EIA/EMP Report of Beneficiation Plant –BRPL - State Pollution ...

EXECUTIVE SUMMARY 

0.1 INTRODUCTION 

S.S.Environics (India) Pvt. Ltd. 

EIA/EMP Report of Beneficiation Plant –BRPL 

M/s Brahmani River Pellets Limited (thereafter referred as BRPL) proposes 

to commission a beneficiation plant near Bhadrasahi chowk in village Tonto, 

Barbil tehsil, Keonjhar district, Orissa to produce concentrated iron ore fines @ 

4.0 million tones per annum. 

The proposed project shall not have any captive iron ore mine and shall be based 

only on the iron ore fines generated/to be generated by the various iron ore 

mines operative in the area. The proposed beneficiation plant shall have 

following major components: 

• Beneficiation plant at Tonto village; 

• Tailing Dam at Nalda village; 

• Belt conveyor for transportation of iron ore from mines; 

• A pipeline (12 inch in diameter and 230.5 km in length) to proposed Pellets 

plant in Kalingnagar Industrial Complex Sukinda tehsil, Jajpur district, Orissa, 

for transportation of beneficiated iron ore; 

• 15.375 km rubber lined pipeline of 8 inch in diameter to tailing dam for tailing 

discharge; and 

• 18.92 km pipeline of 12 inch in diameter for water supply from Baitarini river. 

Proposed beneficiation plant and tailing dam have Latitude: 22 o 02' 36” N & 

Longitude: 85 o 22' 10” E and Latitude: 22 o 09' 47” N & Longitude: 85 o 24' 35” 

E respectively (as per Survey of India toposheet no. 73 F/8, scale 1:50000). The 

accessibility to site is as per hereunder: 

• Road: The beneficiation plant site is just beside NH-215. 

• Rail: The nearest railway station is at Barbil, which is about 6.5 km from the 

beneficiation plant site and is located on the Howrah-Barbil section of South 

Eastern Railway. 

• Air: The nearest airport is at Bhubaneswar, which is about 300 km from 

beneficiation plant site and well connected by road. 

The proposed project is designated to be developed under the Environmental 

Impact Assessment (EIA) Notification and amendments under Environment 

(Protection) Act (EPA), 1986. Proposed project falls under “Category A” as per 

the notification issued on 14 th September 2006 by Ministry of Environment & 

Forests (MOEF) as new environment clearance procedure. 

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M/s S.S.Environics (India) Pvt. Ltd., (thereafter referred as SSE), 

Bhubaneswar, Orissa, has been retained by BRPL to carry out Environment 

Impact Assessment (EIA) study and to prepare Environment Management Plan 

(EMP) for the proposed project. The study has been carried out as per the Terms 

of Reference (TOR), issued by MOEF for carrying out the EIA/EMP study vide 

letter No J-11015/121/2007-IA.II (M) dated 29 th May 2007 (based on the duly 

filled Form 1 along with pre-feasibility report submitted and subsequent 

presentation made to MOEF) as the first step of the notification issued on 14 th 

September 2006. 

0.2 PROJECT DESCRIPTION 

� Land Requirement 

The details of land envisaged to be procured for the proposed project are as per 

given below: 

Sn Particulars Area (ha) Remarks 

1 Beneficiation Plant 44.53 • Private land- 3.49 ha 

• Government Land- 41.04 ha 

2 Tailing Dam 45.06 • Private land- 32.52 ha 

• Government Land- 12.54 ha 

3 Corridor for belt conveyor 

(Length:1.0 km & Width 5 m) 

0.5 Within MISL lease 

4 Pipeline for transportation of Iron 

Ore Slurry to Pellet plant 

(Length:230.50 km) 

5 Pipeline for water from Baitarini 

river (Length:18.92 km) 

6 Pipeline for transportation of 

rejects to tailing 

dam(Length:15.375 km) 

Nil • All along the NH-215 and SH- 

20. 

Nil • All along the NH-215/Major 

District Road (MDR) /Other 

District Road (ODR ) 

Nil • All along the NH- 215/MDR/ 

ODR 

The details of existing land use pattern (as per revenue records) of the land 

proposed to be procured are as per given below: 

Sn Particulars 

Area (ha.) 

Plant Tailing Dam Corridor for Belt 

conveyor* 

Govt Pvt Govt Pvt Govt Pvt 

1 Jungle 27.10 0 12.54 0 0 0 

2 Gochar 6.25 0 0 0 0 0 

3 Grazing 0 0 0 0 0 0 

4 Road 0 0 0 0 0 0 

5 Waste 7.69 3.49 0 32.52 0.5 0 

6 Cultivated 0 0 0 0 0 0 

7 Residential 0 0 0 0 0 0 

Total 41.04 3.49 12.54 33.52 0.5 0.0 

* within MISL ML area 

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Proposal for Stage –I clearance for jungle as forest land has been submitted to 

Chief Conservator of Forests (CCF) vide letter no HO-IDCO/DCF/FC/75-07-12158, 

dated 5.07.2007. 

The proposed land utilization plans are as per given below: 

Sn Particulars 

Area (hect.) 

Beneficiation Plant Tailing Dam 

1 Plant/Dam 5.790 34.56 

2 Storage of raw material 17.179 0.0 

3 Water reservoir 3.040 0.0 

4 Administrative Buildings 0.230 0.25 

5 Storage of fuel 0.0 0.0 

6 Greenbelt/plantation 15.391 10.25 

7 Others (conveyor corridor and road) 2.9 0.0 

Total 44.53 45.06 

� Raw Material 

Low grade (Fe – 60~63%) iron ore fines (-10mm) @ 4.75 million tpa shall be 

beneficiated to produce about 4.0 million tpa concentrate with an average grade 

of +64.5% Fe. Mine of Mideast Intergrated Steel Limited (MISL) at Roida shall be 

the major supplier of iron ore fines and shall fulfill about 50% of the 

requirement. The balance requirement of iron ore fines for the proposed 

beneficiation will be augmented from various mines located in Jamda - Koira 

valley of Bonai synclinorium located mainly at Joda, Koira & Roida sectors. The 

major sources are expected to be from Thakurani mines of Sesa Goa Ltd, Jajang, 

Oraghat, Tehri & Bico of Rungta Mines Ltd, Kasia of Essel Mining & Co Ltd & 

Bolani of SAIL. 

It is envisaged that iron ore fines @ 2.5mtpa from MISL mine and @1.0 mtpa 

from KN Ram mine for the proposed plant will be transported through belt 

conveyor) while @1.25 mtpa by roads. Considering 300 working days and 16 

tonnes per truck/dumpers, total number of trip to the plant shall be 260 per day. 

The maximum distance of any mine from where iron ore fines shall be procured 

is within 2 km. 

The traffic density of the NH215 will not increase due to the proposed trucks 

movement since the movements are restricted from mines to beneficiation plant 

and the movement shall be on purely internal hauling and shall cross NH215 at 

one point while transporting from KN Ram mine. 

� Manufacturing Process 

The pellet feed iron ore concentrate to be produced in the beneficiation plant 

must be 100% of minus 100 mesh (-150 micron) to meet slurry pipeline 

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transportation system design criteria. The concentrate shall also have 

approximately 80% of (-) 325 mesh (- 45 micron) material and a nominal grade 

of 64.5% Fe to meet the pellet plant process requirement. 

Two identical beneficiation circuits, each with a capacity to produce 2 mio tpa of 

iron ore concentrate are envisaged. Beneficiation process consists of: 

• Primary wet grinding; 

• Hydro cycloning; 

• Two stage spiral classification; 

• Single stage high gradient magnetic separation; 

• Regrinding and thickening of concentrate received from both spirals; and 

• Magnetic separators. 

The details of main machinery/equipment envisaged for the proposed beneficiation 

plant are as per given below: 

Sn Particulars Quantity Capacity 

1 Primary ball mill 2 330 tph (each) 

2 Primary Hydro cyclone (26” dia.) 10 100 tph (each) 

3 Primary spirals 308 starts - 

4 Cleaner spirals 228 starts - 

5 Secondary Hydro cyclone (10” dia.) 20 50 tph (each) 

6 Regrinding ball mill 2 230 tph (each) 

7 Linear screen 2 151.5 tph (each) 

8 Cone splitter 2 28 tph (each) 

9 HGMS 2 137.5 tph (each) 

10 Intermediate Thickener (55m dia.) 1 303 tph 

11 Concentrate Thickener (48m dia.) 1 558 tph 

12 Tailing Thickener (60m dia.) 1 98 tph 

13 EOT crane (Ball mill Bay) 2 60t/10t 

14 EOT crane (HGMS Bay) 2 12t/3t 

� Power 

Total power requirement during operation phase of the proposed beneficiation 

plant shall be 18.5 MW which is proposed to be obtained from the North Eastern 

Electricity Supply Company of Orissa Ltd. (NESCO). One standby Diesel 

Generator having a capacity of 750 KW is envisaged which shall be used in case 

of power failure only. 

0.3 ANTICIPATED ENVIRONMENT IMPACTS & MITIGATION MEASURES 

� Land Use Pattern 

About 59.81% of total land proposed to be acquired belongs to government land 

while rest of the land belongs to private land. About 44.25% of total land is 

designated as jungle as per local revenue records. No cultivated and grazing land 

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is proposed to be acquired. Total area envisaged for the project is only 89.59 

hect, which is very small as compared to the total study area. 

Mitigation Measures 

• Forest clearance for land designated as jungles shall be obtained from MOEF 

before clearing the site. 

� Water Resources 

The maximum and average estimated water requirements during operation 

phase are 11520 m 3 /day (0.134 m 3 /s) and 7520 m 3 /day (0.087 m 3 /s) 

respectively which shall be drawn from the Baitarini river at Kanpur village. A 

water intake well and pumping station shall be provided on the bank of Baitarini 

river to draw the water and same shall be transported through a 18.92 km long 

pipeline to beneficiation plant site. It is evident from the data available of last 27 

years from the secondary sources for flow rate available in Baitarini river at 

Kanpur village that: 

• The minimum flow rate was less than 0.5 m 3 /s during the month December, 

February, Mach and April; 

• The minimum flow rate available was 0.16 m 3 /s during the month of April; 

and 

• During lean season, water availability shows a sign of uncertainty. 


• Excess water to be stored in the tailing dam shall be utilized during lean 

season; 

• Alternate sources shall be evaluated and considered; and 

• Regular record of water flow of Baitarini River shall be maintained. 

� Ambient Air Quality 

The proposed beneficiation process is a wet process and the potential particulate 

matter emission shall be limited to the raw material handling and conveying. 

Otherwise, all unit operations will be carried out in wet mode and in closed 

circuit. The details of anticipated air pollution and its management are as per 

given below: 

Sn Activity Type of Pollutants Management 

1 Transportation of iron ore fines 

By belt conveyor • Fugitive Dust • Belt conveyor shall be fully covered 

• Transfer points shall be provided with 

dedusting system such as bag filters 

with a outlet dust concentration of 50 

mg/Nm 3 . 

v

By trucks/ 

dumpers 

2 Handling & 

storage at plant 

site 

3 Operation of DG 

set in case of 

power failure 


• Dust 

• Dust, SO2, NOX & 

CO due to 

Vehicular 

movement 


• Trucks shall be properly covered with 

tarpaulin 

• Preventive maintenance of vehicles 

• Fugitive Dust • Adequate arrangement for water spray 

shall be provided 

• Storage yard shall be properly fenced 

and bushes shall be planted at the 

periphery of yard 

• SPM, SO2, NOX & 

CO 

• Adequate stack height as per CPCB 

guidelines shall be provided 


In addition to mentioned above, other mitigation measures are as per given 

below: 

• Level sensor to have a gap of only half-meter in between stacking boom and 

top of pile; 

• Plant roads & approach roads shall be made of bitumen/ concrete; and 

• Effective house keeping shall be carried out. 

� Water Quality 

During beneficiation process, water shall be discharged via three different ways: 

o Along with tailings to tailing dam; 

o Along with beneficiated iron ore to pellet plant at Jajpur; and 

o As domestic waste water. 

It is envisaged that: 

• Tailings shall not contain any soluble mineral hence; overflow from dam shall 

be recycled back to process @ 2352 m 3 /day (max) and 1892 m 3 /day 

(average); 

• At pellet plant, water resulting from filtration of slurry shall be used for 

process and domestic usage after adequate treatment; and 

• Domestic waste water shall be generated @31m 3 /day. Primary and 

secondary treatment shall be provided to make treated water fit for irrigation 

purposes to be used for green belt development /plantation. 

In addition to above, water quality of the study area may get affected due to: 

1. Ground water quality due to leaching from tailing dam 

The sub soil investigation of the site allocated for tailing pond and on the axis of 

the proposed earthen dam indicates that the top soil is of gray colored clay soil 

with gravel up to 1.5 m level form top. The permeability of soil is 4.21x10 -4 

cm/sec. The next layer consists of boulder mixed gravel up to 6.0m. There after, 

disintegrated rock strata is encountered. 

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Local clay liner will be provided to check the seepage through tailing dam. The 

density of the clay liner will be achieved to the prescribed moister content of 

± 3% which shall provide a permeability of 10 -6 to 10 -7 cm/sec. The dam 

foundation will be made impermeable as far as possible by cotton grouting. The 

leaching because of percussion through foundation is remote as the clay liner on 

the sides of the embankment with cotton grouting will provide an impermeable 

layer. Hence leaching due to seepage through dam is almost zero. Also the tailing 

thickener shall be made out of RCC structure connected to a full leak proof under 

flow system leaves no scope of leaching. 

2. Surface water quality due to spill over the tailings along with storm 

water during monsoon season 

The catchments area of the tailing dam is almost a valley impounded from three 

sides and making the surface runoff discharge to the nearby Laskara nallah, 

which meets Karo river at a distance of 6km in northern site of the catchments. 

The topographical representation clearly indicates the limited run off from the hill 

top to the valley. 

The average annual rainfall in the study area is about 1400 mm and considering 

the infiltration, evapotransporation and evaporation, the annual run off shall be 

around 50 mm. Free board holding capacity of the tailing dam shall be 

considered on the basis of 250 mm run off which is 5 times higher than the 

actual. 

The dam is designed to hold the rain water over the area of the dam only. No 

surface run offs shall enter the dam from the catchment area, as retaining 

wall/toe walls shall be provided before the embankment of the tailing dam. 

In addition to sufficient free board taking into the runoff deposition, provision of 

pumping back the excess water from the impounded catchments has been 

considered in designing the embankment structure of the dam. 

In design of the dam, provision of spillway is included to release excess 

rainwater. These spillways shall be designed as temporary structures (as raised 

embankment) with sufficient free board. The spillway will be designed to contain 

and control hydraulic jumps that occur at the bottom of the spillway. 

Hence, chances that may result in suspended solids and turbidity in run off water 

during the monsoon period are remote. 

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� Soil Quality 

The details of solid waste generated and its management are described 

hereunder: 

Sn Source Quantity Disposal 

1 Raw water treatment plant 72 m 3 /day Shall be used for filling of low lying area 

2 Tailings from thickener 0.7 mio tpa Shall be disposed off in tailing dam 

3 Sewage Treatment Plant 4-5 kg/day Shall be used as manure for green belt 

development/plantation 

� Ecology 

The impact on the ecology of the study area during operation phase may 

account for the following: 

• Water availability to the downstream users of the Baitairni river with respect 

to withdrawal point at village Kanpur; 

• Tailing's spillover from tailing dam during monsoon season; and 

• Due to operation of project. 

As explained during the impact assessment on water resources on the basis of 

last 27 years flow data of Baitairni river at Kanpur village, the water availability 

during lean season flow at Kanpur village is uncertain and may affect the 

downstream ecology, if continues to withdraw. Hence, impact may be significant 

and adverse. 

There shall be remote chances of spillover of tailings during monsoon season due 

to the following reasons: 

• Free board holding capacity of the tailing dam during monsoon shall be 

considered on the basis of 250 mm run off which is times higher than the 

actual; 

• The dam is designed to hold the rain water over the area of the dam only. No 

surface run offs shall enter the dam from the catchment area, as retaining 

wall/toe walls shall be provided before the embankment of the tailing dam. 

No run off entry is envisaged; and 

• Sufficient free board taking into the runoff deposition has been taken into 

consideration and also near the tailing dam, provision of pumping back the 

excess water from the impounded catchments have been considered in 

designing the embankment structure of the dam. 

During normal operation, ecology shall have positive impact due to the following 

reasons: 

• Compensatory afforestation shall be carried out; and 

• Development of greenbelt/plantation of earmarked land of 28.64% of the 

total project area of 89.59 hect. 

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0.4 ENVIRONMENT MONITORING PLAN 



The details of recommended frequency and parameter of environment 

monitoring for the proposed project during operation are as per given below: 

Sn Component Parameter Locations Frequency 

Beneficiation Plant 

1 Ambient Air TSPM, RSPM 3-4 locations at the 

boundary of premises 

12 hourly samples, 

twice in a week 

2 Stack TSPM, SO2, NOx, CO DG set Once in a year 

3 Noise Level Hourly Leq At the boundary of the Once in two week 

plant premises 

for 24 hours 

4 Waste Water As per GSR 422 (E) for At outlet of STP Once in three 

inland surface water 

months 

Tailing Dam 

1 Waste Water Turbidity Overflow from tailing Once in a day during 

dam and water at 

upstream and 

downstream of Laksar 

nallah 

monsoon period 

pH, Fe, Al, Si, oil & Inlet and outlet – Once in three month 

grease etc 

tailing dam 

2 Ground pH, Fe, Al, Si etc 6-7 locations adjacent Once in a year 

water 

to tailing dam site 

3 Soil pH, Fe, Al, Si etc 6-7 locations adjacent 

to tailing dam site 

Once in a year 

The recommended monitoring plan shall be modified as per the conditions to be 

stipulated by MOEF/OPCB, if any. 

0.5 BENEFITS OF PROJECT 

� Property Management 

About 59.81% of total land proposed to be acquired belongs to government land 

while rest 40.19% of total land belongs to private land. Nine (9) families are 

envisaged to be rehabilitated as land oustee. Land acquisition is under progress. 

4(1) notification for acquisition of private land has already been made by Govt. 

of Orissa on 19.09.2007. The Rehabilitation packages will be as per R&R Policy, 

2006 of Govt. of Orissa. 

� Employment & Socio-economic 

During operation phase, the total number of direct employment envisaged is for 

268 skilled, semi-skilled and unskilled workers. The unskilled labour shall be by 

and large recruited from the local area and for others; preference shall be given 

to locals on the basis of availability of skill. In addition to direct employment, 

proposed project shall generate a number of indirect job opportunities on local 

and regional basis. 

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In addition to payment of additional royalty, sales tax and excise duty to the 

Government, BRPL shall continue its efforts to improve the socio-economic 

status of the local habitants. BRPL shall review various welfare schemes going 

on in the area from time to time and take appropriate decisions of 

modifications/additions of welfare schemes as per requirement of local habitants 

to the maximum possible extent. 

0.6 ENVRIONMENT MANAGEMENT PLAN 

� Environment Management Cell 

It is necessary to have a permanent organizational set up charged with the task 

of ensuring effective implementation of all identified mitigation measures. 

Conscious of this, BRPL shall have a department consisting of officers from 

various disciplines to coordinate the activities concerned with the management 

and implementation of the environmental control measures during construction 

and operation phase of the proposed project. BRPL shall also develop a welldocumented 

system to monitor and control pollution. 

Basically, this department shall undertake monitoring of the environmental 

pollution levels by measuring fugitive emissions, ambient air quality, water and 

effluent quality, noise level etc., either departmentally or by appointing external 

agencies wherever necessary. In case, the monitored results of environmental 

pollution shall be found to exceed the allowable values, the Environmental 

Management Cell suggests remedial action and gets these suggestions 

implemented through the concerned plant authorities. The Environmental 

Management Cell shall also co-ordinates all the related activities such as 

collection of statistics w.r.t health of workers and population of the region, 

afforestation and green belt development. 

� Cost of Environment Management Plan 

The details of estimated capital and recurring cost of the proposed 

environmental management plan are as per given below 

Sl. 

No 

Particulars 

Capital Cost (Rs. in 

lacs) 

Recurring cost per 

annum 

(Rs. in lacs) 

1 Air Pollution Control 50.00 22.00 

2 Water Pollution Control 1048.00 164.00 

3 Noise Pollution Control 15.00 6.00 

4 Environment Monitoring & Management 25.00 13.00 

5 Occupational Health 14.00 6.00 

6 Green Belt/plantation 10.00 6.00 

Total 1162.0 217.0 

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EIA/EMP Report of Beneficiation Plant –BRPL - State Pollution ...

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