

    mm,+10 mm) is again screened on double deck screen and from there size (-10

    mm) sent to the product DCMP Fines Bins while size (+10 mm, -32 mm) sent for

    further crushing and rescreening. The crushed product of tertiary crusher is

    screened and after screening undersize (- 810 mm) is sent to the product DCMP

    Fines Bins and the oversize again sent to the tertiary crusher for further crushing

    which will be in the form of closed circuit.

    It is proposed that a fraction of ROM (run off mine) of iron ore will also be processed

    in mobile crushing, screening & washing plant.

    DENSE MEDIA SEPARATION (DMS) PROCESS FOR SUBGRADE PLANT

    TSL owns its captive iron ore mines in Jharkhand and Odisha. The ore is classified

    as per the statutory norms. The ore > 55% Fe is fed in the processing plants as

    Dry ROM Ore, Hard ROM Ore and Wet Rest ROM Ore.

    While mining, the subgrade ores (Ore with Fe > 45 but

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 14

    tank. In flat screen again it will get washed and overflow material will report to

    discard stockpile and underflow containing solution of Ferro Silicon ore will report

    to dilute medium tank.

    Dilute media collected in dilute media tank shall be treated in magnetic separator.

    Process water (nonmagnetic component) will be collected as make up water where

    magnetic component (containing Ferro Silicon) will report to Correct media tank.

    To separate possible sub grade material from the heavy media collected in ‘correct

    media tank, the liquid is pumped to a primary densifier cluster cyclone. Under flow

    of the cyclone reports back to correct media tank whereas its overflow reports to

    secondary densifier tank. The liquid in secondary densifier tank is processed in

    densifier to segregate the heavy media liquid in ‘correct media tank’ and dilute

    medium in dilute media tank. There shall also be provision to add make up FeSi or

    process water in secondary densifier tank as required.

    The discard from the wet separation screen at -1mm size shall be treated in a degrit

    cyclone. Overflow of the cyclone is sent to a thickener. Underflow of the thickener

    is screened at -1 mm. The oversize of the screen is discarded in the discard

    stockpile and effluent is sent back to the hydro-cyclone.

    The expected outcome of the plant is Size: -32+6 mm, Fe: 62%, Al2O3 - 2 to 3%

    3.6 Raw Material Required along with Estimated Quantity, Likely Source, Marketing

    area of Final Product/s, Mode of Transport of Raw Material & Finished Product

    Explosive & detonator are used as a raw material for the production of iron ore.

    SME (Site Mixed Emulsion Explosives). Nonel (non-electric initiation) and electronic

    detonators are used for blasting and sourced from local depot of Solar explosive.

    The final product is sent to TSL steel plant after beneficiation of ore.

    Mode of transport of raw material inside mine is by dumpers and beneficiated

    product through conveyors belts followed by railways & a small part through trucks

    covered with tarpaulin.

    3.7 Resource Optimization/Recycling & Reuse envisaged in the Project (if any should

    be briefly outlined):

    The subgrade, Gig reject & slime generated during the mining & beneficiation

    process will be stacked separately for its use for blending and beneficiation purpose.

    This will help us to optimize the resources and increase the life of mine.

    3.8 Availability of Water & its source, Energy/Power Requirement & Source should be

    given

    Water Demand & its Source:

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 15

    Noamundi iron ore mine is a hilly iron deposit and all mining operations are

    concentrated on hill top. The mining will not intersect ground water table during

    the plan period. Also, there is no discharges from mine. It is proposed that water

    requirement will be made from nearby Karo & Baitarni Rivers which has sufficient

    capacity throughout the year and water regime will remain unaffected because of

    the increase in production. During expansion project the water demand shall go up

    to 29, 000 KLD from Baitarani River, for which application has been made.

    Power Requirement & its Source

    Presently the power requirement of Noamundi iron ore mine is 12.6 MVA, which

    includes current power requirement of wet plant ~4.3 MVA, dry plant ~1.2 MVA,

    conveying and dispatching (PP2) ~ 3.5 MVA. Township and service building ~3

    MVA, mining area ~ 0.6 MVA. The future requirement will increase ~ 76 MVA, which

    includes new raw water pump house to cater the water requirement of plant

    expansion ~3 MVA, Up-gradation of existing processing plant and new plants ~

    23.6 MVA, New MHS and RLS ~5.8 MVA, slurry pumping to Jamshedpur plant ~

    31.39 MVA. Based upon the future requirement new facilities will be added in our

    power distribution system.

    3.9 Quantity of Wastes to be Generated (Liquid & Solid) & Scheme for their Management / Disposal

    During the expansion waste will be generated both from mining & beneficiation.

    The waste from mining is overburden generated during extraction of ore, which

    shall be stacked separately and reclaimed after adequate plantations in the area as

    per progressive reclamation activities. During expansion period FY-2019, FY-2020

    & FY-2021 the planned waste of 5.19 million tonnes, 5.17 million tonnes & 8 million

    tonnes generated. Presently there are two waste dumps namely waste dump No 1

    and waste dump No 2. During the plan period, there is proposal of two additional

    waste dumps creation namely Waste Dump No 3, Waste dump No 4. Thus all the

    overburden waste generated during mining shall be tacked in these four waste

    dumps. Some part of the waste shall be used for bench floor leveling, making berms

    etc. The mineral with future economic value known as subgrade generated in the

    mine also stacked separately in subgrade dump No 1 for its use in the future.

    During expansion plan period three more subgrade dumps are proposed. The total

    quantity of sub grade stacked in the subgrade dumps is close to 25.32 million

    tonnes and waste dumped in the aforesaid waste dumps is close to 7.5 million

    tonnes respectively as on 01.04.2019.

    In the iron ore beneficiation, dry & wet beneficiation is been practiced as per ore

    quality. The high-quality ore is been processed in dry plant where as in wet the

    poor-quality ore or low-grade ore or ore with other gangue mineral are processed,

    where waste generation in the form of slime reject, Jig reject. In the wet

    beneficiation, the crushed ore washed by process water and after washing of ore,

    slime the semi-solid material is fed to the thickener from where clear water

    overflows and is reused back in the plant. About 80% of water utilized for

    processing is recycled. Rest 20% water carries the underflow sludge. The underflow

    sludge is pumped into the slime dam having large storage capacity in which solids

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 16

    are allowed to settle and only clear water is decanted & recovered and reused in

    the process. After full capacity utilization the slime pond get evacuated and dry

    slime is stored in designated place for future use. The Jig reject generated from Jig

    process is blended in product material and thus waste is also used. However, the

    Jig reject is stored in designated area for future use.

    The wastewater generated from surface runoff are passed through garland drain

    followed by settling pits. The process water is recirculated through high rate

    thickener-slime pond-water holding thickener & back in the process, thus it acts as

    PETP i.e. Primary Effluent Treatment plant facility, however, there is no discharge

    from mine or process plant. The water loss observed is due to evapotranspiration

    and moisture loss in product. The water generated from hospital and HEMM

    washing shall be treated adequately by ETP, oil trap. The water from colony passed

    through septic tank followed by soak pits, however two 50 KLD STP and one 10

    STP is also installed. In future many more ETP & STP are been constructed.

    3.10 Schematic Representation of the Feasibility Drawings which give information of EIA Purpose

    Detailed schematic representations of the feasibility covering for the purpose of EIA

    will be given in the Environmental Impact Assessment report.

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 17

    4.0 SITE ANALYSIS

    4.1 Connectivity

    The project site Noamundi is located at a distance of 130 km from Jamshedpur and

    70 km from Chaibasa. The site is well connected by state highway no 4 & by south

    eastern railways with a station at Noamundi (NOMD). The nearest town are

    Jagannathpur (20 km), Barbil (20 km) on either side. The nearest airport is Ranchi

    at a distance of 205 km.

    4.2 Land Form, Land Use and Land Ownership

    The expansion project is a brownfield project with production expansion only.

    Present land use is already under industrial mining purposes. Land utilization during

    the expansion will be as per the approved Mining plan. The ownership of the entire

    project land lies with Tata steel.

    4.3 Topography

    The topography of the area is undulated and hilly terrain. The project site is situated

    at altitude of 600 m above mean sea level (MSL). The mineral deposit has a widely

    undulating terrain with steep escarpments, moderately elevated plateau and

    narrow winding valleys. The deposit is bifurcated into two ridges, namely, the

    Eastern Ridge and the western ridge with elevation varying between a high and low

    contour of 738 m and 516 m respectively, topographical map enclosed.

    4.4 Existing Land Use Pattern

    The project area comprises of 1230.42 ha includes the mine lease area of 1160.06

    ha. The Noamundi project area consists of 762.43 ha forest land, 467.99 ha non-

    forest land. The land use pattern in the lease area and the details of forest land

    including diverted and un-diverted forest land is as follows:

    TABLE-1

    LAND USE PATTERN

    Forest

    Reserve Forest -

    Protected Forest 762.43 ha

    Non-Forest

    Agricultural -

    Private land 76.59 ha (in Lease 41.85 ha + Outside lease 34.74 ha)

    Government land 391.40 ha (in Lease 355.78 ha +Outside lease 35.62 ha)

    Total Area 1230.42 ha

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 18

    Break-up of Forest Land (ha)

    Diverted

    Forest

    Applied for

    Diversion

    Safety

    Zone

    Total Forest

    Land

    370.92 383.37 8.14 762.43

    As on date, about 370.92 ha forest lease area has been diverted for mining activity out of

    762.43ha, for the rest of forest land application has been made for forest diversion for

    mining purpose and is at advanced stage of approval. The present and proposed land use

    details of mine lease are as on 01.04.2019 are given in the following Table-2.

    TABLE-2: PRESENT LAND USE PATTERN OF LEASE AREA

    Sr. No.

    Particulars Forest

    Land (Ha) Non-Forest Land (Ha)

    Total (Ha)

    1 Area under mining 165.382 211.623 377.005

    2 Storage for top soil 0.000 0.000 0.000

    3 Waste dump site 4.271 27.648 32.369

    4 Mineral storage 27.590 9.811 37.401

    5 Infrastructure 14.810 2.554 17.364

    6 Roads, Conveyor, Pipeline,

    Electric line 8.090 0.000 8.090

    7 Railways 0.000 0.000 0.000

    8 Tailing pond 48.037 34.628 82.665

    9 Effluent Treatment plant 0.000 0.009 0.009

    10 Mineral separation plant 18.290 1.500 19.790

    11 Township area 84.000 61.110 145.110

    12 Others (Magazine, Rain water

    harvesting) 0.000 1.317 1.317

    Total Utilized Area 370.920 350.200 721.120

    Safety Zone 8.140 6.130 14.270

    Total Unutilized Area 383.370 41.300 424.670

    Total Lease Area 762.430 397.630 1160.060

    TABLE-3: PROPOSED LAND USE AREA AT THE END OF PLAN PERIOD

    Sr. No. Particulars Forest Land

    (Ha)

    Non-forest

    Land (Ha)

    Total (Ha)

    1 Area under mining 234.824 217.099 451.923

    2 Storage for top soil 0.108 0.000 0.108

    3 Waste dump site 31.458 34.038 65.496

    4 Mineral storage 90.194 7.835 98.029

    5 Infrastructure 14.810 5.018 19.828

    6 Roads, Conveyor, Pipeline,

    Electric line

    11.180 9.600 20.780

    7 Railways 0.000 0.000 0.000

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 19

    8 Tailing pond 73.615 34.628 108.243

    9 Effluent Treatment plant 0.000 0.009 0.009

    10 Mineral separation plant 21.490 17.450 38.940

    11 Township area 69.398 42.369 111.767

    12 Others (Magazine, Rain

    water harvesting)

    0.000 3.381 3.381

    TOTAL UTILIZED AREA 547.077 371.427 918.504

    Safety Zone 8.140 6.130 14.270

    TOTAL UNUTLISED AREA 207.213 20.073 227.286

    TOTAL LEASE AREA 762.43 397.63 1160.06 Source : IBM Approved Mining Plan

    TABLE-4

    LAND USE DETAILS OF PROJECT AREA (1230.42 HA)

    Sr. No. Head Forest Non-Forest Total Area

    1 Mine lease 762.430 397.630 1160.06

    2 Beneficiation Plant & Railway

    dispatch facility 00 70.36 70.36

    Total Area (ha) 762.430 467.99 1230.42

    The existing total project area for mining, beneficiation and dispatch is 1230.42 ha.

    Apart from 1230.42 ha project area other separate area 71.087 ha is used for

    airstrips, pump house and small residential colony at Sangram sahi (11.90ha), which

    makes the total land of Noamundi is 1301.507 ha.

    As the area is existing operational mining area and far away from sea, thus CRZ is

    not applicable.

    4.5 Existing Infrastructure

    a) Site Services:

    Canteen: Noamundi Iron ore Mine has provided canteen facilities at LRP plant, railway

    siding, near central workshop and mega Centre. These canteens take care of the tea,

    snacks and meals for all the employees. Separate enclosures for serving the women

    employees have been provided in the canteen at all locations.

    Rest Shelters: There are three well-ventilated, neat and clean rest shelters at

    Noamundi Iron ore mine in addition to the canteen which also serves as a rest shelter.

    First Aid Station: Several first-aid stations manned by qualified first-aiders during all

    working hours are being maintained in Noamundi Iron Mine. The First Aid Stations

    are provided with all necessary equipment’s as per the requirement of the Mines

    Rules, 1955. The company’s hospital at Noamundi Township, with telephonic

    communication, being nearby serve as first aid rooms for the mine.

    All other facilities, which include provision of wholesome drinking water, urinals and

    latrines as per the provisions of The Mines Rules, 1955 has been provided in the

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 20

    mines. The ancillary facilities such as equipment garage, workshop and stores are

    described below:

    Equipment Garage: The equipment garage takes care of repair and maintenance of

    all working equipment such as dumpers, excavators, dozers, drills etc. The garage

    has provision of various repairing and handling facilities, major overhauling of HEMM.

    In addition to this, a mobile service van has been provided which takes care of routine

    servicing and minor repairs of the equipment in the field.

    Mega Centre: The mega center is located beside the equipment garage & housing the

    offices of Noamundi & Katamati as well as the canteen meant for the employees

    working in that area,

    Central Workshop: There is a well-equipped workshop, which cater to the requirement

    of Noamundi iron ore mine as well as Katamati iron ore mine. The workshop consists

    of Blacksmith shop, Carpentry shop, welding and machine shop etc. to take care of

    most of the machining, milling jobs required for both HEMM and processing plant

    Relocation of Infrastructures: In view of the future expansion of mining activities, the

    following infrastructures will either be a falling very close or infringing with the

    expanding mining areas.

    Hence, they need to be relocated which includes equipment garage with mega center,

    vocational training center, workshop, civil & electrical office, security office, GM

    office, water supply complex, part of township, hospital etc.

    4.6 Soil Classification

    The distribution of different soil types of the area depends much on its

    physiographic and lithologic variations. The soil of the project defined as a mixture

    of rock and mineral material with the organic matter.

    4.7 Climatic Data from the Secondary Sources

    The climate here is tropical. In winter, there is much less rainfall than in summer.

    The average annual temperature in Noamundi is 24.9°C. The rainfall here averages

    1364 mm. The district is characterized by tropical to sub-tropical climate with hot

    summer, high and well-distributed rainfall during the monsoon and a cold winter.

    The summer season lasts from March to May, the rainy season starts in June and

    continues up to September. October and November constitute the autumn season

    and winter starts in December. May is the hottest month of the year with a

    maximum temperature of about 46o C. The southwest monsoon is the principal

    source of rainfall in the area.

    4.8 Social Infrastructure Available

    There is no likelihood of effect of outside people or influx on the existing local

    population. The lessee is spending substantial amount through Tata Steel Rural

    Development Society for peripheral developments such as education, health,

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 21

    sports, afforestation etc. Hence the benefits to the community and its economy

    because of this project are quite appreciable.

    5.0 PLANNING BRIEF

    5.1 Planning Concept (types of industries, facilities, transportation etc.), Town and

    Country planning/Development authority Classification

    The proposed project is production expansion of existing operational iron ore mine

    & its beneficiation plant and planning for excavation shall be governed by the

    approved mining plan.

    5.2 Population Projection

    Since inception of mining activities in production of iron ore mining from this mining

    project is beneficial. Direct and indirect employment will be generated due to the

    project. Unskilled /semi-skilled manpower can be sourced from the local area and

    skilled manpower will be sourced from outside. Due to expansion of project 359

    additional manpower is required along with existing in direct and indirect work. No

    increase in population is envisaged since the mining operation is carried out since

    long back in this area.

    5.3 Land use Planning

    Proposed expansion project will be set up in the existing mining lease area for built-

    up structures, green belt etc. will be same as per scheme suggested in the approved

    mine plan for existing mine. Land use planning for proposed expansion project will

    be followed as per approved mine plan.

    5.4 Assessment of Infrastructure Demand (Physical & Social)

    TSL has assessed the demand of infrastructure (physical & social) in nearby area

    of the mine site and development activities have been started under corporate

    social responsibilities programs as per the plan.

    5.5 Amenities/ Facilities

    Rest shelters, toilets, drinking water facilities, first aid facilities, and regular medical

    checkup facilities have been provided for laborers and their families.

    6.0 PROPOSED INFRASTRUCTURE

    6.1 Industrial Area (Processing Area)

    Details of proposed infrastructure includes installation of new wet and dry plant,

    mobile crushing & screening facility, slurry pipeline for material dispatch, upgradation

    of water receiving line, modification in existing plant to receive more ore feed, new

    HEMM & its maintenance area, new auxiliary infrastructure such as enhanced water

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 22

    treatment plant, water collection pond, upgraded water pipeline, new thickeners,

    new slime briquetting plant, low grad beneficiation plant, new dispatch system,

    enhanced loading system, new private & public railway sidings, offices etc.

    6.2 Residential Area (Non-Processing Area)

    The existing residential area shall be modified to the state-of-the-art facility and

    new area shall be developed due to demolishing of old structures.

    6.3 Greenbelt

    Afforestation:

    During 2010-11, out of 8,500 saplings, it was proposed to plant 2,500 saplings in

    dump slope which has been completed, the remaining 6,000 saplings were planned

    for gap filling in already afforested area, against which we could plant 2,500

    saplings only in the available area due to high survival rate of 85% and excess

    plantation of 29,500 sapling during the previous years.

    During the year 2019-2020 to 2021-2022, a total of 50,000 saplings to be planted

    on dump slope in order to stabilize the dumps. Terraced contours were made on

    which pits were dug and samplings were planted after making required soil

    amendments. These saplings are watered and protected to ensure their survival.

    The afforestation program in the next three years will include plantation of different

    species like Karanj, Amaltash, Kachnar, Baheda, Shemal, Anida, Kurchi, Arjun,

    Ficus species, Jamun etc.

    Conceptual Reclamation of Mined Out Area:

    The mined out area will be reclaimed and rehabilitated as indicated in the Table

    below:

    RECLAMATION OF THE MINED-OUT AREA

    Activity Conceptual Land Degradation by

    mining

    Reclamation measures

    Area in ha Area in ha Measures

    Mining Excavation

    823.441

    126.00

    349.209

    304.472

    43.760

    • Afforestation of mine benches by plantation already done.

    • Afforestation of mine benches by plantation to be done.

    • Backfilling with overburden, waste, tailing and mineral rejects and subsequent afforestation.

    • Bottom benches forming a pit shall be converted for water storage.

    Dumps/ Tailing dam

    118.791

    • Filling with overburden/ tailing generated

    during mining/ beneficiation process and subsequent afforestation.

    Source: IBM approved Mining Plan

    6.4 Social Infrastructure

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 23

    Employment, medical facilities, educational facilities, transportation etc. will be

    further strengthened by Tata Steel Ltd.

    6.5 Connectivity (Traffic & Transportation Road/Rail/Metro/Water ways etc)

    The site is well connected with NH-4 & South Eastern railways. However, the

    existing public road may get expanded & widen as the work is under progress. The

    site is well connected via Noamundi railway station with a daily train to Jamshedpur,

    Rourkela etc. The nearest airport is Ranchi which is at 205 km.

    6.6 Drinking Water Management (Source & Supply of water)

    The daily drinking water is been managed by the major source river. The unit is

    proposing to supply drinking water facility via dug well.

    Due to production enhancement there is negligible increase in domestic water

    majorly used for drinking.

    6.7 Sewerage System

    The project site has existing colony with sewerage arrangement. All the households

    are connected with septic tank followed soak pits. However, currently three Sewage

    Treatment Plants (STP) of 2x50 KLD & 10 KLD are working smoothly. In future,

    some additional Sewage Treatment Plants (STP) shall be constructed. The water

    treated water from plant is used for horticulture activities.

    6.8 Industrial Waste Management

    Industrial waste such as overburden, slime, jig reject etc shall be generated as per

    process and managed adequately as per standards.

    6.9 Solid Waste Management

    Industrial waste such as overburden, slime, jig reject etc shall be generated as per

    process and managed adequately as per standards. During course of mining some

    additional dumps (sub grade, OB, slime, Jig etc) shall be generated due to economic

    value of material for future use.

    6.10 Power Requirement and Supply/ Source

    Considering the expansion of the mine, the consumption will increase to ~ 76 MVA.

    in future for which required infrastructure will be laid down at suitable location. The

    electricity will be used mainly in illumination as well as operating processing plant

    and office building along with other infrastructure area. The unit also has solar

    power plant of 3 MW which shall support and enhance in future accordingly. The

    facility for renewable power generation from Solar Energy has been constructed at

    Hill-1&2. It is the first solar plant of more than 3 MW in iron mine in the world. The

    total fenced area is of 19.2 acres.

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 24

    7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN

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

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

    given)

    No R&R plan is required as no displacement of people is proposed for the expansion

    of mining project.

    8.0 PROJECT SCHEDULE & COST ESTIMATES

    8.1 Likely date of start of construction and likely date of completion (Time schedule of

    the project to be given)

    It is a running mine. The expansion project will be commissioned after getting all

    the regulatory approvals.

    8.2 Estimated Project Cost along with analysis in terms of economic viability of Project

    Total estimated cost of expansion is Rs 5,558 Crores, which includes the cost of

    slurry pipeline of Rs 2,000 Crores from Noamundi to Jamshedpur and project cost

    for mining & beneficiation is 3558Cr only. However as per Corporate Environment

    Responsibility (CER) guideline dated 1st May 2018 of MoEF&CC no. 22-65/2017-

    IA.III, the total environmental cost for Brownfield project is approximately 14

    Crores.

    9.0 ANALYSIS OF PROPOSAL

    9.1 Financial and Social Benefits with Special Emphasis on the Benefits to the Local

    People including the Tribal Population if any

    Proposed expansion project will result in growth of the surrounding areas by

    increasing direct and indirect employment opportunities in the region including

    ancillary development and supporting infrastructure. Special emphasis on Financial

    and Social benefits will be given to the local people including tribal population, if

    any, in the area. Development of social amenities will be in the form of medical

    facilities, education to underprivileged and creation of self-help groups.

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 25

    ANNEXURE-I: MINING LEASE DETAILS

    Tata Steel Limited (TSL) holds the Noamundi iron ore mine lease over an area of 1160.06 ha

    located at Noamundi, West Singhbhum district of Jharkhand State and is being worked for

    winning of iron ore for captive purpose of steel manufacturing. Noamundi Iron ore mine’s lease

    was originally granted from 01.01.1922 for a period of 30 years over an area of 1160.06 ha. 1st

    Renewal for 30 years w.e.f. 01.01.1952 over an area of 1160.06 ha. 2nd Renewal over an area

    of 1160.06 ha granted by Govt of Bihar vide their memo no.4795 dated 01.09.1984 and lease

    deed executed on 20.10.1985. Third Renewal of lease was applied on 17.12.2009. EC for

    Noamundi was granted for the entire lease area of 1160.06 Ha with total project area of 1230.42

    Ha vide letter number No J-11015 /104 /2011-IA.II(M) dated 10.06.2013 for production of 10

    MTPA of ROM and expansion of beneficiation plant from 10 MTPA to 18 MTPA with

    dispatch. FC has been granted over an area of 370.92 ha for mining purpose vide no 8-279,

    1985 FC Pt Dated 04.09.2014 and the FC over balance area of 383.37 Ha is in advanced stage

    of approval (recommendation for grant of Stage I submitted by State Government to MoEF on

    14th Sept 2018).

    State Government renewed the lease over a reduced area of 768.55 Ha on 13.12.2014 in view

    of MOEF circular no F.No. 11-362/2012-FC dated 01.02.2013. The said circular was

    superseded by MoEF circular number F.No. 11-599/2014-FC dated 01.04.2015. Subsequently

    on enforcement of MMDR (Amendment) Ordinance 2015, the said express order was partially

    modified vide letter dated 12.2.2015 by Government of Jharkhand whereby State decided to

    extend the Noamundi Mine up to 31.03.2030 in line with the MMDR Amendment Ordinance

    2015 over the entire lease area of 1160.06 Ha (copy of the letter enclosed below). However,

    the same was withdrawn vide letter no ̀ 1613 dated 31.07.2015. The withdrawal was challenged

    by Tata Steel in High Court of Jharkhand vide WPC 3768 of 2015 filed on 12.08.2015. The

    court vide its order dated 28.06.2018 directed the State Government to decide on the

    representation of Tata Steel which is already pending before the State of Jharkhand in

    accordance with law and in light of Section 8A(5) of the MMDR Act 1957. (copy of the order

    enclosed below). The matter is under consideration of State Government for renewal/extension

    of the lease.

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 26

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 27

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 28

    ANNEXURE-II

    SURFACE PLAN

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 29

    ANNEXURE-III

    CONCEPTUAL PLAN

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 30

    ANNEXURE-IV

    GEOLOGICAL PLAN

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 31

    ANNEXURE-V

    FLOW CHART OF THE BENEFICIATION PLANT

    Material Flow sheet of existing wet plant, Noamundi

    Material Flow sheet of existing dry plant, Noamundi

    Material Flow sheet of existing dry plant, Noamundi

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 32

    Material Flow sheet of new crushing, screening & washing plant, Noamundi

    Material Flow sheet of new dry processing plant, Noamundi

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 33

    Flow sheet of proposed Low grade beneficiation plant, Noamundi

  • Pre-Feasibility Report for Expansion of Noamundi Iron Ore Mine (ML Area

    :1160.06 Ha), From 10 MTPA to 19 MTPA (ROM) With Total Excavation of 27 MTPA and Enhancement of Iron Ore Beneficiation Capacity (Feed to Plant) From

    18 MTPA to 27 MTPA in Total Project Area of 1230.42 ha at Noamundi

    Pre Feasibility Report

    Vimta Labs Limited, Hyderabad 34

    Block diagram of upstream facilities at Noamundi of future iron ore slurry

    pipeline