PRE--FFEEAASSIIBBIILLIITTYY RREEPPOORRTT (IInn tteerrmmss...
Transcript of PRE--FFEEAASSIIBBIILLIITTYY RREEPPOORRTT (IInn tteerrmmss...
1
PPRREE--FFEEAASSIIBBIILLIITTYY RREEPPOORRTT
((IInn tteerrmmss ooff pprroovviissiioonn ooff EEIIAA NNoottiiffiiccaattiioonn 22000066)) FOR
THE PROPOSED EXPANSION OF PRODUCTION CAPACITY OF REFINED SILVER FROM 600 TPA TO 800 TPA AT PANTNAGAR
SILVER PLANT, UTTARAKHAND
Submitted to
Ministry of Environment Forest & Climate Change
(MoEF & CC)
New Delhi
Submitted by
Hindustan Zinc Limited
Pantnagar Silver Plant, Pantnagar – 263153
April, 2018
CONTENTS
Chapter No.
Description Page No.
1.0 EXECUTIVE SUMMARY 1
2.0 PROJECT INTRODUCTION 2
3.0 SITE ANALYSIS 3
4.0 PROJECT DESCRIPTION 6
5.0 PROPOSED INFRASTRUCTURE 16
6.0 REHABILITATION & RESETTLEMENT (R & R) PLAN 18
7.0 PROJECT IMPLEMENTATION SCHEDULE 18
8.0 COST ESTIMATION 19
9.0 Financial and Social Benefits 19
10.0 Conclusion 19
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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1.0 EXECUTIVE SUMMARY
1.1 Introduction
Hindustan Zinc Limited (HZL) is an India-based company, which is engaged in the mining and smelting of Zinc, Lead and Silver metal in India. The Company's segments are mining and smelting of Zinc, Lead and Silver and Wind energy. The Company's operations include five Zinc-Lead mines, over four Zinc Smelters, a Lead Smelter, a Zinc-Lead Smelter, seven sulphuric acid plants, a silver refinery plant and over six captive power plants in the state of Rajasthan. In addition, the Company also has a rock-phosphate mine in Maton near Udaipur in Rajasthan and Zinc, Lead, Silver processing and refining facilities in the State of Uttarakhand. The Company also has wind power plants in the States of Rajasthan, Gujarat, Karnataka, Tamil Nadu and Maharashtra. It has a metal production capacity of over one million tons per annum with its key Lead-Zinc mines in Rampura Agucha and Sindesar Khurd, and smelting complexes in Debari Chanderiya and Dariba, all in the state of Rajasthan. HZL is currently operating silver plant of 600 TPA capacity at SIDCUL, Pantnagar, Uttarakhand since 2011. Now, it is proposed to increase silver plant annual capacity from 600 TPA to 800 TPA (monthly 85 Tonnes with overall capacity of 800TPA) in existing plant by increasing percentage of silver in raw material.
1.2 Salient Features of the Project
Sr. No Particulars Description
1 Project Area Existing Silver Plant is located in SIDCUL area. No new land is required for this proposed expansion project
2 Capacity Proposed Production Capacity of refined silver will be extended from 600 TPA to 800 TPA (monthly 85 Tonnes with overall capacity of 800TPA)
3 Process Technology The manufacturing process consist Pyro-metallurgical refining of anode slime in furnaces and hydrometallurgical refining in electrolysis section
4 Raw materials Anode Slime & High Grade Metal (HGM) are the primary raw materials
5 Water Requirement
& its source
No additional water is required for the proposed expansion. Existing plant water requirement is 325 m3/day which is being met from bore wells for which necessary permission is available
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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Sr. No Particulars Description
6 Power Requirement & its source
No additional power is required for the expansion. Existing power requirement is 2 MW which is being met from Uttarakhand State Power Corporation Limited
7 Fuel requirement & source
No additional fuel requirement for this proposed project
Existing fuel requirement is 4500 MT per annum.
500 KVA DG set which will be used for emergency power supply to critical loads.
8 Employment Existing resources is sufficient. There will be ample opportunity for indirect employment.
9 Project Cost Additional capital cost 20 Cr. is involved.
2.0 PROJECT INTRODUCTION
Hindustan Zinc Limited (HZL) is currently operating Silver plant of 600TPA Capacity located
at State Industrial Development Corporation Limited (SIDCUL), Pantnagar village, Kichha
tehsil, Udham Singh Nagar District, Uttarakhand State. The project site is part of the
Notified Industrial Area administered by SIDCUL, Department of Industries, Government of
Uttarakhand. Now, the proposed expansion project is to increase Silver plant annual
capacity from 600 TPA to 800 TPA (monthly 85 Tonnes with overall capacity of 800 TPA) in
existing plant.
The existing project of M/s HZL accorded Environment Clearance for 500 TPA refined silver
production by SEAC/SEIAA, Uttarakhand vide letter no. EC- 51/10/265 dated 16.03.2010.
The EC was amended for 500 TPA to 600 TPA refined silver production by MOEF&CC vide
letter no F. No. IA—J-11011/170/2017-IA-II-(I) dated 29.06.2017. As per the Schedule of
EIA notification published on 14th September 2006 & its amendments, our proposed
expansion is listed at SI. No 3(a) under category “B“. Since the SEAC, Uttarakhand is not yet
constituted; the proposal is submitted to MOEF&CC.
The proposed unit located at Pantnagar village, Kichha tehsil, Udham Singh Nagar District,
Uttarakhand State. HZL Pantnagar Silver Plant was established in 2010-11, in 10 ha of land
is part of Notified Industrial Area administered by SIDCUL, Department of Industries,
Government of Uttarakhand. The proposed expansion will not require any additional land
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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for the project. No forestland involved. The entire land has already been acquired for the
project.
2.1 Nature of the Project
The proposed expansion project in existing plant is to increase silver plant annual capacity
from 600 TPA to 800 TPA (monthly 85 Tonnes with overall capacity of 800 TPA). This plant
shall treat the “Anode Slime” & “HGM, (High grade Metal)” produced as a by-product in
the HZL Lead smelters in Rajasthan to recover the silver. The existing plant shall also have
the necessary utilities and auxiliary support system like power distribution, fuel oil storage
& distribution, compressed air, water treatment system etc.
2.2 Objectives of Project
To enhance the plant silver production capacity with auxiliary facilities:
Silver plant capacity of 800 TPA;
Input is increasing due to increase in percentage of silver content in raw material; and
To increase monthly production quantity from 60 MT to 85 MT refined silver with an overall annual capacity of 800 TPA.
2.3 Need of the Project
India is a net importer of silver and is used in various industrial applications like electrical contacts & conductors, clinical applications, photographic applications etc. However the primary consumption of silver in India is for ornamental purposes. Silver produced from the proposed project shall be primarily supplied in Indian market. Looking at the market opportunities & economy of scale, it is proposed to increase the plant capacity from 600 TPA to 800 TPA refined silver ingot (60 MT to 85 MT per month with overall annual capacity of 800 TPA).
3.0 SITE ANALYSIS
3.1 Location of Site
The project is located at State Industrial Development Corporation Limited (SIDCUL), Pantnagar village, Kichha tehsil, Udham Singh Nagar district, Uttarakhand state. The project site is part of the Notified Industrial Area administered by SIDCUL, Department of Industries, Government of Uttarakhand. Site is located at the intersection of latitude 29020’7”N and longitude 79024’01”E. Study area map is shown in Figure-1.
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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3.2 Meteorological Data The climatic conditions of the region as available are as follows:
Maximum of mean daily temperature : 40.70C Minimum of mean daily temperature : 9.90C
Relative humidity : 22 % to 86 % Total rainfall : 1058.1 mm Prevalent wind direction : W (annual)
3.2.1 Available Land Area The Proposed expansion is within the existing plant premises of 10 ha. No new land is required for this proposed project.
3.2.2 Road Connectivity The site has good connectivity with the existing plant road network. NH-87 is about 0.8 km from project site in southern direction.
3.2.3 Rail Connectivity The nearest railway station is Pantnagar which is about 10 km from the plant.
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
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FIGURE-1 STUDY AREA MAP
The baseline monitoring study has been started in the current summer season i.e. March 2018 to May 2018 for the proposed expansion project.
Environmental Setting
SN Particulars Details
1 Location Plot No 2 & 3, Sector 14, IIE, State Industrial Development Corporation Ltd (SIDCUL)
Village Pantnagar
Tehsil Kichha
District Udham Singh Nagar
State Uttarakhand
2 Latitude 290 02’ 07” N
3 Longitude 790 24’ 01” E
4 Elevation above Mean Sea Level 220 m
5 Climatic Conditions as per IMD, Pantnagar-
JOR
NADI
Rudrapur
Sampathpur
Jahangirpur
Mohanpur No1
Mohanpur No2
HaridaspurBasanthpur
Chitranjanpur No1
Chitranjanpur No2
Jalnagar
Udaipur
Panchananpur
Kalinagar
ChandipurNetajinagarDineshpur
Lakhipur
Radhakanthpur
Jainagar
Rampura
Amarpur
Arjunpur
Shivpur
Dharampur
TilpurKulha
Bhajpuri
Majra Bhupsingh
Lalpuri
Matkota
Bhatbhaj
Haripura
Madanpura
Charanpur
Motipur No1
Motipur
No2Chandanpur
Vijaynagar
Sundarpur
Narpatnagar
Maneharkhera
Dibdiba
Bhagawanthpur
Jafarpur
Anand Khera
No1 Anand Khera
No2
Jagadishpur
Haldi
Munshi Farm
Chhantarpur
Rampura
Panthnagar
Shyapkhatani khattaDurgapur No2
Fauji Matkota
Matkota Farm
Pattharchatta
Bengali Colony
Shrirampur
Dhimria Block
Praphullanagar
Jaganpuri
Madhpur
D H I M R I P.F
Aerodrame
Agricultural
University
T A N D A P.F
G A N G A P U R P A T I A P.F
Kiratpur
Bhamrola
BagwaraBhadaipura
Phulsungha
GangapurPratappur
Narayanpur
Phulsunghi
1 0 1 2 KM
Road
Railway Line
Nadi Nallah
Settlements
10 Km
Plant Site
N
SCALE
LEGEND
Rudra
pur C
hann
el
Baraur N
Phulwa
Nad
i
Hal
di N
adi
Pattha
rcha
tta
Nad
i
Khairiy
a Nad
i
Kag
aren
Nad
i
Jaga
dish
pur Cha
nnel
Upper
Bha
kra
Chann
el
Vija
ynag
ar M
inor
Bha
galy
a Nad
i
Sam
adpu
ri C
hann
el
Buksaura
79° 20' 79° 25' 79° 30'
79° 20' 79° 25' 79° 30'
29°
05'
29°
00'
29°
05'
29°
00'
NH
-87
NH-87
NH-74
Datiyal Khari
Baigul N
adi
Dhimri Nadi
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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Temperature Max. 41.20C Min. 1.20C
Relative Humidity Maximum- 87%, Minimum- 30%
Wind Speed range 0.20 to 11.0 m/s
Predominant wind direction W and E
Average Annual rainfall 1375 mm
6 Nearest Highway NH-87 (0.8 km, S)
7 Nearest Railway Station Haldi (5.9 km, E)
8 Nearest airport Pantnagar (6.3 km, E)
9 Ecologically sensitive areas (National Parks / Wild life sanctuaries / bio-sphere reserves)
None within 10 km
10 Reserved / Protected Forest Dhimri P F (2.2 km, NNE) Gangapur Patiya P F (2.7 km, NE) Tanda PF (8.9 km, NE)
11 Nearest village Pattharchatta (0.8 km, SE)
12 Densely populated or built-up area Rudrapur (6 km, S)
13 Archaeologically important places/ Monuments
None within 10km
14 List of Industries SIDCUL industrial area
15 Seismicity The project area falls under seismic zone-IV as per IS: 1893 (Part-1): 2002.
16 Nearest water bodies Dhimri nadi (3.0 km, W) Baigul nadi (3.1 km, ESE)
4.0 PROJECT DESCRIPTION
The proposed project is an expansion of the existing Pantnagar silver plant at SIDCUL, Pantnagar. The plant map showing the general location, project boundary & project site layout with coordinates is shown in following Figure-2.
4.1 Raw Material Anode Slime & HGM is the primary raw material for the proposed silver refinery. The same will be transported from the smelter owned by HZL or bought from other sources.
BASIC RAW MATERIAL– Silver Plant
Raw Material Existing Additional Requirement
Total Requirement
Anode Slime/Dore Silver 2900 700 3600
High Grade Metal 1080 1080
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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4.2 Process
4.2.1 Silver - Introduction Anode slime from lead electro refining plant of HZL’s existing smelter will be transported to the silver plant for further refining. Also, HGM from HZL smelter will be transported and refined in the electrolysis section along with the silver rich alloy which is produced from anode slime through pyro-metallurgical route. Both these raw materials are traded in the market and hence depending on requirements these raw materials will be sourced from open market. The overall process block diagram of the silver plant is as below:
4.2.2 Raw Material Handling The anode slime transported from HZL smelter by trucks are unloaded in the raw material storage bay inside the refinery building. The other flux materials used for the process are also stored in separate bays in the raw material storage area.
4.2.3 Noble Furnace – 1st Stage of Pyro Refining
The steps followed in the Noble Furnace smelting include:
Charging
Melting
oxidizing by air blast and slag formation
Precipitation
Tapping and noble lead discharge
FIGURE-2
PLANT LAYOUT
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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The proportioned charges will be fed in batches of regular interval. The melting stage will last for 12 hours. Compressed air is blown into the molten mass through iron pipes to stir the bath and promote the oxidization and slag formation. At this time the slag is divided into two layers. The upper layer is composed of metal silicates and antimonite which are of high fluidity. The lower layer contains silver with low fluidity, and therefore it is called sticky slag.
Noble Furnace
Anode Slime Flux
Air
LDO/HSD
Oxidation Prophase Slag
Noble Lead
Off Gas
Cupel Furnace
Flux
Air
LDO/HSD
Silver Alloy
Electrolytic Cell House
Silver Powder
Refined Silver
Dore Silver/VRF M
Off Gas
Cooling Duct
Cooling Duct
Bag Filter
Bag Filter
Antimony Concentrate
Antimony Concentrate
Bismuth Concentrate
Copper Matte
Transported to HZL Smelter for re-cycling
Silver Anode Slime
Oxidation Slag
Spent Solution
Induction
Furnace
To ETP
- - - - -Silver Nitrate
Junker Furnace
HGM
VRF Zinc & Dross
BBOC Furnace
Silver Anode
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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After the sticky slag is removed, the noble lead is blown with air to volatize the impurities such as copper, bismuth, arsenic and antimony. After this oxidation of impurities and its removal, the noble lead is tapped from the furnace. Highly fluid lead slag, it shall be returned to the blast furnace and fuming furnace system to recover lead. And since the silver content in sticky slag and oxidizing slag is high, they are recycled in the noble lead furnace. The volatized impurities from the noble furnace contains high antimony, the collected “antimony concentrate” is sold to antimony producers and allied industries. Light diesel oil/HSD is used as the fuel for noble lead furnace to maintain the temperature. The compressed air for smelting is supplied by a high temperature centrifugal fan.
4.2.4 Cupel Furnace
The noble lead produced from the noble furnace is sent for further treatment to cupel furnace. Two cupel furnaces are installed to match the production of Noble furnace. The niter and silver anode slime will be measured and charged into the cupel furnace. The process in the cupel furnace includes:
Charging;
Melting;
Blowing;
Oxidizing and slag formation;
Copper removal; and
Silver alloy discharge. Charge fed into the furnace is melted and air is blown through the pipes and the charge is oxidized. During this stage sequentially Lead is oxidized, Antimony concentrate, Bismuth Concentrate is produced. Then the flux material niter is added to generate molecular oxygen, which is used to produce “copper matte” by oxidizing copper. After removal of antimony, bismuth and copper the 97% pure silver alloy is produced. Primary oxidizing slag which contains lead is recycled in the noble lead furnace to recover lead. The bismuth concentrate, copper matte, antimony concentrate will be sold to allied industries which use these materials. The silver alloy is cast into silver alloy anode plate in the anode plate casting machine and then sent to the silver electro refining section. The fuel of cupel furnace is Light diesel oil. The compressed air used in the smelting is supplied from the high pressure centrifugal fan.
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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Direct current is connected to the silver electrolyzing cell. The product is pure silver of 99.95% grade or above. If there is precious metal in the silver alloy, it will concentrate in the silver anode slime.
4.2.5 Junker Furnace The intended purpose of the coreless induction furnace system is the melting and condensing of a ternary alloy of Zn+Ag+Pb. The installation is used to separate zinc from the ternary alloy. Separation of the zinc is made possible by the different vapour pressure characteristics of the elements present. The process is promoted and accelerated by performing the evaporation procedure in vacuum. As the result is required to be chemically pure zinc the process must be performed in the absence of oxygen. Zinc has a high affinity to oxygen and would quickly oxidise into ZnO. The process comprises the following steps: 1. Melting down of the ternary alloy 2. First evacuation of the melt 3. Purging with protective gas with the vacuum pump running 4. Evacuation to the process vacuum 5. Zinc condenses and flows from the hot melt into a cold collecting pot. 6. The incoming zinc vapour condenses and heats the collecting pot (condenser) to above the zinc melting temperature but below the zinc evaporating temperature. 7. After condensation the furnace vacuum is relieved and the collecting pot (condenser) tapped. 8. The metal bath remaining in the furnace (liquid) is tapped into suitable collecting containers. 9. The process starts again from item 1.
4.2.6 BBOC Furnace BBOC furnace is bottom below cupellation furnace is advance technology of cupel furnace after cupel furnace and junker furnace output comes this silver alloy charged in BBOC furnace and again oxidation started through bottom side with auto feeding the lance with controlled manner of oxygen flow. After charging and melting the silver alloy oxygen blowing given for 1 hours than slag tapped and this process continue till slag formation stopped. Than we have to put lead shot in BBOC furnace and again blowing done for 1 hours than silver purity reach approx. 99.2% to 99.5% than cast the anode approx. 12 kg each and send it to electro reefing section.
4.2.7 Silver Electrorefining – Hydrometallurgy Section The silver refining includes:
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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Electrolyte generation;
Silver electro refining;
Treatment of the silver anode slime;
Spent solution treatment; and
Melting & casting etc. The main raw material of silver electro refining is the silver alloy plate from the pyro-metallurgical refining and auxiliary material includes: nitric acid, ethyne, sodium carbonate, niter, sodium borate, charcoal, sodium chloride etc. In the electro-refining process the anode is the impure silver alloy plate. The cathode is made of stainless steel plate. The aqueous solution of nitric acid and silver nitrate is used as electrolyte. Acetylene is used to coat the mould surface and form a layer before the silver casting, which is favorable to the mould release. Charcoal lump, sodium carbonate, niter and borax are also added to purify the electrolyte. Sodium chloride is used to treat the waste solution of the silver electro refining to recover the silver. During the electrolysis silver powder is obtained which is washed and dried and further treated in the medium frequency furnace. Medium frequency induction furnace is used to melt the silver powder at 1150oC ~ 1250 oC and cast into silver ingots of 31 kg each. When casting the silver bullion, proper amount of niter, sodium carbonate (NaCO3), borax and charcoal are added. Finally the ingots will be weighed with electric balance and sent to the safe storage.
4.2.8 Dust Collection
According to the off-gas conditions and characteristic of the dust, the flow of dust collection is determined as below: Noble furnace→Cooling duct→Bag filter→Fan→Discharge Cupel furnace→Cooling duct→Bag filter→Fan→Discharge The off-gas of cupel furnace and noble furnace is of small quantity of off-gas, having low dust content. The off-gas is cooled first in cooling ducts and then filtered by the bag filter before let out to atmosphere.
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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The collected dust from the cooling duct and bag filter are conveyed by the drag chain conveyors and rotary valve before it is collected in dust pots.
4.2.9 Hygiene Ventilation
In the silver plant pyro section (Cupel furnace and Noble Furnace), there may be occasional fugitive emissions from the furnace tap holes & launders. To ensure the good operating & working condition, well designed hygiene ventilation system is provided. Industrial fans are used in the furnace area to lower the ambient temperature and improve the working conditions for operators. Nitrogen oxide is formed when silver electrolyte is prepared. The NOx generated from the preparation tank is removed by effective hygiene system. This NOx containing gas is passed through a fiber glass purification tower where alkali solution (sodium hydroxide solution) is sprayed to absorb the NOx in the off-gas. Then it is let out to the atmosphere. To improve efficiency, double-stage absorption tower is adopted and the total absorption efficiency is above 98%.
4.2.10 Cooling Water System Soft water is used in the cooling water system of silver refinery. The return water from the equipment are by gravity and is collected in hot water pool before it is pumped back to cooling tower. Process flow of circulating water:
A medium temperature counter flow glass reinforced plastic cooling tower is selected with change in temperature Δt=100C.
4.2.11 Water Balance
No additional water is required for the proposed expansion. Existing plant water requirement is 325 m3/day which is being met from bore wells for which necessary
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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permission is available. The water balance diagram of the proposed Pantnagar Silver Refinery is given below:
4.3 Annual Production
Units in TPA
Water flow Diagram HZL-PMP-Pantnagar
Cooling Tower blow down
WTP reject for
gardening purposes
(25 m3)
For cooling
purposes in
DG set (0.3
m3)
Water reservoir
Cooling tower for
silver plant for
cooling purposes
(20 m3)
Cooling tower for
Zinc & Lead plant
for cooling purposes
(190 m3)
Zinc/silver
plant inductor
cooling (24
m3)
Domestic use for
drinking /cleaning
/washing purposes
(50m3)
STP plant
(25 m3)
STP Treated water
for gardening
purposes (25 m3)
Ground water from Borewell
325 m3
Filter tank
Industrial use
(260 m3)
RO & DM plant
(50 m3)
Evaporation/drift
losses
Evaporation/drift
losses
Evaporation
Evaporation
Water for
gardening (15 m3)
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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Unit Existing Additional Proposed Quantity
Total Quantity
Products
Refined Silver 600 TPA 200 800
By-products
Antimony Concentrate 1400 400 1800
Bismuth Concentrate 140 220 360
Copper Matte 140 - 140
Oxidation Slag 840 410 1250
Silver Nitrate 25 - 25
Silver Anode Slime/ Silver Sand
- 10 10
Lead SLAG - 450 450
VRF Zinc - 650 650
VRF Zinc Dross - 100 100
4.4 Major Design Facilities
Unit Existing Additional Proposed Capacity
Total Capacities
Noble Furnace
1 No (14 TPD) - 1 No (14 TPD ) fired by LDO/HSD/PNG/FO/LSHS
Cupel Furnace
2 No (2.5 TPD) - 2 No (2.5 TPD each) fired by LDO/HSD/PNG/FO/LSHS
Induction Furnace
3 No (0.6 TPD) 3 No (2 X1 TPD + 1X1.5 TPD)
3 No (2 X1 TPD + 1X1.5 TPD)
Junker Furnace
- 1 No (4 TPD) 1 No (4 TPD)
BBOC Furnace
- 1 No (4 TPD) 1 No (4 TPD)
4.5 Consumables
The requirement of other consumables (fuels & process chemicals) required is given below:
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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CONSUMABLES PER ANNUM
Consumables Unit Quantity
Coke MT 87
Soda Ash MT 250
Salt Peter (Potassium Nitrate) MT 89
Nitric Acid MT 50
Ethyne MT 10
Charcoal MT 20
Sodium Chloride MT 15
Borax MT 15
LDO/HFO/LNG/FO/PNG/LSHS MT 4500
Calcium Fluoride MT 40
Sulphuric Acid MT 5
Lime MT 5
5.0 PROPOSED INFRASTRUCTURE
5.1 Industrial Area (Processing Area)
DG set of 500 KVA capacity is existing for emergency/backup power requirement. Apart from the DG set the following common utilities already exist, 1. Water treatment plant; 2. Fuel oil storage and handling; 3. Compressed air & instrument air system; and 4. Power receiving and distribution system.
5.2 Residential Area (Non Processing Area) The project is located in SIDCUL industrial plot. Hence, not applicable.
5.3 Industrial Waste Management The contributors for the process effluents are:
Wastewater from spent electrolyte purification section; and
Wastewater from the NOx absorption tower in electro-refining section.
The quantity of these process effluents are minimum (approximately 1 m3/day). The whole process is on batch production. Hence, the generation of this effluent is intermittent and of
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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low volume. These effluents are securely collected in effluent collection tanks and transported safely to CETP, SIDCUL. The other sources of waste water generation are:
Cooling tower bleeds;
De-Mineralized Water plant effluents; and
Diesel Generator house wastewater.
These effluents will be comparatively less contaminated and not the process effluents. Effluents will be used in green belt development after necessary chemical dosing and neutralization.
5.4 Solid Waste Management From the silver plant operations, there will be no solid waste generation which will require long term storage. The waste oil, used oil, oil soaked cotton waste, filter and grease will be the hazardous waste generated from this operation which shall be stored in properly sealed containers and kept on separate concrete floor and will be sold to registered recyclers.
5.5 Power Requirement & Supply / Source Source of Power No additional power required for this proposed project. Existing Power of 2 MW required for the plant is being met from Uttarakhand State Power Corporation Limited (UPCL). Emergency Generator Existing 500 KVA DG set will be used for emergency power supply to cater to critical loads.
5.6 Auxiliary Services
The auxiliary services planned for the smelter complexes are:
Cathode storage yard;
Water receipt treatment and distribution;
Water treatment plant;
Laboratory;
Stores;
Finished goods godown;
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
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LDO storage;
Heavy fuel storage; and
Instrument air/plant air supply unit.
5.7 Electrical System
The design is based on the following: (i) Reliability of service; (ii) Safety to personnel and equipment during operation and maintenance; (iii) Ease of maintenance and operational convenience; (iv) Maximum interchangeability of equipment and facility for future addition; and (v) Suitability for applicable environmental factors. Relevant codes and standards of BIS, Indian Electricity rules & regulations, petroleum rules (GOI), Fire insurance regulations, Tariff Advisory Committee Regulations and regulations laid out by electrical inspectorate have been followed.
5.8 Fire Alarm System Fire Alarm System comprises of individual glass type manual points provided at strategic locations within the access of 60 m, automatic sensors, smoke detectors, hooters etc. The system shall be designed to provide audio-visual indication at the main panel located in the security room and zonal panel in control room.
6.0 REHABILITATION & RESETTLEMENT (R & R) PLAN The proposed project will be set up within the existing plant premises, thus no additional land is required. Hence, R & R plan is not envisaged for the project.
7.0 PROJECT IMPLEMENTATION SCHEDULE Project will be implemented within 12 months after obtaining all necessary clearances.
8.0 COST ESTIMATION
Expansion of Existing Silver Plant from 600 TPA to 800 TPA Silver Production at Sidcul,
Pantnagar, Uttarakhand State
19
Capital cost for increasing the capacity is 20 Crores and production will be managed by existing resources.
9.0 Financial and Social Benefits Proposed expansion project will result in growth of the surrounding areas by increasing indirect employment opportunities in the region including ancillary development and supporting infrastructure. Special emphasis on financial and social benefits is being/ will be given to the local people. Uttarakhand state will get revenues in terms of taxes and local people will get direct & indirect employment. Business opportunities for local community will be available like transport of material to market, maintenance & house-keeping contract work, supplying goods, food to people etc. In addition, lots of CSR activities are being / will be carried out by the company.
10.0 Conclusion
Proposed expansion project will result in conservation of natural resources, growth of the surrounding areas by increased indirect employment opportunities in the region including ancillary development and supporting infrastructure. Special emphasis on Financial and Social benefits will be given to the local people. Development of social amenities will be in the form of medical facilities, education to under privileged and creation of self-help groups. No adverse effect on environment is envisaged as proper mitigation measure will be taken up for the proposed expansion units.