Benchmarking on the requirement of Land, Water and Power for Iron Ore Beneficiation and Pellet Plants of various capacities- A case study in Odisha
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1 Benchmarking on the requirement of Land, Water and Power for Iron Ore Beneficiation and Pellet Plants of various capacities- A case study in Odisha September 15, 2017 By K. Ranjan DGM (I/c), MECON Ltd., Ranchi
2 Structure of Presentation Sl No Description 1 Objective & Scope of Study 2 Technological Facilities 3 Supporting Auxiliary & Service Facilities 4 Assumptions 5 Requirement of Land 6 Requirement of Water 7 Requirement of Power 8 Plants Visited by MECON Team as Case Studies 9 Conclusion
3 OBJECTIVE & SCOPE OF STUDY To achieve optimum requirement of land, water & power for Beneficiation & Pellet Plants Case Study for BP & PP of capacities Mtpa on standalone & integrated basis Feed iron ore (-) 10 mm size Fe 45-55% & 55-60% Area estimated based on consideration of technological & service facilities Comparison as Case Study with a few plants in Odisha
4 PANORAMIC VIEW OF BENEFICIATION PLANT MECON LIMITED
5 PANORAMIC VIEW OF PELLET PLANT MECON LIMITED
6 MAJOR SUB-UNITS OF BENEFICIATION PLANT Screening Unit Filtration Unit Scrubbing Unit Thickener Concentrate, Intermediate & Iron Ore Rejects Subunits of BP Grinding mill unit Primary & Regrind Mill Magnetic Separation Unit Classification
7 SCREENING HOUSE MECON LIMITED
8 SCRUBBER UNIT MECON LIMITED
9 GRINDING MILL MECON LIMITED
10 CLASSIFICATION UNIT MECON LIMITED
11 THICKENERS MECON LIMITED
12 FILTRATION UNIT MECON LIMITED
13 MAJOR SUB-UNITS OF PELLET PLANT Pellet Cooler (in case of Grate Kiln) Slurry storage tanks Filtration unit Pellet screening Sub-units of PP Coarse additive storage cum grinding unit Induration unit including process fans Storage cum mixing cum balling unit
14 SLURRY STORAGE TANKS MECON LIMITED
15 FILTRATION UNIT MECON LIMITED
16 ADDITIVE STORAGE-CUM-GRINDING UNIT MECON LIMITED
17 MIXING & BALLING UNIT MECON LIMITED
18 INDURATION UNIT MECON LIMITED
19 PELLET SCREENING MECON LIMITED
20 ANNULAR COOLER (In GRATE-KILN) MECON LIMITED
21 SUPPORTING AUXILIARY & SERVICE FACILITIES RMHS Yard Raw Water Reservoir Pump House & Cooling Towers Compressed Air Station Repair & Maintenance Shop Administrative Building Electrical Substation & Control Room Fire fighting PH incl. Hydrant sys, automatic fire detection, water spray system etc. Welfare canteen, medical care faclities etc. DG Station Road & rails Security post other service buildings
22 ASSUMPTIONS Rectangular shape land in 2 : 3 ratio (approx.) More or less flat contour of land Storage of raw materials - fifteen (15) days Storage of finished pellets - fifteen (15) days Storage of raw water - fifteen (15) days Green belt as per statutory norms of MOEFCC Smooth and uninterrupted flow of materials Provision of adequate area for dumping of ore rejects (8.0 years to 10 years) considering m stack height
23 REQUIREMENT OF LAND Sl. No Capacity of the plant (in Mt/yr) Description Standalone beneficiation plant (45-55% Fe) Standalone beneficiation plant (55-60% Fe) Area (in Acres) Standalone pellet plant Integrated beneficiation plant (45-55% Fe) and pellet plant Integrated beneficiation plant (55-60% Fe) and pellet plant
24 AREA : STAND-ALONE BENEFICIATION PLANT all figures are in 45-55% Fe 55-60% Fe Acres
25 AREA : STAND-ALONE PELLET PLANT all figures are in Acres
26 AREA : INTEGRATED BENEFICIATION & PELLET PLANT all figures are in Acres 45-55% Fe 55-60% Fe
27 REQUIREMENT OF DUMP AREA Sl. No. Capacity of the plant (in Mt/yr) Time period for storage (in Years) Dump area Beneficiation plant Area (in Acres) 1. 45% to 55% Fe % to 60% Fe Tailing Pond (Wet) : 30% additional area requirement over the above area required for Iron Ore Rejects (Dry)
28 REQUIREMENT OF WATER Sl. No Capacity of the plant (in Mt/yr) Description Standalone beneficiation plant (45-55% Fe) Standalone beneficiation plant (55-60% Fe) Make-up water (in m 3 /h) Standalone pellet plant Integrated beneficiation plant (45-55% Fe) and pellet plant Integrated beneficiation plant (55-60% Fe) and pellet plant Apart from process needs, the above requirement also includes drinking, fire fighting and other minor needs.
29 WATER : STAND-ALONE BENEFICIATION PLANT 45-55% Fe 55-60% Fe all figures are in m 3 /h
30 WATER : STAND-ALONE PELLET PLANT all figures are in m 3 /h
31 WATER : INTEGRATED BENEFICIATION & PELLET PLANT all figures are in m 3 /h % Fe 55-60% Fe
32 REQUIREMENT OF POWER Sl. No Capacity of the plant (in Mt/yr) Description Standalone beneficiation plant (45-55% Fe) Standalone beneficiation plant (55-60% Fe) Maximum Demand (in MVA) Standalone pellet plant Integrated beneficiation plant (45-55% Fe) and pellet plant Integrated beneficiation plant (55-60% Fe) and pellet plant Assumptions of Basic Design Parameters Incoming power supply 220 / 132 / 33 kv, 3 Ph., 50 Hz Power factor 0.95 and above MECON LIMITED
33 POWER : STAND-ALONE BENEFICIATION PLANT 45-55% Fe 55-60% Fe all figures are in MVA
34 POWER : STAND-ALONE PELLET PLANT all figures are in MVA
35 POWER : INTEGRATED BENEFICIATION & PELLET PLANT all figures are in MVA 45-55% Fe 55-60% Fe
36 BREAK-UP OF LAND AREA REQUIREMENT Raw materials and finished products storage Water reservoir Green belt Technological facilities Service facilities CAS & electrical system Others comprise of water supply facilities (excluding water reservoir), pump houses, roads & drainage, administrative building, repair & maintenance shop, welfare canteen, security post & other service buildings, etc. MECON LIMITED
37 AREA REQUIRED FOR RMHS & FINISHED PRODUCTS Sl. No. Capacity of the plant (in Mt/yr) Description Area (in Acres) Standalone beneficiation plant (45-55% Fe) Standalone beneficiation plant (55-60% Fe) Standalone pellet plant Integrated beneficiation plant (45-55% Fe) and pellet plant Integrated beneficiation plant (55-60% Fe) and pellet plant MECON LIMITED
38 AREA REQUIRED FOR WATER RESERVOIR Sl. No Capacity of the plant (in Mt/yr) Description Standalone beneficiation plant (45-55% Fe) Standalone beneficiation plant (55-60% Fe) Area (in Acres) Standalone pellet plant Integrated beneficiation plant (45-55% Fe) and pellet plant Integrated beneficiation plant (55-60% Fe) and pellet plant MECON LIMITED
39 AREA REQUIRED FOR GREEN BELT Sl. No Capacity of the plant (in Mt/yr) Description Standalone beneficiation plant (45-55% Fe) Standalone beneficiation plant (55-60% Fe) Area (in Acres) Standalone pellet plant Integrated beneficiation plant (45-55% Fe) and pellet plant Integrated beneficiation plant (55-60% Fe) and pellet plant
40 AREA REQUIRED FOR TECHNOLOGICAL FACILITIES Sl. No Capacity of the plant (in Mt/yr) Description Standalone beneficiation plant (45-55% Fe) Standalone beneficiation plant (55-60% Fe) Area (in Acres) Standalone pellet plant Integrated beneficiation plant (45-55% Fe) and pellet plant Integrated beneficiation plant (55-60% Fe) and pellet plant
41 AREA REQUIRED FOR SERVICE FACILITIES Sl. No Capacity of the plant (in Mt/yr) Description Standalone beneficiation plant (45-55% Fe) Standalone beneficiation plant (55-60% Fe) Area (in Acres) Standalone pellet plant Integrated beneficiation plant (45-55% Fe) and pellet plant Integrated beneficiation plant (55-60% Fe) and pellet plant
42 BREAK-UP OF QUANTITY OF WATER REQUIREMENT Technological requirement Others Losses : Compressor losses, Cooling losses, etc. Balance requirement includes drinking, fire-fighting, ACVS, etc. MECON LIMITED
43 WATER REQUIRED FOR TECHNOLOGICAL FACILITIES Sl. No Capacity of the plant (in Mt/yr) Description Standalone beneficiation plant (45-55% Fe) Standalone beneficiation plant (55-60% Fe) Make-up water (in m 3 /h) Standalone pellet plant Integrated beneficiation plant (45-55% Fe) and pellet plant Integrated beneficiation plant (55-60% Fe) and pellet plant
44 WATER REQUIRED FOR OTHER FACILITIES Sl. No Capacity of the plant (in Mt/yr) Description Standalone beneficiation plant (45-55% Fe) Standalone beneficiation plant (55-60% Fe) Make-up water (in m 3 /h) Standalone pellet plant Integrated beneficiation plant (45-55% Fe) and pellet plant Integrated beneficiation plant (55-60% Fe) and pellet plant
45 PLANTS VISITED BY MECON TEAM AS CASE STUDIES Sl. Name of plant Type of plant Location Status of plant No. 1. Jindal Steel & Power Ltd. Integrated BP & PP Barbil, In Operation Keonjhar 2. Brahmani River Pellets Ltd. Stand-alone Barbil, In Operation beneficiation plant Keonjhar 3. Arya Iron & Steel Company Stand-alone pellet plant Barbil, In Operation Ltd. Keonjhar 4. International Minerals Trading Co. Pvt. Ltd. Stand-alone beneficiation plant Barbil, Keonjhar Under Implementation 5. Pro Minerals Pvt. Ltd. Stand-alone beneficiation plant Barbil, Keonjhar Under Implementation 6. Ardent Steel Ltd. Stand-alone pellet plant Telkoi, In Operation Keonjhar 7. Sree Metaliks Ltd. Integrated BP & PP Telkoi, Keonjhar In Operation (only PP) 8. Brahmani River Pellets Ltd. Stand-alone pellet plant Duburi, Jajpur In Operation 9. Essar Steel Ltd. Stand-alone pellet plant Paradeep, Jagatsinghpur In Operation
46 IRON ORE BENEFICIATION PLANT AS CASE STUDIES Item Sree Metaliks Ltd. Pro Minerals Pvt. Ltd. MECON s Estimate Capacity (Mt/yr) Feed (% Fe) Product (% Fe) Land (acres) Not available Water (m 3 /h) Power (MVA) 2.5 MW 4.5 MW 7
47 IRON ORE BENEFICIATION PLANT AS CASE STUDIES Item Brahmani River Pellets Ltd. MECON s Estimate REMARKS Capacity (Mt/yr) Feed (% Fe) Product (% Fe) Land (acres) Water (m 3 /h) Power (MVA) Water requirement is on the higher side due to disposal of iron ore concentrate from Barbil to Jajpur through slurry pipeline (192 km).
48 0.6 Mt PELLET PLANT AS CASE STUDIES Item Sree Metaliks Ltd. Ardent Steel Ltd. MECON s Estimate Land (acres) Water (m 3 /h) 21 Not available 30 Power (MVA) Power requirement of M/s Ardent Steel includes, - Grinding of iron ore fines - Raw material handling yard
49 1.2 Mt PELLET PLANT AS CASE STUDIES Item Arya Iron & Steel Company Ltd. MECON s Estimate Land (acres) 50 Water (m 3 /h) No data/information received 50 Power (MVA) 10
50 4.0 Mt PELLET PLANT AS CASE STUDIES Item Jindal Steel & Power Ltd. Brahmani River Pellets Ltd. MECON s Estimate Land (acres) No data/ Water (m 3 /h) information Not available 125 Power (MVA) received It seems that green belt & other associated facilities has been compromised Seven (7) days finished pellet storage yard Less power consumption due to not operating at full capacity
51 6.0 Mt PELLET PLANT AS CASE STUDIES Item Essar Steel Ltd. MECON s Estimate Land (acres) Water (m 3 /h) Power (MVA) Pellet plant is under integrated steel plant complex. Water consumption is more due to the inclusion of wet grinding of iron ore. Plant is operating at lower production capacities.
52 CONCLUSION These figures are guiding norms for State Govt. & also for Entrepreneurs for getting allocation of land and infrastructure facilities in an optimal manner.
53 THANK YOU MECON LIMITED
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