Orient Abrasives Limited Pre-feasibility Report: Mining of 96030 TPA Bauxite ROM in lease area 25.8798 Ha at Survey number 330/P, Mewasa Village, Kalyanpur Taluka, District Jamnagar, Gujarat ORIENT ABRASIVES LIMITED PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA TABLE OF CONTENTS 1 EXECUTIVE SUMMARY ..........................................................................................4 2 INTRODUCTION ...................................................................................................6 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 THE PROJECT PROPONENT ........................................................................................ 6 THE PROJECT BACKGROUND ...................................................................................... 6 BRIEF DESCRIPTION OF THE NATURE OF THE PROJECT ...................................................... 6 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY / REGION ............................ 7 DEMAND-SUPPLY GAP.............................................................................................. 7 IMPORTS V/S INDIGENOUS PRODUCTION ....................................................................... 7 EXPORT POSSIBILITY ............................................................................................... 7 DOMESTIC / EXPORT MARKETS .................................................................................. 7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ............................ 8 2.9.1 2.9.2 3 Direct ......................................................................................................... 8 Indirect ...................................................................................................... 8 PROJECT DESCRIPTION .......................................................................................9 3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS ......................... 9 3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND PROJECT BOUNDARY AND PROJECT LAY OUT WITH COORDINATES) ................................................................................. 9 3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE 10 3.4 SIZE OR MAGNITUDE OF OPERATION.......................................................................... 10 3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ........................................................... 10 3.5.1 Salient Features of Mode of Working ........................................................... 11 3.5.2 Year Wise Production for Five year period .................................................... 11 3.5.3 Production for Plan Period .......................................................................... 12 3.6 CONCEPTUAL MINING PLAN ..................................................................................... 13 3.6.1 Exploration ............................................................................................... 13 3.6.2 Ultimate Pit Limit ....................................................................................... 13 3.6.3 Stacking of mineral rejects and disposal of waste ......................................... 13 3.6.4 Plantation ................................................................................................. 14 3.7 EXTENT OF MECHANIZATION.................................................................................... 14 3.8 TRANSPORT ........................................................................................................ 14 3.9 BLASTING .......................................................................................................... 14 3.10 RAW MATERIALS REQUIRED ALONG WITH QUANTITY LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCT MODE OF TRANSPORT OF RAW MATERIAL & FINISHED PRODUCTS .................................... 14 3.11 RESOURCE OPTIMIZATION / RECYCLING AND REUSE ENVISAGED IN THE PROJECT ................... 15 3.12 AVAILABILITY OF WATER ITS SOURCE AND ENERGY/POWER REQUIREMENT ........................... 15 3.12.1 Water ....................................................................................................... 15 3.12.2 Fuel.......................................................................................................... 16 3.13 WASTE GENERATION AND MANAGEMENT ..................................................................... 16 3.13.1 Solid Waste Management ........................................................................... 16 3.13.2 Liquid Waste Management ......................................................................... 17 3.14 SCHEMATIC REPRESENTATION OF FEASIBILITY DRAWING WHICH GIVES INFORMATION FOR EIA PURPOSE ...................................................................................................................... 17 4 SITE ANALYSIS ...................................................................................................18 4.1 4.2 4.3 4.4 CONNECTIVITY .................................................................................................... 18 LAND FORM, LAND USE AND LAND OWNERSHIP ............................................................ 18 TOPOGRAPHY ...................................................................................................... 19 GEOLOGY OF THE MINING LEASE AREA ....................................................................... 19 ORIENT ABRASIVES LIMITED 2 ORIENT ABRASIVES LIMITED PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA 4.5 EXISTING LANDUSE 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 HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN ............................................................................. 19 4.6 EXISTING INFRASTRUCTURE .................................................................................... 20 4.7 SOIL CLASSIFICATION ............................................................................................ 20 4.8 CLIMATIC DATA FROM SECONDARY SOURCES ................................................................ 20 4.8.1 Temperature ............................................................................................. 20 4.8.2 Wind ........................................................................................................ 20 4.8.3 Rainfall ..................................................................................................... 21 4.8.4 Cloud Cover .............................................................................................. 21 4.8.5 Humidity ................................................................................................... 21 4.9 SOCIAL INFRASTRUCTURE ....................................................................................... 21 5 PLANNING BRIEF ...............................................................................................22 5.1 5.2 5.3 5.4 5.5 6 PLANNING CONCEPT .............................................................................................. 22 POPULATION PROJECTION ....................................................................................... 22 LANDUSE PLANNING .............................................................................................. 22 ASSESSMENT OF INFRASTRUCTURE DEMAND................................................................. 22 AMENITIES / FACILITIES ......................................................................................... 22 PROPOSED INFRASTRUCTURE ...........................................................................23 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 INDUSTRIAL AREA (PROCESSING AREA) ...................................................................... 23 RESIDENTIAL AREA (NON-PROCESSING AREA) .............................................................. 23 GREENBELT ........................................................................................................ 23 SOCIAL INFRASTRUCTURE ....................................................................................... 23 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD / RAIL / METRO / WATERWAYS) .......... 23 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ....................................... 23 POWER REQUIREMENT AND SUPPLY / SOURCE .............................................................. 23 INDUSTRIAL WASTE MANAGEMENT ............................................................................ 23 SOLID WASTE MANAGEMENT ................................................................................... 23 SEWAGE SYSTEM .................................................................................................. 23 7 REHABILITATION AND RESETTLEMENT (R& R) PLAN .......................................24 8 PROJECT SCHEDULE AND COST ESTIMATES ......................................................25 8.1 PROJECT SCHEDULE .............................................................................................. 25 8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT ....................................................................................................................... 25 9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)...................................26 9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE AREA .............................................................. 26 INCLUDING TRIBAL POPULATION, IF ANY, IN THE ORIENT ABRASIVES LIMITED 3 ORIENT ABRASIVES LIMITED PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA 1 EXECUTIVE SUMMARY M/s Orient Abrasives Limited (OAL) is a Public Limited Company, incorporated under Companies Act, 1956, having its registered office at 1307, Chiranjiv Tower, 43 Nehru Place, New Delhi, India - 110019. OAL was established as a venture to manufacture calcined and fused alumina products in 1974, in technical collaboration with Karborundum, Bentueky, Czechoslovakia, by the Rajgarhia Group of Industries. M/s OAL holds mining lease of Varada – II Bauxite Mine over an area of 25.8798 hectares, in survey number 330/P of Village Mewasa, Taluka Kalyanpur, District Jamnagar of Gujarat state, granted by the Government of Gujarat, Industries & Mines Department by their grant order MCR/1584 (0-18)1915-CHH dated 23/04/1985. The mine was executed on 23/09/1985, vesting with lessee mining rights for 20 years. The lease got expired on 22/09/2005 and prior to that, the lessee has applied first renewal application on 13/09/2004 for the lease and it is under the consideration of State Government. The modified mining plan was approved by the Indian Bureau of Mines (IBM), vide their letter number 682 (23) (511)/2007 MCCM (N) UDP dated 08/05/2007. Further the mining scheme was approved vide their letter number 682 (23) MS-490/2009 MCCM (N) UDP dated 21/08/2009. The proposed project is for expansion of quantity of bauxite mining at Varada - II mine lease from 9514.9 TPA (Pre- 1994) to 96030TPA ROM. The mine lease is designated as Government land and does not involve any forest area within it. It is a piece of non-irrigated barren land. Considering mineable reserves of 8,18,688 MT and considering average rate of production to be 76,000MT, life of mine would be around 12 years. Mining will be carried out by manual open cast mining method. Bauxite horizon is present on surface on part of the area and below thin cover of soil or limestone in part of the area. Soil/Limestone having a thickness of 1.0 m is removed first by formation of one bench. Bauxite is excavated by forming 3 benches of thickness 1.5 m each. Bauxite horizon is compact in nature and requires drilling and blasting. Drilling is being done by jackhammer using drill rods and blasting with the help of explosives. The blasted material after manual sorting will be loaded in trucks. High grade bauxite will be transported to company’s manufacturing unit at Porbandar using covered trucks. According to approved mining plan, during five years, total 4.8220 hectare area will be worked out and in that period around 477378 tonnage of ROM will be generated, along with this around 16940 m3 of overburden and 43398 m3 of mineral waste (20% of ROM) will be generated. During Afforestation programme, about 250 plants will be grown covering 2500 m2 area. The total area covered including existing plantation will be about 6500 m2 upto lease renewal period. Water will be required for domestic, green belt development and dust suppression. Water stored in old pits will be used for green belt development and dust suppression while water supplied through tankers will be used for domestic purposes. Water requirement would be around ~ 5.15 KLD. The mine will be worked in eight hour shifts i.e. during day time only, & hence no electricity for lightning is required. Diesel will be used as fuel for running equipments at the mining site. Consumption of diesel is estimated to be 5 lit/hr for compressor & 3 lit/hr for water pump when in use. In the proposed mining scheme the soil/limestone generated will be the OB, and besides this the waste that is likely to be generated will be in the form of associated clay with the bauxite ORIENT ABRASIVES LIMITED 4 ORIENT ABRASIVES LIMITED PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA horizon as mineral waste, which is below the threshold grade and has no sale value. All the waste which consists over burden will be backfilled over mined out areas. All air emissions, liquid and solid wastes will be handled as per the applicable norms of the MoEF, CPCB, & GPCB as relevant. About 114 skilled and unskilled miners will be engaged in mining activities for the project. The proposed activities shall generate indirect employment in the region due to the requirement of workers to provide service related to auxiliary and ancillary works, which would marginally improve the economic status of the people. Further the additional benefits to the down stream units such as iron industries, steel industries, cement plants and metallurgical industries also add value to the society. ORIENT ABRASIVES LIMITED 5 ORIENT ABRASIVES LIMITED PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA 2 INTRODUCTION 2.1 The Project Proponent M/s Orient Abrasives Limited (OAL) is a Public Limited Company, incorporated under Companies Act, 1956, having its registered office at 1307, Chiranjiv Tower, 43 Nehru Place, New Delhi, India - 110019. OAL was established as a venture to manufacture calcined and fused alumina products in 1974, in technical collaboration with Karborundum, Bentueky, Czechoslovakia, by the Rajgarhia Group of Industries. It is a multi-divisional company, having a head office at New Delhi, manufacturing facilities at Porbandar (Gujarat) and Bhiwadi (Rajasthan) and distinction of being ISO - 9001 (Quality Management System - QMS) certified. The Company offers a wide range of refractory and monolithic products for the iron and steel industry and enjoys a large domestic and international clientele. An in-house R&D facility supports the division’s product development initiatives. 2.2 The Project Background M/s OAL holds mining lease of Varada – II Bauxite Mine over an area of 25.8798 hectares, in survey number 330/P of Village Mewasa, Taluka Kalyanpur, District Jamnagar of Gujarat state, granted by the Government of Gujarat, Industries & Mines Department by their grant order MCR/1584 (0-18)1915-CHH dated 23/04/1985. The mine was executed on 23/09/1985, vesting with lessee mining rights for 20 years. The lease got expired on 22/09/2005 and prior to that, the lessee has applied first renewal application on 13/09/2004 for the lease and it is under the consideration of State Government. The modified mining plan was approved by the Indian Bureau of Mines (IBM), vide their letter number 682 (23) (511)/2007 MCCM (N) UDP dated 08/05/2007. Further the mining scheme was approved vide their letter number 682 (23) MS-490/2009 MCCM (N) UDP dated 21/08/2009. 2.3 Brief Description of the Nature of the Project The proposed project is for expansion of quantity of bauxite mining at Varada - II mine lease from 9514.9 TPA (Pre- 1994) to 96030TPA ROM. The mine lease is designated as Government land and does not involve any forest area within it. It is a piece of non-irrigated barren land. Considering mineable reserves of 8,18,688 MT and considering average rate of production to be 76,000MT, life of mine would be around 12 years. In Varada – II bauxite area the nature of deposit is bedded, mineral bauxite is present in form of bed, which is overlain by a cover of limestone. The proposed project entails open cast mining in the mining lease of Varada - II bauxite mine by using drilling and blasting. As the mining lease was already worked out therefore on the basis of geological data gathered from the working pits, ore reserves were estimated. ORIENT ABRASIVES LIMITED 6 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED Table 1: Category wise Reserves of Bauxite (MT) Proved Category Probable Category Possible Category (Tonnes) (Tonnes) (Tonnes) 5,64,547 4,11,753 1,39,899 Total (Tonnes) Reserve Blocked up in barrier Mineable Reserves (Tonnes) (Tonnes) 1,17,6199 N.A 8,69,538 In all 5,64,547 MT of geological reserves of proved category has been calculated in the approved modified mining scheme, and out of 9,76,300 MT of demonstrated reserves 8,69,538 MT was considered under mineable reserves. 2.4 Need for the Project and its Importance to the Country / Region Bauxite mining is a very important economic activity in the Saurashtra region of Gujarat. Gujarat State is one of the three major bauxite bearing and producing areas in India. On an average, annually Gujarat produces around 1.0 to 1.2 million tons of bauxite in India amounting to 17-18% of the national production (around 6.0 Million Tons). Quality wise the grades vary from low to high grade alumina, low silica, and low calcium oxide. The main grades produced based on Al2O3 content include: < 50%, 50 - 56% and > 56% Mineralogical tests have indicated that the bauxite of this area is highly suitable for metallurgical purposes. Bauxite mining industry of the region contributes significantly to the State Gross Domestic Product and provides direct employment to about thousands of labour. Additional jobs are created by way of transportation and related jobs, ancillary to mining. This project aims to augment the high grade bauxite supply to OAL’s Porbandar manufacturing unit. The end products of OAL’s Porbandar manufacturing unit are vital inputs for iron & steel industries. Consequently, this project aims at keeping many of the key metallurgical industries within the country well supplied with required materials 2.5 Demand-Supply Gap This is an existing captive mine for supply of high grade material to Orient Abrasive Limited’s Plant located at Porbandar. Hence demand supply issues whilst important, are not considered in the current situation. 2.6 Imports v/s Indigenous Production This is an existing mine for the supply of high grade material to OAL’s plant located at Porbandar and OAL has not imported high grade material yet. 2.7 Export Possibility Nil, high grade bauxite from the mine will be used in OAL’s manufacturing unit at Porbandar, while low grade will be sold to local consumers only after getting permission from Government of Gujarat. 2.8 Domestic / Export Markets High grade bauxite from the mine will be used in OAL’s manufacturing unit at Porbandar, while low grade will be sold to local consumers only after getting permission from Government of Gujarat. ORIENT ABRASIVES LIMITED 8 ORIENT ABRASIVES LIMITED 2.9 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA Employment Generation (Direct and Indirect) due to the Project 2.9.1 Direct Mine will work in one shift i.e. general shift likely employment is as follow One Mines Manager One Part Time Mining Engineer Two Driller Hundred and Ten Unskilled Labor 2.9.2 Indirect Few people would be engaged in providing support services to the mining operation including transportation of ROM. The exact number of such persons is likely to be in the order of ~ 2030. Bauxite produced from mine will be processed in OAL plant at Porbandar and final product will be sold to customers for use or further processing. This will generate additional economic demand that could translate into additional employment. ORIENT ABRASIVES LIMITED 9 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED 3 PROJECT DESCRIPTION The information presented in this chapter is based on IBM approved mining plan. 3.1 Type of Project including Interlinked and Interdependent Projects The mine is a captive mine for OAL’s manufacturing unit at Porbandar, Gujarat. 3.2 Location (Map Showing General Location, Specific Location and Project Boundary and Project Lay Out with Coordinates) Location The mine is located at survey number 330/P, Village Mewasa, Taluka Kalyanpur, District Jamnagar in Gujarat State. Map showing location of lease is attached as Plate II (Location and Key Plan). The lease area is having north south trending low ridges of bauxite in eastern side and remaining area is almost plain ground sloping towards west. The area is covered by very scanty vegetation, mostly babool bushes grown over barren stony wastelands. No watercourse is present in the area in form of nallahs, rivers etc. Error! Reference source not found. shows the latitude and longitude of the area. Latitude and Longitude of the Site Table 2: Latitude and Longitude of lease area Co-ordinates Latitude Longitude 1 22°14'38.8'' 69°18'30.5'' 2 22°14'40.5'' 69°18'33.9'' 3 22°14'43.8'' 69°18'40.9'' 4 22°14'45.2'' 69°18'43.5'' 5 22°14'40.8'' 69°18'47.8'' 6 22°14'41.3'' 69°18'48.7'' 7 22°14'47.5'' 69°18'45.4'' 8 22°14'47.0'' 69°18'45.1'' 9 22°14'48.4'' 69°18'35.7'' 10 22°14'48.9'' 69°18'35.2'' 11 22°14'47.7'' 69°18'33.2'' 12 22°14'45.9'' 69°18'33.4'' 13 22°14'43.6'' 69°18'28.1'' 14 22°14'42.6'' 69°18'26.4'' 15 22°14'43.8'' 69°18'23.9'' 16 22°14'42.4'' 69°18'23.6'' 17 22°14'40.4'' 69°18'23.4'' 18 22°14'39.9'' 69°18'25.7'' 19 22°14'36.3'' 69°18'26.7'' 20 22°14'35.3'' 69°18'19.0'' 21 22°14'34.3'' 69°18'17.5'' ORIENT ABRASIVES LIMITED 10 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED Co-ordinates Latitude Longitude 22 22°14'28.8'' 69°18'17.9'' 23 22°14'27.9'' 69°18'17.5'' 24 22°14'27.0'' 69°18'17.5'' 25 22°14'26.6'' 69°18'15.4'' 26 22°14'25.8'' 69°18'14.2'' 27 22°14'25.4'' 69°18'13.1'' 28 22°14'25.2'' 69°18'12.4'' 29 22°14'25.1'' 69°18'10.7'' 30 22°14'27.0'' 69°18'11.3'' 31 22°14'29.9'' 69°18'11.6'' 32 22°14'32.1'' 69°18'11.5'' 33 22°14'32.6'' 69°18'12.7'' 34 22°14'33.8'' 69°18'13.1'' 35 22°14'35.0'' 69°18'12.1'' 36 22°14'35.2'' 69°18'11.0'' 37 22°14'33.2'' 69°18'6.9'' 38 22°14'29.6'' 69°18'7.9'' 39 22°14'28.0'' 69°18'4.5'' 40 22°14'25.6'' 69°18'4.1'' 41 22°14'23.8'' 69°17'58.8'' 42 22°14'19.2'' 69°18'0.2'' 43 22°14'24.0'' 69°18'17.5'' 44 22°14'31.2'' 69°18'22.8'' 3.3 Details of Alternate Sites Considered and the Basis of Selecting the Proposed Site No alternate site has been examined, since mine is with OAL since 1985. 3.4 Size or Magnitude of Operation Name: Varada - II Bauxite Mine Area: 25.8798 hectares Survey No.: 330/P Existing Capacity: 9514.9 TPA Proposed Production Capacity: 96030 TPA 3.5 Project Description with Process Details The present project aims at the production of bauxite minerals at the rate of 96030 TPA form Varada – II bauxite mine lease in order to provide bauxite to Orient Abrasive Ltd for captive use in Porbandar plant. The production data from pre 1994 to 2010 is given below in Table 3. Table 3: Production Data from mine ORIENT ABRASIVES LIMITED 11 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED Year Production (Metric Tonne) Maximum production in any one financial year since commencement of mining operation (1987) till financial year ending 1994 9514.900 1994-95 (April – March) 8130.57 1995-96 (April – March) 876.135 1996-97 (April – March) 1056.775 1997-98 (April – March) 69 1998-99 (April – March) 0 1999-2000 (April – March) 0 2000-01 (April – March) 0 2001-02 (April – March) 50 2002-03 (April – March) 0 2003-04 (April – March) 98.84 2004-05 (April – March) 7733.84 2005-06 (April – March) 2800.421 2006-07 (April – March) 3722.51 2007-08 (April – March) 39781.69 2008-09 (April – March) 26333.55 2009-10 (April – March) 25338.21 3.5.1 Salient Features of Mode of Working Mining will be carried out by manual open cast mining method. Bauxite horizon is present on surface on part of the area and below thin cover of soil or limestone in part of the area. Soil/Limestone having a thickness of 1.0 m is removed first by formation of one bench. Bauxite is excavated by forming 3 benches of thickness 1.5 m each. Bauxite horizon is compact in nature and requires drilling and blasting. Drilling is being done by jackhammer using drill rods and blasting with the help of explosives. The blasted material after manual sorting will be loaded in trucks. High grade bauxite will be transported to company’s manufacturing unit at Porbandar using covered trucks. 3.5.2 Year Wise Production for Five year period First Year (2009-10) During first year mining will be carried out in east part of the area from Pit No. 1 controlled by section M-M1. The orientation of face will be north-south. The bauxite having an average thickness of 4.5 m will be excavated by forming three benches and OB will be removed by forming one bench in part of the proposed area. ORIENT ABRASIVES LIMITED 12 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED Second year (2010-11) In second year mining will have controlled by section M-M1. The face formed at the end of first year will be advanced westerly. Second year excavation will be done at west of pit No 1. The bauxite having an average thickness of 4.5 m will be excavated by forming three benches of 1.5 m each. The limestone present with 1.0 m thick will be excavated by one bench. Third year (2011-12) In the third year the mining will have controlled by section M-M1. The face formed at the end of second year will be advance westerly as shown in year wise development plan and section. During third year mining will be done for mineral bauxite with average thickness of 4.50 m. Bauxite will be removed by forming three benches of 1.5 m each. Limestone will be excavated by forming one bench in part of the proposed area. Fourth year (2012-13) In the fourth year mining the strip will have controlled by section M-M1 as shown in year wise development plan and section. The mining will be done in west of strip III. The face formed at the end of third year will be advanced westerly as shown in year wise development plan. The limestone will be excavated by forming one bench. Bauxite will be removed by forming three benches of 1.5 m each. Fifth year (2013-14) During fifth year the strip has controlled by section M-M1. During fifth year, the mining will be done at west of strip IV. The face formed at the end of forth year will be further advanced westerly as shown in year wise development plan and section. Bauxite will be removed by forming three benches of 1.5 m each. The limestone present with 1.0 m thick will be excavated by one bench. The total area will be mined out in the mining period is given in Table 4. Table 4: Area to be mined out in Five years Year Area (m2) I (2009-10) 9660 II (2010-11) 9620 III (2011-12) 9680 IV (2012-13) 9700 V (2013-14) 9560 3.5.3 Production for Plan Period Production of bauxite and waste to be generated is given in Table 5. Table 5: Production for Planned Period Volume (m3) Year OB ROM Tonnage of ROM Recovery of Bauxite (80% of ROM) Production of Bauxite Plant Grade (25% of production MT) Non-plant grade (75% of production MT) 2009-10 4480 43470 95634 76507 19127 57380 2010-11 960 43290 95238 76190 19048 57142 2011-12 1480 43560 95832 76666 19167 57499 ORIENT ABRASIVES LIMITED 13 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED 2012-13 4980 43650 96030 76824 19206 57618 2013-14 5040 43020 94644 75715 18929 56786 Total 16940 216990 477378 381902 95477 286425 Life of Mine Considering mineable reserves of 8,18,688 MT and considering average rate of production to be 76,000MT, life of mine would be around 12 years. 3.6 Conceptual Mining Plan 3.6.1 Exploration Entire mine lease area is falling under proved, probable and possible category (Category 111) reserves. Exploration is required. It is proposed to put two bore holes during reserve scheme period. 3.6.2 Ultimate Pit Limit In the mining lease area the ore blocks limits are determined either by the limit of the lease boundary or by the limits of the ore body. These limits have been duly marked in the geological plan as well as in Conceptual Plan and Section plate 9. During coming 12 years the entire lease area leaving the statutory barrier will be converted into one pit having dimensions of 1042 m in length which varies from 20 m to 180 m and average depth will be about 7.0m as shown in Conceptual Plan and Section plate 9. 3.6.3 Stacking of mineral rejects and disposal of waste The past experience of mining activity in the lease as well as the details of maturity of voids after mining marked out in the present mining scheme has shown that the voids created by mining will be much larger than the one required for filling of waste rocks and soil. Due to this complete backfilling of mined out area up to original ground level is not possible and therefore the east part of the area will be backfilled and other part of the area will be used as water reservoir. Upto the lease renewal period i.e. 2025 the ~ 12.54 ha of the area will be mined out of which ~ 3.59 ha will be backfilled and ~ 8.95 ha of area will be covered under water reservoir as shown in Conceptual Plan and Section plate 9. Generation of soil, waste, and OB is shown in Table 6. Table 6: Year wise Generation of waste Year OB Vol. (m3) Waste volume, 20% of ROM (m3) Total in-situ volume of waste (m3) 2009-10 4480 8694 13174 2010-11 960 8658 9618 2011-12 1480 8712 10192 2012-13 4980 8730 13710 2013-14 5040 8604 13644 Total 16940 43398 60338 ORIENT ABRASIVES LIMITED 14 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED 3.6.4 Plantation It is proposed to undertake plantation programme in the lease area and for that plantation work will be carried out along the statutory barrier and backfilling area. During the plantation about 250 plants will be grown covering 2500 m2 area. The total area covered including existing plantation will be about 6500 m2 upto lease renewal period. 3.7 Extent of Mechanization Except for drilling in bauxite zone, all the other operations like mining sizing and loading will be carried out manually. Crowbars pick axe and hammers etc. will be utilized. Besides this one low headwater pump will also be utilized for dewatering of working pits if necessary. Drilling and blasting will be required. The machinery required will be given in the following Table 7. Table 7: Machinery Required S.No. Equipment Quantity 1 Jackhammer Two 2 Portable compressor One 3 Water pump 5.0 PHP (It will used for dewatering when required) One 3.8 Transport Transport to Plant The high grade bauxite will be transported to company’s manufacturing unit at Porbandar using hired trucks. 3.9 Blasting Small scale blasting will be carried out by conventional explosive loading, only if OB is found to be hard and for developing cracks in bauxite deposits. Blasting is completely controlled and do not harm any building. 3.10 Raw Materials Required along with Quantity likely Source, Marketing area of Final Product Mode of Transport of Raw Material & Finished Products Raw Materials Proposed project is mining of ROM for recovery of high grade bauxite for captive use in OAL’s plant located at Porbandar. Marketing Company has got the lease for its captive consumption, so abrasive and refractory grade material is completely used for companies own plant situated at Porbandar. The low grade will be dumped separately and lessee will sale it when get permission from government. Details of market assessment are given in Table 8. Table 8: Market Assessment Sales-Spot Material will sale from the ex-mines itself Buyers Cement companies, export through third party ORIENT ABRASIVES LIMITED 15 ORIENTT ABRASIVES LIMIITED PRE – FEEASIBILITY REPORRT: MINING 25.8798 HA, S. NO 330//P MEWASA VILLAAGE, TALUKA KALYANPPUR, JAMNAGAR BAUXITE AT LEASE AREA M Maintenance of competitiv ve pricing Price of material decide ed as per markket conditions Re-nego otiation on op ption Materiial will sale onlyy if getting pro ofit, price is negotiable according tto market and relation with b buyers Depend ds on market co onditions but estimated as: Pric ce of materiall Cost of o production + royalty paid to t govt. + depreciattion of infrastru ucture used + profit p margins Refracto ory material is n not saleable, on nly low grade is saleabl ble. Presently PM PMV / sale valuee of low grade mate terial ranging Rs. Rs 350-550, dep epends on percentag ge of alumina. Volume Closing sto ock of materiall Mode of Transport Bauxitte will be tran nsported by tractor to staccking and sortting ground. H High grade ba auxite will be tra ansported by hired /owned d truck to com mpany’s manu ufacturing unit at Porbanda ar. Low grade e bauxite will be stacked se eparately 3.11 Resource e Optimiza ation / Recy ycling and Reuse Env visaged in the t Project The fo ollowing will be b done: W Water will storre in old pits to t use for wattering the pla antation and d dust suppresssion. 3.12 Availabillity of Wate er its Sourc ce and Ene ergy/Powerr Requirem ment 3.12.1 Water Waterr will be supp plied by tanker for domesticc use; water stored in old pits will be ussed for planta ation and dusst suppression n. Total amou unt of water re equired is 5.1 15 KLD. LD All values are in KL ORIENTT ABRASIVES LIMIITED 16 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED 3.12.2 Fuel The mine will be worked during an eight hour shifts i.e. during day time only, hence no electricity is required for lighting. Diesel will be used as fuel for running equipments at the mining site. Consumption of diesel is estimated to be 5 lit/hr for compressor & 3 lit/hr for water pump when in use. 3.13 Waste Generation and Management 3.13.1 Solid Waste Management Types of Solid Waste In the proposed mining scheme the soil generated will be the OB, and besides this the waste that is likely to be generated will be in the form of associated clay with the bauxite horizon as mineral waste, which is below the threshold grade and has no sale value. The expansion factor for the loosened soil, waste, and OB is considered as 1.3. The yearly rate of generation of waste as well as OB has been shown in Table 6. Quantity of Waste The quantity of waste generated during the scheme period is given earlier in the report as Table 6. Selection of Dumping Site In the proposed mining scheme, it is proposed that, the overburden and waste generated will be backfilled in east part of the mined out area and levelled. The voids available are much more as compared to the required one therefore; the problem of disposal of OB and waste will not be there. The OB and waste generated in next five years will be refilled in the matured voids. Extent of backfilling is given in Table 9. Table 9: Extent of Backfilling Extent of Backfilling Years Total Backfilling Material (m3) Area to be Backfilled (m2) Avg. height of backfilling 2009-10 14518 2640 5.5 2010-11 9898 1800 5.5 2011-12 10636 1934 5.5 2012-13 15204 2764 5.5 2013-14 15156 2756 5.5 Total 65412 11894 5.5 Method of Handling and Disposal Backfilling of overburden and waste will be done side by side at the time of its generation therefore; the problem of height and spread will not arise. As the volume of voids is much more as compared to that of material available for backfilling therefore, whole land will not be backfilled upto the original ground level. Due to that the east part of the lease will be backfilled upto original level and rest of the area will be utilized as water reservoir. In the reservoir the higher benches of excavated mining pit shall be terraced and plantation will be done for stabilizing the slope. The slope of higher benches will be made gentle for easy accessibility by local people to pond and fencing will be done around the reservoir. ORIENT ABRASIVES LIMITED 17 ORIENT ABRASIVES LIMITED PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA 3.13.2 Liquid Waste Management Sewage Sewage will be disposed off in soak pit at site. 3.14 Schematic Representation of Feasibility Drawing which gives Information for EIA Purpose Mining plan plates are attached. ORIENT ABRASIVES LIMITED 18 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED 4 SITE ANALYSIS 4.1 Connectivity In the vicinity of mining lease there are no public roads or railway line. The mining lease for bauxite under reference is about 2.5 km from village Mewasa and approachable only by cart track. Mewasa can be approachable by Ran, which is located about 1 km north of tar road connecting village Limbdi with Dwarka. Limbdi is located on the Jamnagar-Okha State Highway no. 25 and is about 35 km from Khambaliya. The nearest railway station is Bhatia which is about 25 km from Mewasa and located on Okha-Jamnagar-Rajkot-Viramgam broad gauge section of western railway. Generally, the people around these places avails autorickshaw and trucks (transporting ore) for reaching Limbdi and Bhatia. The nearest seaport is Okha which is about 75 km from Mewasa village and nearest airport is located at Jamnagar, which is around 110 km from Virpur. Porbandar, which is a seaport also having a airport is located around 110 km from Mewasa village. The Taluka headquarters is at Kalyanpur, which is about 40 km from Mewasa village. 4.2 Land Form, Land Use and Land Ownership Entire lease area is designated as Government Wasteland. Lease is owned by M/s Orient Abrasives Limited. Existing land use and proposed landuse after 5 years is given Table 10. Table 10: Existing and Proposed Landuse S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Head Area Under Mining Storage of Topsoil OB/Dump Mineral Storage Infrastructure Road Railways Greenbelt Tailing pond ETP Mineral separation Plant Township Area Other to specific Setting Tank Total ORIENT ABRASIVES LIMITED Area considered as fully reclaimed & Rehabilated (Ha.) Net are considered for calculation (Ha.) Existing Landuse (Ha.) Additional area requirement during Five year plan period (Ha.) 5.6160 4.8220 10.4380 2.0102 8.4278 - - - - - - - - - - 0.0600 0.8000 0.8600 - 0.8600 0.0800 0.0400 0.0100 0.0500 0.0100 0.0800 0.0900 - 0.0100 0.0800 0.0900 - - - - - - - - - - - - - - - - - - - - 5.7960 5.6820 11.4780 2.0102 9.4678 Total area (Ha.) 19 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED 4.3 Topography The lease area is having north south trending low ridges of bauxite in eastern side and remaining area is almost plain ground sloping towards west. The area is covered by very scanty vegetation, mostly babool bushes grown over barren stony wastelands. The area is not covered by any watercourses in form of river, natural nallah etc. No permanent drainage course exists in the area. It is an active mining area, but crops like Bazara, groundnut etc are cultivated during monsoon in near by agriculture land. Maximum yield per hectares of bazaar and groundnut is around 2500 kg. The nearest human settlement is in Virpur village at a distance of 1.5 km. The co-ordinates of site are given in Table 2. 4.4 Geology of the Mining Lease area The geology of the ML area and its vicinity is broadly confirms to the regional geology. Entire lease area is covered with soil and major part of it has been mined out. The bauxite is present on the surface in part of the area and in part of the area bauxite is present below OB. Stratigraphic sequence found in the area is given in Table 11. Table 11: Stratigraphic Sequence in Lease Area 4.5 Formation Average Thickness Topsoil / limestone 0.3 M/ 1.0 M Bauxite 4.5 m Lithomargic Clay - Existing Landuse 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 HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given The lease area granted is a private land, it is a piece of barren land, and no forest land is involved in the area. Existing land use pattern of the site along with the proposed one is given in Table 10. Details regarding to the other ecological and important areas are provided in Table 12. Table 12: Important Features and Sensitive Ecological locations S.No. Feature Name 1 2 3 4 Forest land National Park Wild Life Sanctuary Eco-sensitive Zone 5 Water bodies 6 CRZ Zone Marine National Park Marine National Park Marine National Park Rani River Sea Rani River, unnamed water bodies 7 8 9 Nearest Railway Station Airport Highways ORIENT ABRASIVES LIMITED From Project Site Distance (km) Direction ~ 3.725 ~ 3.725 ~ 3.725 ~ 0.68 ~ 4.0 NW NW NW W N Not included in CRZ area Bhatia ~ 16.70 S Jamnagar State Highway 25 ~ 74 ~ 9.96 ENE SSE 20 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED 4.6 Existing Infrastructure The lease area is well connected by road, State Highway 6 (Jamnagar-Okha); details are given in Section 4.1. 4.7 Soil Classification According to soil classification of District Resource Map Jamnagar, Gujarat, the soil type exist here is fine, loamy, mixed and calcareous. 4.8 Climatic Data from secondary sources The climate in the region shows broadly four seasonal variations1, namely: Winter : December - February Summer : March – Mid June Monsoon : Mid June - September Post-monsoon : October - November Information presented in subsequent paragraphs is from the Indian Meteorological Department (IMD), Long Term Climatological Tables, 1951-1980, Jamnagar (A). These tables give useful information about a region’s weather, since they are collected over a 30-year period. 4.8.1 Temperature Mean daily maximum temperature is recorded in the month of May at 39.5°C. Highest mean temperature is recorded 43.8 °C in the month of May. Mean daily minimum temperature is recorded in the month of January 9 °C and lowest mean temperature is recorded in the month of January is 4.6 °C. During the post-monsoon months of October and November mean daily maximum – mean daily minimum temperatures remain between 35.9-15.5 ºC. In winters, i.e. December, January and February, mean daily maximum – mean daily minimum temperatures remain between 35.9-15.5 ºC between 29.8-9.0 ºC. 4.8.2 Wind2 Long- term wind direction data is presented in Table 13 and indicates that the predominant wind during the study period (October & November) is calm at daytime and wind direction is observed to be from NW to N directions at evening. Table 13: Predominant Wind Direction Predominant Wind Direction First Predominant Wind Direction Second Predominant wind Direction Third Predominant wind Direction Month Morning Evening Morning Evening Morning Evening January February March April NE Calm SW W N N W W E NE W SW NE NE/W/NW NW NW Calm E Calm NW NW E/Calm N N 1 Source: District Gazetteer Jamnagar 2 Indian Meteorological Department (IMD), Long Term Climatological Tables (1951-1980), Jamnagar (A) ORIENT ABRASIVES LIMITED 21 PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA ORIENT ABRASIVES LIMITED Predominant Wind Direction First Predominant Wind Direction Second Predominant wind Direction Third Predominant wind Direction Month Morning Evening Morning Evening Morning Evening May June July August September October November December W SW SW SW SW Calm Calm NE/E W W W W W NW N N SW W W W W SW E Calm NW NW SW SW/NW NW N NE NE NW S S S NW/S W NE SE SW/N/Calm SW NW S/N SW W NW NW 4.8.3 Rainfall The total rainfall in a year is observed to be 578.9 mm. Distribution of rainfall by season is 4.3 mm in winter (December, January, February), 2.0 mm in summer (March, April, May), 531.5 mm in monsoons (June, July, August, September) and 35.6 mm in post-monsoons (October – November) 4.8.4 Cloud Cover The area remains cloudy between June - September, which is the active period of the monsoon season. Generally cloud cover ranges from 6 to 7 Oktas during this monsoon season. 4.8.5 Humidity Most humid conditions are found in the monsoons, followed by summer, post-monsoons, and winter in that order. Mornings are more humid than evenings and humidity ranges from a high of 77-87% in monsoon mornings to a low of 36-40% in winter evenings. During post-monsoon season, in morning humidity remains between 64-76 % and in the evening it remains between 40-48%. Nearest IMD station from the lease area is Jamnagar 4.9 Social Infrastructure The land proposed for the project is government wasteland and has no vertical development over it. There is no social infrastructure available at the site or in the immediate vicinity of mine. Bhatia which is about 25 km form Mewasa village have good marketing facilities and apart form that is also have a P & T office, a primary health center, dispensary, maternity and child welfare center. The other important villages located around Mewasa are Virpur, Habardi, Mota-Asota, Pindara and Ran. ORIENT ABRASIVES LIMITED 22 ORIENT ABRASIVES LIMITED PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA 5 PLANNING BRIEF 5.1 Planning Concept Type of Industry: Mining of bauxite Facilities: Drinking water, first aid, mine office, rest shelter Transportation: High grade bauxite will be transported through trucks to company’s manufacturing unit at Porbandar Town and Country Planning Development Authority Classification: not applicable, since this is a mining project 5.2 Population Projection Not applicable since the project entails mining of bauxite on government waste land. 5.3 Landuse Planning As mentioned in Section 4.2 above. 5.4 Assessment of Infrastructure Demand A temporary rest shelter for labour will be constructed at mine site. A water tank (capacity of 500 liters) will be constructed for storing drinking water. Haul road is well maintained and water sprinkling will be carried out time by time in order to maintain the road condition. 5.5 Amenities / Facilities Facilities for drinking water and first aid will be provided in the existing mine office and rest shelter ORIENT ABRASIVES LIMITED 23 ORIENT ABRASIVES LIMITED PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA 6 PROPOSED INFRASTRUCTURE 6.1 Industrial Area (Processing Area) Not applicable. 6.2 Residential Area (Non-Processing Area) Not applicable. 6.3 Greenbelt Around 250 plants will be grown covering 2500 m2 area. The total area covered including existing plantation will be about 6500 m2 upto lease renewal period. 6.4 Social Infrastructure Discussed in Chapter 4, Section 4.9. 6.5 Connectivity (Traffic and Transportation Road / Rail / Metro / Waterways) As per Section 4.1 6.6 Drinking Water Management (source & supply of water) Discussed in Chapter 3, Section 3.12.1. 6.7 Power Requirement and Supply / Source Discussed in Chapter 3, Section 3.12.2 6.8 Industrial Waste Management Discussed in Chapter 3, Section 3.13 6.9 Solid Waste Management Discussed in Chapter 3, Section 3.13.1. 6.10 Sewage System Discussed in Chapter 3, Section 3.13.2 ORIENT ABRASIVES LIMITED 24 ORIENT ABRASIVES LIMITED PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA 7 REHABILITATION AND RESETTLEMENT (R& R) PLAN No rehabilitation and resettlement is either required or proposed for the project as mining will be carried out entirely on Government wasteland. ORIENT ABRASIVES LIMITED 25 ORIENT ABRASIVES LIMITED PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA 8 PROJECT SCHEDULE AND COST ESTIMATES 8.1 Project Schedule The mine lease is working site of OAL however; OAL will start production at proposed rate only after obtaining necessary clearance from Central and State Government 8.2 Estimated Project Cost along with Analysis in Terms of Economic Viability of the Project Total cost of project would be ~ Rs.3044194.60. The mine has been sanctioned by the Government for captive consumption only and not for sale of products; hence the profitability factor does not arise at this stage ORIENT ABRASIVES LIMITED 26 ORIENT ABRASIVES LIMITED PRE – FEASIBILITY REPORT: MINING 25.8798 HA, S. NO 330/P MEWASA VILLAGE, TALUKA KALYANPUR, JAMNAGAR BAUXITE AT LEASE AREA 9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 9.1 Financial and Social Benefits with Special Emphasis on the Benefit to the Local People including Tribal Population, if any, in the Area Critical analysis of the existing socio-economic profile of the area vis-à-vis its scenario with proposed project activities identifies the following: About sixteen unskilled miners will be engaged in mining activities for the project. The proposed activities shall generate indirect employment in the region due to the requirement of workers in supply auxiliary and ancillary works, which would marginally improve the economic status of the people. Further the additional benefits from the down stream units such as iron industry, steel industry, cement plant and metallurgical industry also add value to the society ORIENT ABRASIVES LIMITED 27