PRE- FEASIBILITY REPORT - Welcome to...
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PRE- FEASIBILITY REPORT
(In terms of provision of EIA Notification 2006)
For
Expansion of Maton Rock Phosphate mines from 0.18 MTPA to .5
MTPA
AT
MATON MINES, DISTRICT – UDAIPUR, RAJASTHAN
By
Hindustan Zinc Limited
Rajasthan
Submitted to
Ministry of Environment & Forest (MoEF)
New Delhi
May – 2012
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
1.0 EXECUTIVE SUMMARY
H
industan Zinc is India’s only integrated producer of Zinc and Lead and is
among the world’s leading zinc and lead producers with ore production
capacity of 9.75 million tonnes per annum. Its metal production capacity is
currently 1,064,000 tonnes per annum (879,000 tonnes per annum for Zinc
metal and 185,000 tonnes per annum for Lead metal) and associated by-
products i.e. Cadmium, Silver, Sulphuric acid etc. Hindustan Zinc Limited
(HZL) is Asia’s largest non-ferrous metal producer of Zinc and Lead and is
Head quartered at Udaipur, Rajasthan. HZL is world's second largest
integrated producer with a global share of approximately 6.0% in Zinc.
H
ZL has its operations in exploration, mining, ore processing, smelting and
refining of Zinc, Lead, Cadmium and Silver. It is also a major producer of
sulphuric acid as a by-product of Lead-Zinc metal processing. HZL also has
large investment in wind energy having capacity of 273 MW and thermal
power generation of 474 MW.
HZL also has Rockphosphate mining with an annual capacity of 0.18 million
tonnes.
T
he Maton mine is an operating mechanized opencast mine located at Village
Maton, Tehsil Girwa, District Udaipur, Rajasthan. It is located at about 12 km
southeast of Udaipur at a latitude 2432’34’’ and longitude 7347’30’’ and
falls in the Survey of India toposheet No. 45H/14. The Phosphate deposit of
Maton is located in a hill, which trends NE-SW. Site is well connected from
two sides by asphalt road from Udaipur. The nearest airport is at Dabok about
12 Km NW of the project site. The nearest railway station is Rana Pratapnagar
which is 8 km to the NW of Maton.
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
T
he instant proposal is for expansion from 0.18 million TPA to 0.5 million TPA
of ore production from its Maton mine of Rock Phosphate.
E
nvironment Clearance was granted by MoEF for 0.18 million TPA ore
production from Maton mechanized Opencast mine vide letter no.J-
11015/169/2009-IA.II (M) dated 17.03.2010. Consent to operate was granted
by Rajasthan SPCB for establishment of mine and associated structure vide
letter no. F(Mines)/Udaipur(Girwa)/13(1)/2009-2010/5608-5612 dated
26.11.2010 and F(Mines)/Udaipur(Girwa)/13(1)/2009-2010/1116-1120 dated
18.05.2011. The mining operations are being carried out as per the above
permissions.
2.0 INTRODUCTION OF PROJECT
2.1 Identification of Project and Project Proponent
2.1.1 Identification of Project
The deposit was discovered by the Geological Survey of India (GSI) in 1966/67.
There after an exploration program for the assessment of the deposit was under
taken. Based on the finding of GSI, HZL took over the lease on 17.03.1970 for a
period of 20 years with a view to develop the deposit as a captive mine for
meeting the in-house requirement of Rock Phosphate for the zinc smelter Debari
Udaipur.
Maton Rockphosphate mine have been engaged in the mining of Phosphorite ore
since inception. The initial lease area of 247.96 ha. was granted on 17.03.1970.
Subsequently the lease was renewed after the first approval period for ten years
w.e.f. 16.03.1990 and thereafter was granted an extension as second approval over
a reduced area of 143.13 ha (due to surrendering of Forest land) for a further
period of ten years w.e.f 16.03.2000. The application for further renewal has been
applied for and is under process of renewal with state Govt.
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
The mine was non-operational during 2001-2009. However, there has been an
upsurge in the demand of rockphosphate since 2007 which encouraged the
company to review the economics of reopening of the mine in 2009. The consent
to operate under Air and Water Act is granted by Rajasthan SPCB.
Clearance was granted by MoEF for 0.18 million TPA ore production from Maton
mechanized Opencast mine vide letter no.J-11015/169/2009-IA.II (M) dated
17.03.2010. Consent to operate was granted by Rajasthan SPCB for establishment
of mine and associated structure vide letter no.
F(Mines)/Udaipur(Girwa)/13(1)/2009-2010/1116-1120 dated 18.05.2011. Ever
since, the mine is in operation and operating to its rated capacity. The instant
proposal is for expansion from 0.18 million TPA to 0.5 million TPA of ore
production from Maton mine.
In India the economy being predominantly based on agriculture, the fertilizer
application to the cultivable lands plays a pivotal role in getting desired crop
production. To meet, the food requirements of ever increasing population, as per
the Planning Commission, the utilization of NPK fertilizers is expected to increase
at the rate of 4% till 2017.
India is net importer of its Phosphate requirements to the extent of 90%.
Indigenous sources are able to cater upto the extent of 10%. The imports inter alia
includes Rock Phosphate, Phosphoric acid which is an inter-mediatory for
production of DAP and NPK fertilizers, Mono Ammonium Phosphate and Triple
super phosphates. Out of the above, India is importing about 7.5 MT of Rock
Phosphate balance is met by indigenous resources to the extent of about 1.5 MT
(of the different grades). Of the 1.5 MT, HZL is contributing 0.18 MT from Maton
Mines. Considering the huge gap between Demand and Supply, HZL is proposing
to increase / expand its capacity from 0.18 to 0.5 MT.
2.1.2 Project Proponent
Hindustan Zinc Limited (HZL) is the only integrated Lead & Zinc manufacturer in
India and owns captive Lead and Zinc mines that supply complete requirement of
Lead and Zinc concentrate for its smelters. HZL operates mechanized open cast
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
mine at Rampura Agucha as well as underground Mines at Rajpura Dariba,
Sindesar Khurd, and Zawar Mines in the state of Rajasthan with state of the art
technology to meet the ore requirement of its smelting operation. The smelting
capacity stands 1.064 Mt of metal (0.879 Mt of Zinc and 0.185 Mt of Lead) and
associated by-products i.e. cadmium, silver, sulphuric acid etc. are located at its
smelters at Debari, Vizag, Chanderiya and Dariba in Rajasthan and a Melting and
Casting plant each at Pantanagar and Haridwar in Uttarakhand.
The fiscal and financial performance of the company for the past five year has
shown remarkable upsurge. The company has come a long way with technology
upgradation, research and development activities, up keeping of environment,
safety and ecological balance besides exploring new business opportunities. HZL
is also having a Rock Phosphate Mine viz. Maton Mines operating at 0.18 MtPA
capacity. HZL is also having Captive Power Plants and Wind Farms..
2.1.2.1 Growth
The growth of HZL is shown below.
TABLE-2.1
GROWTH PROFILE OF HINDUSTAN ZINC LIMITED
Sr. No Description Installed Capacity, MTPA
2002 2011
1 Zinc Lead Ore Mining and Beneficiation 3.2 10.05
2 Zinc Metal Production 0.169 0.879
3 Lead Metal Production 0.043 0.185
4 Sulphuric Acid Production 0.352 1.373
5. Captive Power Plant (MW) Nil 474
6. Wind Power (MW) Nil 273
7. Rock Phosphate NIL 0.18
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
TABLE-2.2
EXISTING MINING & SMELTING UNITS OF HZL
2002 2011
Zawar Group of Mines Rajasthan Lead Zinc Ore MtPA 1.2 1.5
Rajpura Dariba Mine Rajasthan Lead Zinc Ore MtPA 0.631 0.9
RampuraAgucha Mine Rajasthan Lead Zinc Ore MtPA 1.35 6.15
Sindesar Khurd Mines Rajasthan Lead zinc Ore MtPA 0 1.5
Maton Mines Rajasthan Rock
Phosphate
MtPA 0 0.18
Zinc MT 59,000 88,000
Sulphuric Acid MT 104,000 419,000
Cadmium MT 160 320
Zinc MT 40,000 56,000
Sulphuric Acid MT 72,000 72,000
Cadmium MT 115 115
Zinc MT 70000 525,000
Lead MT 35,000 85,000
Sulphuric Acid MT 1,76,000 752,000
Silver MT 74 168
Cadmium MT 375 375
Zinc MT Nil 210,000
Lead MT Nil 100,000
Sulphuric Acid MT Nil 400,000
Zinc MT NIL 400,000
Lead MT NIL 100,000
Silver MT NIL 350
Haridwar Zinc Plant Uttrakahand Zinc MT NIL 250,000
Unit
A. Mining Units
Annual Capacity
B. Smelting Units
Debari Zinc Smelter Rajasthan
VizagLead-Zinc Smelter Andhra
Pradesh
UttrakahandPantnagar Melting and
Casting Plant
Name of the Unit State Main
Products
Chanderiya Smelter
Complex
Dariba Smelter Complex
Rajasthan
Rajasthan
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
2.2 Brief Description of Nature of Project
2.2.1 Nature of the Project
The present proposal is for expansion of the existing mechanised open cast rock
phosphate mine at Maton, Udaipur District, Rajasthan from the present capacity of
0.18 MTPA to 0.5 MTPA of ore. The project is a mechanised opencast
rockphosphate mine and is classified as “Category-A” by Ministry of
Environment & Forests, New Delhi as per the EIA notification dated on 14th
September 2006 and further Amendments.
2.2.2 Size of the Project
The proposed rockphosphate deposit lies within the lease area of 143.13 ha with
an estimated ore reserves and resource of approx. 5.2 million tons. The grades
varying from 18 – 33.0% of P205. The target production capacity of mine
proposed is 0.5 million TPA. The ore produced will have an average grade of 23-
26% of P205.
2.2.3 Location of the Project
Maton Mine is located at about 12 km southeast of Udaipur, at a latitude
24032’34’’ and longitude 73
047’30’’ , and falls in the Survey of India toposheet
No. 45H/14. The nearest railway station is Rana Pratapnagar on Udaipur -
Chittorgarh broad gauge line of North - Western Railway at about 8 km away.
The area is connected by airways with the airport being at Dabok which is at
about 12 km. NW on Udaipur-Chittorgarh National Highway No. 76. The Mine is
well connected on two sides by metalled road from Udaipur.
2.2.3 Mining Method
The deposit is being mined by mechanised open cast mining method with benches
of 10 m width and 10 m height. The bench height and width parameters have been
optimized after studies on geo-technical slope stability were carried out by
CIMFR. Dhanbad. The study recommended a slope of 45˚ in footwall ortho-
quartzite upto a depth of 100 m from highest point. Beyond 100 m the overall pit
angle along footwall is suggested to be revised according to local conditions. The
mining of the deposit shall continue with the same method. The present working
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
is confined in E1-W1& E2 lens only. The heavy earth moving machineries
deployed for mining are diesel operated. A crusher is installed for crushing the ore
to a size of <12 mm prior to dispatch.
The mine will continue to be operated as mechanized open cast mines with
increase in the size of the machinery being used to cope up the proposed expanded
mining / excavation requirements. The capacity of the existing crusher will be
increased to match the production. A geotechnical study would also be carried out
for optimum and safe bench parameters with depth.
2.2.4 Importance to the Country & Region
Indian Fertilizer industry is one of the vital industries for Indian economy, since it
manufactures a very critical raw material for agriculture .The main objective of
the fertilizer industry is to ensure the supply of primary and secondary nutrients in
the required quantities.
The fertilizer industry in India has performed a vital role in enabling the necessary
increase in the use of plant nutrients for achieving the objectives of self
sufficiency in food grains production and accelerated and continuous agricultural
growth.
Rock phosphate constituets as a basic feed stock for manufacture of phosphatic
fertiliser.
2.3 Need for the Project and its Importance to the Country
The basis for success in the phosphate business is access to lower-cost phosphate
rock, a resource that is geographically concentrated. China, the US and Morocco
together account for approximately two-thirds of world rock production and
Morocco alone typically supplies more than one-third of global exports.
Approximately 30 percent of global phosphate producers are non-integrated,
relying on imports or domestic purchases for their rock supply.
India has limited indigenous supply of phosphate rock and is the world’s largest
importer, accounting for about 30 percent of global trade.
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
The following graph shows the Projection of fertilizer nutrients for 12th Five year
Plan.
0
5
10
15
20
25
30
35
2012-13 2013-14 2014-15 2015-16 2016-17
('0
00
to
nn
es)
Year
k
P
N
Source: FAI, New Delhi
2.4 Import Vs Indigenous Production
The present production of Rockphosphate in India is estimated at 1.5 MT whereas
the imports are estimated as 7.4 MT. If we consider the likely increase in
consumption @4.8% per year, the gap between Demand and supply is likely to
increase further. Whereas, on accounts of limited resources available with
RSMML (which is the main producer) and MP Mining Corp, the overall domestic
production is likely to remain stagnant.
The following graph clearly suggests the Demand of Rock Phosphate.
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
0
1
2
3
4
5
6
7
8
2004 2006 2008 2010 2012
In M
illio
n T
on
ne
s
Year
Demand
Import
Indegeneous
Source: 1. Mineral and Metal Trading Corporation of India Ltd.
2. International Fertilizer Industry Association, Paris
2.5 Export Possibility
As India is already having scarcity of rockphosphate for its domestic
consumption, the chances of export do not exists in near future.
2.6 Domestic and Export Market
India has very limited resources of Rock Phosphate as against the Demand. The
major use of Rock Phosphate in India is for manufacture of SSP, DAP, MAP,
TSP, Phosphoric acid, Di-calcium Phosphate and elemental phosphorus. The Rock
Phosphate from proposed expansion is proposed to be supplied as a feed stock to
SSP, Phosphoric Acid manufacturing either for standalone use or for blending
purpose.
There is no export market for rock Phosphate in India as per the reasons given
above.
2.7 Employment Generation.
The proposed expansion would provide direct employment opportunity for about
180 persons (30 Executives and supervisors and 150 skilled and unskilled
manpower) besides indirect employment.
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
3.0 PROJECT DESCRIPTION
3.1 Type of Project
The proposed project is a mechanized Open Cast mining project of Rock
phosphate
of Hindustan Zinc limited situated at Village – Maton; Tehsil – Girwa; Dist.
Udaipur.
3.2 Location
Maton Mine is located at about 12 km southeast of Udaipur, at a latitude
24032’34’’ and longitude 73
047’30’’ and falls in the Survey of India toposheet
No. 45H/14. The phosphate deposit of Maton is located in a hill, which trends NE-
SW, rising nearly 100 m above valley level. The climate is semi-arid with an
average annual rainfall of 600 mm. The temperature varies from 45C in summer
to as low as 1C in winter. The area is drained by a nallah, which is a tributary of
seasonal Ahar river draining to UdaiSagar Lake. Maton mine receives power at
33 KV from Aklingpura substation of AVVNL. The nearest railway station is
Rana Pratapnagar on Udaipur - Chittorgarh broad gauge line of North - Western
Railway at about 8 km away. Water requirement is met through rainwater stored
in old mine workings and purchase from 3rd
party sources.. The area is connected
by airways with the airport being at Dabok which is at a distance of 12km. The
Mine is well connected on two sides by metalled road from Udaipur. The revenue
map is attached for reference.
3.2.1 The general location map is as shown below.
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
Maton Mines
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
The details of environmental setting are given in Table-3.1.
TABLE-3.1
ENVIRONMENTAL SETTING OF THE SITE
Sr. No. Particulars Details
1 Latitude 24032’34’’
2 Longitude 73047’30’’
3 Elevation above MSL 568m
4 Climatic conditions
(Based on IMD Ajmer)
Annual Maximum Temp: 450 C
Annual Minimum Temp: 10C
Annual Average Rainfall: 600 mm
5 Present land use of mine site Agriculture, grazing , and barren land
6 Nearest Highway NH-76 (6 km, NW)
7 Nearest Railway Station Rana Pratapnagar (8 Km,NW.)
8 Nearest Airport Dabok (12 km)
9 Nearest Village Maton, Khardadia
10 Nearest Town/City Udaipur (12 km NW) City and District
11 Hills/Valleys Aravalli Hills
12 Reserved/Protected forest Bara Mandra RF, Kantla RF, Panwari RF,
Hinlashla RF, Segara RF, Hora RF,
Umara RF, Bagdara RF, Amarbir RF,
Sant RF.
13 List of Industries Major Industry RSMML at distance of 5
km and HZL’s Debari Zinc Smelter at 8
Kms
14 Socio-economic factors No fresh land acquisition.
15 Seismicity Seismic Zone-II.
3.3 Alternate Sites Considered
No alternate site is applicable since ore deposit is present at Maton.
3.4 Size of Operation
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
The project has been planned to produce 0.5 MTPA Rock phosphate Ore from the
mechanized opencast mine by expanding from the present 0.18 MTPA. The
salient features of the proposed project are given in Table 3.2
TABLE-3.2
SALIENT FEATURES OF THE PROJECT
Sr. No. Description Details
1 Name of Mine Maton Rockphosphate Mine
2 Mine lease area 143.13 ha
3 Mine Lease No ML-6/89
4 Ore mineral Rock Phosphate
5 Proved Reserves
Probable and Possible reserves
1.293 million Tonnes
Approx. 3.894 million Tonnes
6 Average Grade 24-26% P205
7 Ore body Width 3 m to 15 m.
8 Overall Strike length & Direction 3.2 kms , N40ºE- S40ºW
1.2 Kms with in Surface Rights
9 Ore body Dip 50º - 80º towards N50ºW
10 Mineable Reserves 2.5 million Tonnes
11 Established Depth Upto 520 mRL (190 mtrs)
12 Mode of Entry Haul Road
13 Method of Mining Open Cast Mechanized Mine
14 Rated Ore Production 0.5 Million Tpa.
15 Transportation of Ore By Truck/ Dumpers
16 Waste Rock Generation Approx. 11.5MT/Year (Avg)
17 Power requirement 1.0 MW
18 Water requirement 500 KLD
19 Manpower requirement About 180 (30 executives &
supervisors, 150 unskilled,
semiskilled & skilled personnel)
* The Reserves & Resources are estimated as detailed below in section 3.5.2
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
3.5 Project description with Process details
3.5.1 Geology
The rocks of Maton area belonging to Aravalli Super group of Proterozoic age,
strikes N 40E-S40W and dips at 50-80 degree’s towards N50 W and display a
synformal structure plunging moderately due NE. Dolomite and argillaceous
dolomite is the oldest formation. Next in the stratigraphic column is ortho-
quartzite and jaspery-quartzite, which hosts stromatolitic rock phosphate. The
rocks overlying rock phosphate are phyllite, which grid into mica-schist at places.
Rock Phosphate in general is unconsolidated, soft to medium hard in nature,
except in few patches where it is compact and cherty. The ore forming mineral is
mainly Fluor-apatite (Ca5 (P04)3F).
The phosphorite horizon in the Maton area extends over a strike length of 1.2 km.
Thickening and thinning of the horizon is quite common. The thickness of the
horizon varies from 3.0 m to as high as 15.0 m.
3.5.2 Ore Reserves
The reserve estimates are based on 1120 m strike length between S-14 to N-65
sections, width of the intersected ore zones and maximum depth up to 520mRL.
The reserve has been estimated by Datamine Software using geo-statistical
method and statistical analysis.
Depletion of reserves: During the plan period of 2009-10 to 2011-12, 0.362 MT
of ore reserves depleted up to the end of FY 2011-12.
Additional reserves estimates: During the plan period no exploration drilling has
been done due to access problem on hill slope. However Rock Phosphate has been
exposed, during mine development, along the strike of E2 lens towards north,
confirming its continuity along the strike up to B block. It can be thus assumed
that the ore body exists along the strike, both at surface and subsurface which may
add to the present reserves and resource.
Resource estimation
The resource estimation has been done by volume of each block * in situ density
and krigged grades. Total estimated reserves and resource upto -520mRL are
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
3.327 MT of rockphosphate. Additional ore if considered will increase the Qty to
5.2 MT. The categorisation of the ore reserves is as under.
The ore reserves at Maton Rockphosphate mine is as under -
CATEGORY Mt %P2O5
A) RESERVES
Proved 1.293 26.33
Probable 0.643 27.43
Total 1.936 26.69
B) RESOURCE
Measured (M) - -
Indicated (I) 3.251 28.10
Total M & I 3.251 28.10
Inferred -
The in-situ geological reserves/resource as on 01.04.12 is shown in the table
below
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
Qty Grade Qty Grade Qty Grade Qty Grade
0.082 27.47 0.082 27.47 0.000 0.082 27.47 690 610
0.210 27.03 0.013 24.27 0.223 26.86 0.000 0.223 26.83 610 570
0.168 31.38 0.172 31.38 0.340 31.38 0.018 31.38 0.358 31.38 570 520
S.Total 0.425 28.83 0.185 30.88 0.610 29.45 0.018 31.38 0.628 29.51
0.071 28.17 0 0.071 28.17 0.000 0.071 28.17 top 690
0.105 28.12 0 0.105 28.12 0.000 0.105 28.12 690 610
0.080 30.14 0.242 28.68 0.322 29.04 0.000 0.322 29.02 610 570
0 0 0.823 31.41 0.823 31.41 570 520
S.Total 0.359 31.41 0.257 28.68 0.616 30.27 0.823 31.41 1.439 30.21
0.148 23 0.148 23 0.000 0.148 23 top 690
0.429 23 0.121 23 0.550 23 0.000 0.550 23 690 610
0.095 23 0.095 23 0.170 23 0.265 23 610 570
0.376 23 0.376 23 570 520
S.Total 0.577 23 0.216 23 0.793 23 0.546 23 1.339 23
B- Block 0.800 0.800
0.219 25.73 0.219 25.73 0.219 25.73 732 690
0.616 24.47 0.121 23 0.737 24.23 0.737 24.57 690 610
0.290 27.88 0.350 26.97 0.640 27.38 0.170 23 0.810 26.48 610 570
0.168 31.38 0.172 31.38 0.340 31.38 1.217 28.81 1.557 29.37 570 520
S.Total 1.293 26.33 0.643 27.43 1.936 26.69 1.387 28.1 3.323 27.36
B- Block 0 0 0 1.864 1.864
TOTAL 1.293 26.33 0.643 27.43 1.936 26.69 3.251 28.1 5.187 27.36
Top to 520
E2
Top to 520
E1
Av.
Grade
Depth of
Estimation
W1
Lens
Proved Probable Reserve Possible Reserves
Total Res.
Top to 520
Top to 520
Top to 520
W1, E1,
E2
Top to 520
Top to 520
As per United Nation framework of Classification (U.N.F.C), Reserve and
Resources position as on 01.04.12 is as follows: (in million T)
BLOCK LENS Mineral
reserve
(111)
Mineral
reserve (121
& 122)
Mineral
resource
(211)
Mineral
resource
(221 & 222)
Mineral
resource
(331)
Mineral
resource
(332)
Mineral
resource
(333)
0.219 732 690
0.616 0.121 690 610
0.29 0.35 0.17 610 570
0.168 0.172 1.217 570 520
S.Total 1.293 0.643 1.387
B- BLOCK B- Block 0 0 1.864
1.293 0.643 3.251TOTAL Top to 520
Location
A- BLOCKW1, E1, E2
Top to 520
Top to 520
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
RESERVES AND ANTICIPATED LIFE OF MINE
A total of 5.187 million T of ore reserve and resources, 1.293MT Proved & 0.643
MT probable reserves) and 3.251 million T of resources have been estimated upto
520 mRL with average grade of 27.36 % in A & B Blocks. At a production rate of
0.18 million TPAin the first year and then @0.5 million tonnes in the subsequent
years, the present life of the mine upto 520 mRL will be about 8 years considering
limits of practical mining open pit of reserves and resources. As explained
previously, exploratory drilling done will further augment the reserves and
resources which would increase the life of the mine beyond 10 years.
3.5.5 Mining
3.5.5.1 Method of Mining:
The deposit is being worked by mechanised open cast mining method with
benches of 10 m minimum width and 10 m height. The bench height and width
parameters have been optimized after studies on geo-technical slope stability were
carried out by CIMFR. Dhanbad. They had recommended a slope of 45˚ in
footwall ortho-quartzite upto a depth of 100 m from highest point. Beyond 100 m
the overall pit angle along footwall has to be revised according to local
conditions. The mining of the deposit is intended to continue with the same
method. The present working is confined in E1-W1& E2 lens only. The entry to
the benches below 600 mRL is by a ramp driven from south side. Hangwall
overburden is removed first, then ore is mined out and then waste of Foot Wall is
removed on the bench to reduce the dilution to the maximum possible extent and
bench is formed. The heavy earth moving machineries deployed for mining are
diesel operated. With expansion, there would be increase in the size of the
machines viz. excavators and trucks to cope up the excavation requirements. The
crusher capacity would also be increased to meet out the crushing requirements of
expanded ore production.
Drilling and Blasting: At Maton Mine the bench height in waste (Over Burden)
and ore is 10 mtrs. The hole dia. for both ore and waste benches is 115/165 mm.
The drilling is carried out with the help of track mounted diesel engine powered
DTH (Down the Hole) drill machines of 115/165mm button bit. Drill machine
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
with dust extractor system is being used for controlling Air Borne Dust. ANFO
(Ammonium Nitrate Fuel Oil) is used as the column charge along with Primary
charge in the form of PETN cast booster or cartridge slurry explosive. The
initiation of the explosive is being done by down the hole delay Non Electric
shock tubes (NONEL). For interhole delay the trunk line delay detonators are used
on surface tie up for improved blast performance, reduced ground vibration and
noise level. The max. charge is kept within limit to minimize environmental
impact of blasting. The no. of blasts required in ore and waste clubbed together
are approx. 20-25 per month. However by increasing the size of the blast, number
of blasts would be reduced to 14 to 15 per month.
Depending upon the strata condition, bench height and rock type, spacing and
burden is being varied. Typical Drill & Blast design parameters are as under.
Spacing : 4 to 5 m
Burden : 3 to 4 m
Depth of holes : 10.5 to 11m
Sub grade drilling : 0.5 to 1.0 m
Primary charge/Booster charge : 250 gm PETN Booster / Cap sensitive
slurry cartridge of 83/125 mm dia (12.5
to 25 Kgs)
Column charge : Non cap sensitive (ANFO/Slurry
Cartridge)
Charge Length : 50-60% of hole depth
Powder factor : 4 to 5 T/Kg of explosive
Pattern of holes : Staggered or Square Pattern
Detonators : Millisecond delay detonators.
Av. No. of holes in a blast : 60 to 70 nos.
Av.Quantity of explosive/hole : 100 Kg. (Approx.)
Quantity of explosive/Blast. : 6-7 T (Approx)
Safe storage of explosive : Explosive is being sourced from licensed
magazines.
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
Secondary breaking: Oversize boulder’s (Boulder of size more than 1 mtr.) size
reduction is done by Hydraulic Rock Breaker. Secondary Blasting i.e. Pop
Shooting or Plaster shooting is avoided. With proposed expansion, additional rock
breaker would be put in to use to cope up the breaking of boulder. Efforts would
be made with improved blasting techniques as described above to keep generation
of boulders below 1% of total blasted volume.
Presplitting: To achieve stable slopes and control the blast damage to walls, pre-
splitting techniques would be adopted at final pit limits.. The technique would
involve, drilling small dia holes (100-115 mm) at a close spacing of 1.0 to 1.2
mtrs. along the final bench profile line at an angle of 70 to 80 degrees as per the
recommended slopes. These holes would be then charged lightly with 25-32 mm
cartridges which are suspended in to holes axially tied with a detonating fuse. A
charge factor of 0.40 to 0.60 Kg / sq meter would be maintained depending upon
the strata conditions. The holes are then fired instantaneously and are normally
fired prior to the production blast in front of limit line. The final production blast
is called “Trim Blast”. In Trim blast in front of Pre-Split, one or two small dia
production hole line is drilled at a standoff of 1.0 to 1.5 mtrs to reduce the charge
concentration near final wall. The trim blast is fired with inter hole delay of 42 ms
or 65 ms with inter row delays of 100 ms so as to have proper burden relief for
holes and reduced vibrations on wall. The excavation is then done maintaining the
slope. However exact parameters of pre-splitting can only be established after a
number of trial blasts with varying spacing and/or explosive charge and the most
appropriate pattern would be adopted.
The machinery to be deployed for expanded capacity would be as tabulated
below.
TABLE 3.6
DETAILS OF MACHINERIES
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
Equipment Capacity Existing (Nos.) Proposed (Nos.)
2.0 cum 4 2
6.7 cum - 2
Rock Breaker 1 1
20 MT 25 3
50 MT - 20
165 mm 1 2
115 mm 1 2
10 KL 2 -
20 KL - 2
D65 E 2 -
D275 A 2
Motor Grader - 1
Track Dozer
Excavator
Dumper
Drill
Water Sprinkler
The expanded production (ore and overburden) requirement is 40000 to 45000 T
of rock per day. The capacity of machinery has been arrived at after considering
the availability and utilization of the equipments. Four excavators (2 of 6.7 m3 &
2 of 2.0 m3 for ore) and twenty dumpers of 50 T are planned
3.5.5. 2 Conceptual Mine Plan
The present working is confined to E1-W1& E2 lens only. The present entry is
through a ramp along the hill on FW side. Hangwall overburden is being removed
first, then ore is mined and then FW is excavated thereby forming the bench and
reduced dilution. The ore body is proven up to 520 mRL and the pit will be
economical up to this depth of approx 190 meters from the top. It is proposed to keep
a pit slope of 45˚ in footwall ortho-quartzite upto a depth of 100 m from highest
point and beyond 100 m the overall pit angle along footwall has to be made flatter
according to local conditions. A detailed Geotechnical study would also be
conducted to arrive at optimal bench slopes and overall angles and depth of pit.
The mine operation is planned on three shifts per day of 8 hours duration basis. The
mine is scheduled to work for 300 days/ year after keeping margin for weekly day of
rest, public holidays and days lost due to weather conditions like rain, fog & storm.
Ore Production Schedule for Mining Plan period five years after grant of EC
would be as follows
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
Plan period Ore Production
2012-2013 1,80,000
2013-2014 5,00,000
2014-2015 5,00,000
2015-2016 5,00,000
2016-2017 5,00,000
Production in Year 1 has been considered as per existing plan considering the time
required for development of the ore for 0.5 MTPA capacity.
3.5.8 Selection of Dumping Site
The overburden generated from mines will be stacked at earmarked Dump
locations which are at north east of strike direction and East of the strike direction.
These sites have been selected as the area doesn’t bear any mineralisation and is
within the acquired land.
3.6 Raw material required along with estimated quantity likely source,
marketing area of final product/s, Mode of transport of Raw material and
finished.
Maton being a purely mining Project and there wouldn’t be any other process
involved like beneficiation. So no significant raw material requirement is there
except consumable like fuel for equipments and explosive / Ammonium Nitrate
for blasting purpose. The final product would be ROM and/or crushed
Rockphosphate. The mode of transport of material would be through trucks.
3.7 Resource optimization / recycling and reuse envisaged in the project, if any
Not envisaged
3.8 Water & Power Availability & Source
3.8.1 Water Availability
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
An additional 300 KLD of water will be required, as compared to the present 200
KLD for the present capacity of 0.18 MTPA. The additional requirement is
proposed to be extracted from ground from within or outside the mine lease
through bore wells after obtaining requisite approvals and also from the rain water
collection in the pit area, water collection pond is also proposed to be constructed.
3.8.2 Power Availability
Energy requirement will be 1.0 MW after expansion. Power will be wheeled from
captive power plant at Hindustan Zinc’s Zawar mines located 45 kms away
through AVVNL grid.
3.9 Waste Generation and its Management
3.9.1 Solid Waste
The waste rock generated from the mining will be systematically dumped at
earmarked overburden dumps with proper stabilization and plantation. The
physico-chemical analysis of the waste rock indicates that the waste is non-
hazardous in nature and not likely to cause any adverse impacts. Waste generated
by mining will be dumped at pre decided sites in ultimate dump configuration of
10 x 10 meters or 5 x 20 m lifts after obtaining necessary approval. Each lift
would have slope angle of 400 and overall final slope of 27
0. There is no sub grade
mineral available as such there would not be need for stacking of sub grade
mineral separately. The proposed excavation of overburden for five year is as
follows.
Year Qty(T)
2012-13 4680000
2013-14 13000000
2014-15 12500000
2015-16 11000000
2016-17 11000000
Total 52180000
3.9.1 Liquid Waste, effluents
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
No Liquid effluents / waste generation would be there as beneficiation plant is not
proposed.
4.0 Site Analysis
4.1 Connectivity
Maton Mine is located at about 12 km southeast of Udaipur, at a latitude
2432’34’’ and longitude 7347’30’’ and falls in the Survey of India toposheet
No. 45H/14. The nearest railway station is Rana Pratapnagar on Udaipur -
Chittorgarh Broad gauge line of North - Western Railway at about 8 km away.
The area is connected by airways with the airport being at Dabok which is at
about 12 km. (NW) on Udaipur – Chittorgarh NH 76. The Mine is well connected
from two sides by asphalt road from Udaipur. The revenue map is attached for
reference.
4.2 Land Form, Land use and land ownership
4.2.1 Land Form
The general topography of the Mining Lease area is flat to undulated. The
mineralization is within a hillock. HZL has the surface rights over the land where
mining and related activities are being carried out.
4.2.2 Land Use
Total Mine lease area is of 143.13 ha, out of which 114.44 ha is acquired within
mining lease area for carrying out mining and related support activities.
Additionally 81.02 Ha has been acquired outside the ML area for OB storage,
crusher, offices etc.
The pre operational land use pattern of mining lease is as follows:
The present land use detail of acquired land is as per following table.
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
Land Use Area(ha.)
Built up 4.42
Mine pit 19.84
Waste Dump 28.79
Green Belt 62.83
Others 79.58
Total 195.46
No additional acquisition of land is proposed for expansion from 0.18 million
TPA to 0.5 million TPA of ore production at Maton Rockphosphate Mine.
4.2.3 Land Ownership
Village wise details of total land acquired from within the mine lease and outside
the mine lease area for the mining project is as below.
Village Govt Land Private Land Total
Maton 133.1450 49.8378 182.9828
Umra 10.3750 1.2540 11.6290
Lakadwas 0.8216 NIL 0.8216
Karbadia NIL 0.0260 0.0260
Total 144.3416 51.1178 195.4594
4.3 Topography
Topography of the area is shown in attached map.
TOPOGRAPHICAL FEATURES OF THE AREA
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
4.4 Land Use Pattern of Mining Lease
Details of the land is as given in sec 4.2.2 and 4.2.3 above
4.5 Existing Infrastructure and Amenities
Existing Infrastructure viz. Office building, Crusher, and quarters for the security
personnel are available at site. As Udaipur, a major city is nearby from the project
site; all basic amenities like school, hospital, recreational facilities, electrical lines
are available.
4.6 Soil Classification
The texture of soil is mostly sand and silty sand in the study area.
The PH of the soil in the study area ranged from 7.0-7.7. The soil is neutral to
slightly alkaline.
Details of soil sampling locations:
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
Station
Code
Location Distance wrt.
Boundary of
ML Area (km)
Direction wrt
Centre of ML
Area
Present
Land Use
S1 Umra Village 2.2 S Agri. Land
S2 Lakadwas
Village
2.4 E Barren Land
S3 Nr UdaiSagar 3.0 NE Barren
S4 Maton Village 0.5 N Barren Land
S5 Kharbadia
Village
0.6 NW Barren Land
S6 ML area Core Zone - Industrial
area
The soil analysis parameters as per recent monitoring report Dec 2011 are as
shown below:
PARAMETER
S1 S2 S3 S4 S5 S6
pH - 7.66 7.39 7.03 7.22 7.4 7.35
Ca2+ % 4.4 4.3 2.3 2.2 2 3.5
Mg2+ % 1.44 1.14 1.32 0.84 0.36 0.42
SODIUM as Na % 2.12 2.59 2.34 2.39 2.76 2.22
POTASSIUM as K % 0.906 6.25 3.21 1.72 0.73 1.71
AVAILABLE “N” % 0.021 0.0224 0.024 0.0224 0.022 0.0238
CHLORIDE as Cl % 0.025 0.045 0.034 0.148 0.025 0.017
SULPHATE as So4 % 0.37 0.38 0.51 0.38 0.41 0.48
IRON as Fe % 4.42 5.12 6.6 1.3 1.74 2
MANGNESE as Mn % 0.163 0.74 0.837 0.079 0.022 0.027
ZINC as Zn % 0.009 0.0102 0.014 0.0084 0.01 0.0098
ALUMINUM as Al % 1.21 2.54 1.92 1.61 0.88 1.41
LEAD as Pb % 0.002 0.0013 0.003 0.0022 0.002 0.0018
PHASPHATE as Po4% 0.003 0.0045 0.005 0.0057 0.005 0.0064
PHOSPHOURS as P % 0.001 0.0014 0.002 0.0018 0.002 0.002
ORGANIC MATTER % 3.92 3.99 4.56 3.82 2.36 2.8
ORGANIC CARBON % 2.71 2.25 2.68 2.56 1.37 1.82
WATER SOLUBLE
CHLORIDE
% 0.025 0.045 0.034 0.148 0.025 0.017
UNIT RESULTS
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
4.7 Climatic data and secondary sources
The meteorological data recorded during the monitoring period is very useful for
proper interpretation of the baseline information as well as for input prediction
models for air quality dispersion. Historical data on meteorological parameters
will also play an important role in identifying the general meteorological regime
of the region.
The year may broadly be divided into four seasons:
Winter season : December to February
Pre-monsoon season : March to May
Monsoon season : June to September
Post-monsoon season : October to November
Onsite monitoring was undertaken for various meteorological variables in order to
generate the site – specific the data was collected at site every hour continuously
from 1st march 2009 to 31
st March 2009 covering pre-monsoon season. The
generated data then compared with the meteorological data generated by nearest
Indian meteorological Department (IMD) station located at Udaipur at a distance
of (12 km NW)
4.8 Social Infrastructure available
The location is very near to the city of Udaipur and all the basic social
infrastructure as listed below are available.
Hospitals
Banks
Post Office
Railway Station
Bus Station
Schools
Police Station
Shopping Complexes
Sports Infrastructure
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
Cinema Hall
5.0 PLANNING BRIEF
5.1 Planning Concept
The industry is mining. It is proposed for expansion of mine from 0.18 MTPA to
0.5 MTPA of ore production. The mining will be through open cast method by
conventional Shovel Dumper combination and Drilling and Blasting. The
operations will be fully mechanised. The ore excavated will be stacked at ore yard
from where will be loaded in dumpers and will be crushed to <12 mm size.
Separate stock yards of crushed ore will be maintained as per the grade. The ore
will be sold to the parties which shall be transported through trucks by road. All
required infrastructure is already available.
5.2 Population Projection
As per 2001 census, 25646 persons inhabited in 10 villages around Maton Mine.
The distribution of population in the study area is as per the table below.
TABLE 5.1 DISTRIBUTION OF POPULATION IN STUDY AREA
Sl. No. Village Total Family Population
1 Maton 229 807
2 Kharbadia 218 1195
3 Lakadwas 1171 5855
4 Kaladwas 601 3650
5 Eklingpura 338 1860
6 Umra 809 5779
7 DhuniMata 57 245
8 Boiki Pancholi 240 1200
9 Kanpur 897 4485
10 Kamlod 114 570
Grand Total 4674 25646
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
.
5.3 Land use planning
The land use pattern of the total acquired land is as given in Sec 4.2.2 above.
5.4 Amenities and Facilities
i) Education: There exists Primary, Secondary and Senior Secondary Schools
and colleges
ii) Social Infrastructure like Hospitals, Post Office, Bank, Police Station, Bus
Station, Facility Exists
iii) Telecommunication, LPG services, Marketing stalls, Sports infrastructure –
exists
iv) Recreation- Existing Recreation facilities such as cinema hall, Sports
infrastructure
6.0 PROPOSED INFRASTRUCTURE
6.1 Industrial Area
Infrastructure is already available for 0.18 MTPA capacity. The same
infrastructure will be shifted within the mine premises / acquired land on
expanding to 0.5 MTPA if needed.
Road Network – two way road along the mine.
Power transmission – 4 kms of 33 KV transmission line installed through
AVVNL.
Internal roads within mine boundary
Office buildings
The following would be developed as part of the proposed expansion
Truck parking facility
Residential Area: No residential Area shall be developed as HZL is already having
the residential colony at Udaipur.
6.2 Green Belt
HZL has planted 5500 plants saplings from 2009-10 to 2011-12 in an area of
2.225 ha. Thick vegetation will be developed along acquired land boundary to
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
attenuate the dust and noise. The plantation will be carried out along the roads
within the boundary to arrest dust. The plantation will also be carried out on the
waste dumps slopes as and when they mature i.e. reach to final limits after their
stabilization. Plantation will also be done on the top of waste dump benches.
Around 33% acquired area shall be developed with plantation.
6.3 Social Infrastructure
The Maton Mines is very near to the city of Udaipur and its suburbs and all the
social infrastructures as listed below are available.
Education: There exists Primary, Secondary and Senior Secondary Schools
and colleges
Social Infrastructure like Hospitals, Post Office, Bank, Police Station, Bus
Station facility exists
Telecommunication, LPG services, Marketing place exists
Recreation- Cinema hall, Sports infrastructure exists
Looking to above, company doesn’t propose for creation / construction of any
Social Infrastructure. However the company would continue its CSR activities in
surrounding villages of Maton.
6.4 Connectivity
The project site is located 12 Km South East of Udaipur city and is well connected
by Jhamarkotra road from Udaipur. The nearest Airport is Dabok about 12 Km
NW of the Maton Mine. The nearest railway station Rana Pratapnagar is 8 Km
NW of Maton Mine. NH 76 is at 6 km NW from the ML area.
As site is well connected, there is no requirement for any additional infrastructure
except strengthening of internal roads.
6.5 Drinking water management
15 cum/day of drinking water would be required during the operations. Same shall
be purchased from external sources in the same way as being done at present.
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
6.6 Sewerage System
As there will be no township facility developed within the boundary so no
sewerage waste would be there and need for Sewerage System would not be there.
6.7 Industrial Waste Water management
Since the Ore beneficiation Plant is not proposed, there would not be generation of
any industrial waste water and effluents. The rain water collected in mine pit area,
will be used in wet drilling and water sprinkling for dust suppression on haul
roads . Zero discharge of water shall be maintained from mining premises. Storm
water generated shall be allowed to flow naturally ensuring no contamination to it.
Garland drains and de-silt pit will be constructed around the OB dump to ensure
de- silting of rain water. The rainwater will be collected in suitable sump pits and
will also be used in mining operations and dust suppression.
6.8 Solid Waste Management
About 521,80,000 T waste rock (Over Burden) would be generated from the mine
proposed Mining Plan period of five year. Waste rock from the development
heading would consist of quartzite, phyllite, Jaspery quartzite, etc. Mine waste
from development areas shall be transported and dumped in a specifically
assigned area i.e. waste dump area. The waste is non-hazardous in nature and not
likely to cause any adverse impacts. The dumps will be stabilized by plantation of
trees.
The following mitigation measures for solid waste management shall be adopted:
Adequate slope will be maintained to give proper stability to the dump.
Waste will be stacked & leveled systematically in layers.
After reaching the benches to their ultimate height and location, plantation
shall be done on slopes and top.
Construction of garland drains around the Waste dump so that surface run
off from the dump is collected in a sump.
Regular maintenance of the garland drains constructed around the solid
waste dump to collect the surface run off.
6.9 Energy requirement
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
Presently Maton mine receives Power at 33 KV from Aklingpura substation of
AVVNL. Energy requirement will be approx 1.0 MW after expansion. Power will
be wheeled from captive power plant at Hindustan Zinc’s Zawar mines located 45
kms away through AVVNL grid.
7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN
There will not be any additional acquisition of land due to proposed expansion
from 0.18 million TPA to 0.5 million TPA. All the mining operation will continue
within the and acquired land within and outside ML.
8.0 PROJECT SCHEDULE AND COST ESTIMATES
8.1 Project Schedule
The current production of rockphosphate ore of Maton mine is 0.18 MTPA .It is
proposed to increase its production of ore from 0.18 to 0.5 MTPA. The mine will
reach to the expanded capacity of 0.5 MT in Year 2 / year 3.
8.2 Capital Cost Estimates
As the project is going to be completely outsourced so there will be no capital cost
on machineries. The only cost comprise of crusher, office infrastructure, shifting
of power line, small warehouse etc. The total Capital cost has been estimated at
INR 120 million (12 crores)
The calculation below indicates that the project is robust and is economically
viable at a high stripping ratio of 24 considering average sale price of the product
at Rs 2500 per Tonne.
TABLE 8.1
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA
ECONOMICAL
VIABILITY
Description 2012-13 2013-14 2014-15 2015-16 2016-17
Ore prod (Lac tons) Tentative 1.8 5 5 5 5
Total Excavation (in Lac Tons) 48.6 140 125 115 95
Capex (Crusher and Offices) 1200
Revenue @ 2500 (Av price) 4500 12500 12500 12500 12500
Operating Profit 975 2491 3508 4208 5608
Depreciation 420 117 99 85
Tax (30%) 293 621 1017 1233 1657
Net Cash Flow 683 249 2374 2876 3866
All Amounts are in Lacs.
9.0 ANALYSIS OF PROPOSAL (Final Recommendations)
9.1 Financial Benefit
The proposed project will reduce import of rockphosphate and phosphoric acid
thus saving of foreign exchange. It will boon for the fertilizer industry and
agriculture. This will also generate revenue to the state Government as well as
central government. The people around the region will get direct and indirect
employment thus improves the financial status. HZL will also get benefited.
9.2 Social Benefits
The proposed project shall proactively participate in the upliftment of socio
economic index of the communities around the project site by way of financial
and administrative support. The project will open up employment opportunities,
directly and indirectly. There shall be opportunities for entrepreneurs to engage in
many service sectors directly or indirectly associated with the project.
The CSR approach of the company continues to be towards sustainable livelihood
management of the community around. on the present focus areas shall be
continued in education, health, sanitation, drinking water, agriculture, water shed
management, culture identity preservation, tribal welfare, welfare of socially
weaker sections and marginalized people.
Pre Feasibility Report – Expansion of Maton Mines from 0.18 to 0.5 MtPA