PFD File

PRE-FEASIBILITY REPORT
FOR
THE NEWLY PROPOSED BAUXITE BENEFICIATION PLANT
PRODUCTION CAPACITY 200,000 TPAOF HYDRATE ALUMINA
WITH MINERAL THROUGH PUT OF 3,76,000 MT/annum
AT
CHIRANGA VILLAGE, BATAULI BLOCK, SURGUJA DISTRICT,
CHHATTISGARH
PROJECT PROPONENT
MAA KUDARGARHI ALUMINA & REFINERY PVT LTD
5th, 503, 504, 505, Ozone Plaza, Fafadihchowk
Raipur, Chhattisgarh -492001
Email : anath@mkspl.com
Mob: +9650405514
CONSULTANT
AADHI BOOMI MINING AND ENVIRO TECH (P) LTD.

NABET Accredited EIA Consultant – ―A‖ Category.
Certificate No: NABET/EIA/1821/RA 0103
No.3/216, K.S.V.Nagar, Narasothipatti, Salem-636004.
Phone (0427) 2440446, Cell: 09842729655
www.abmenvirotec.com, suriyakumarsemban@gmail.com
August, 2020
Prefeasibility Report for Maa Kudargarhi Alumina & Refinery Private Limited, Raipur.
Consultant: Aadhi Boomi Mining & Enviro Tech Pvt ltd.
CONTENTS
S.No Description Page No.
1. Executive Summary 3
2. Introduction of the Project 6
3. Project Description 19
4. Site Analysis 47
5. Planning Brief 52
6. Proposed Infrastructures 63
7. Rehabilitation and resettlement (r & r) plan 66
8. Project Schedule and cost estimation 67
9. Analysis of proposal 74
2
CHAPTER: 1. EXECUTIVE SUMMARY
1.1 Introduction
The company, MAA KUDARGARHI ALUMINA & REFINERY PVT LTD, proposes to set
up a Bauxite Beneficiation Plant to extract Alumina Hydrate, located at Chiranga village,
Batauli Block,SurgujaDistrict of Chattisgarh State. It intends recover 92% of Alumina
hydrate from bauxite ore containing 33% of Gibbsite and 8-10% of Boehmitein an
economical way by putting Bayer’s Mono digestion circuit in combination with Tri-
gibbsite digestion, called as Double digestion. Feed mineral through put shall be
3,76,000 MT per annum of Bauxite ore to recover 200,000 TPA of alumina hydrate. The
conventional method of extraction by High Pressure and Temperature digestion system
get modified with high tech system of Bayer’s Process Technology with Double
Digestion Technique as it is most economical and viable.
The company, MAA KUDARGARHI ALUMINA & REFINERY PVT LTD, appointed
AADHI BOOMI MINING AND ENVIRO TECH PRIVATE LIMITED, having its office at 3/216,
K.S.V Nagar, Narasothipatti, Alagapuram, Salem – 636 004, Tamil Nadu as EIA
Consultant, having “ A” category accreditation in Mineral Beneficiation forPreparation of
TOR, Draft EIA/EMP report, Final EIA/EMP after Public Hearingand obtaining
Environment Clearance from MoEFCC, NewDelhi.
1.2 Project at a Glance
The proposed new project at a glance is given in Table-1.
TABLE-1PROJECT AT A GLANCE
FEATURE DETAILS
Name of the Proponent and MAA KUDARGARHI ALUMINA & REFINERY PVT
address LTD
New Plant / Expansion New Plant
Survey number 57/1, 70/1 & 70/77
Geographical features Latitude 22057’27.10” to 22058’24.41”N
Longitude 83021’02.3” to 83021’56.58”E
UTM Zone: 44Q
Elevation of the area is 635m - 745m above MSL.
Site Location Chiranga Village, Batauli Block, Surguja District,
Chhattisgarh.
3
Type of Project Bauxite Beneficiation and extracting Alumina Hydrate

Area of Plant in Hectare 91.942 Hectares
Throughput Raw Material 3,76,000 TPAor 1100 TPD
(Bauxite)
Quality of Raw Material Moisture -5%
( Bauxite) Gibbsitic alumina -33.0%
Boehmitic alumina - <8.0%
Reactive silica – 3.0%
Raw Materials other than Coal, Lime,Caustic Soda and Synthetic flocculants
Bauxite
Production 200,000 TPAor 595 TPD
Operating Factor 92%
Technology Bayer’s Process Technology with Double
Digestion Technique
Implementation Period Maximum 24 months except Steam and
power section
Source of Raw Material 1.BarimaBauxite Mine, 2. PathariBauxite Mine
(Bauxite) and 3. Bauxite Narmadapur Mine.
Availability of Raw Material Reserves of Bauxite deposit in Barima and
(Bauxite) Narmadapur mine is available for 25 years @
200,000 TPA of alumina hydrate
Category A
Does it attract any general Not applicable
conditions specified in the
EIA notification, 2006?
Man Power 203 persons – Skilled, 194 persons - outsourced
Water requirement 173 KLPH
Power requirement 7.9 MW on Normal Load and 9.5MW on Peak Load
Project Cost Rs 1146.71crores
Nearest Town Batauli- 4.7km NE
Nearest Railway station Ambikapur-28km - NW
Nearest Airport Ambikapur, Darima Airport – 16Km . Ranchi Air port
is 220 Kms.
4
Brief description of Process Flow
The bauxite received from their own captive mines are upgraded by Bayer’s double
digestion method as under,
i) Crushing and Milling

ii) Desilication
iii) Digestion
iv) Clarification/Settling
v) Mud washing
vi) Security Filtration \ Mud Filtration
vii) Heat Exchanger/Interchange
viii) Evaporation
ix) Precipitation
x) Hydrate classification by Hydro cyclones
xi) Product Filtration and finally output as Alumina Hydrate Cakes
In this process the Bauxite contains Gibbsite (33% Al2O3) and Boehmite (8% Al2O3) are
upgraded to 92% grade with recovery of 54%, ie. 1100 TPD is reduced to 595 TPD of
Alumina Hydrate.
5
CHAPTER - 2
INTRODUCTION OF THE PROJECT/ BACK GROUND INFORMATION
2.1 LAND DETAILS
Details of the proposed area for Alumina Factory are given in Table No. 2.1.
Table No: 2.1. Location details

S.F.No. 57/1, 70/1 & 70/77
Area granted for Proposed Factory (Ha) 91.942 Ha
Village Chiranga
Block Batauli
District Surguja
State Chattisgarh
Owner of the Land CG Govt. Revenue land
2.2Identification of Project Proponent and Project
Maa Kudargarhi Alumina&Refinery Private Limited is a Private incorporated on

01November 2019. It is classified as Non-Government Company and is registered at
Registrar of Companies, Chhattisgarh. It is involved in Manufacture of basic precious and
non-ferrous metals.
Directors of Maa Kudargarhi Alumina & Refinery Private Limited isMrSunil

KumarAgarwal andMr Anil Kumar Agrawal. Address and contact Numbers of Directors
are given under,
Table No: 2.2. Name of Directors
6
Maa Kudargarhi Alumina &Refinary Private Limited having Corporate Identification

Number (CIN) : U27200CT2019PTC009659 and its registration number is 9659.Its Email
address is cs@mkspl.com and its registered address is SHOP NO. 503, 504, 505, OZONE
PLAZA, FAFADIH CHOWK, RAIPUR
MAA KUDARGARHI ALUMINA & REFINERY PVT LTD proposed new Bauxite
Beneficiation Plant to extract Alumina Hydrate with Production Capacity 200,000 TPA in
Chiranga Village, Batauli taluk, Surguja District, Chhattisgarh with new Double Digestion
Technology with mineral through put of 376,000MT per annum.
2.3 Brief Description of Nature of the Project
The production capacity of the newly proposed Bauxite Beneficiation Plant to extract
Alumina Hydrateis 200,000 TPA from 376,000 MT of bauxite per annum from their own
captive bauxite mines located about 16- 28 kms at five locations as given below. The
processing technology would be based on Bayer’s Process but in this project double
digestion system along with Bayer’s process will be introduced i.e. Low Temperature
Digestion and High Temperature Digestion System.
Low Temperature Digestion System - Extract Gibbsitic Alumina from bauxite by adding
Caustic Soda at the temperature of 145oC.
High Temperature Digestion System - Extract Boehmitic Alumina from bauxite by

adding Caustic Soda at the temperature of 245oC i.e. heating thickened underflow of
Low Temperature Digestion @ 245oC.
The estimated rate of hydrate production per day is 595 TPD. The overall operating
factor of hydrate plant is 92%.
The source for the proposed Bauxite BeneficiationPlant is from the following Bauxite
Mines.
7
Table No: 2.3. Source for the proposed Bauxite Beneficiation Plant
As Per Mine
Maximum
Total Land Production
S.No Mines Land Location Schedule Owner
Khasra Capacity/Year
(Tonne)
(Hectares)
Village – Barima
1 Barima Block – Mainpat 69 54.268 SinghalBusines 115290
District – Surguja
Village – Barima
2 Barima Block – Sitapur 7 4.764 SinghalBusines 29980
Village – Barima
3 Barima Block – Mainpat 2 80.414 SinghalBusines 80161
Village – Pathari
4 Pathari Block – Sitapur 12 99.35 MKSPL 198875
Village –
Narmadapur
5 Narmadapur 86 47.812 SinghalBusines 279117
Block – Mainpat
2.4 Geographical Location
The area is represented by Survey of India Topo sheet no. NF-44-04, 08the location
map is given in plate No. 1. The area lies in the northern latitude of 22057’27.10” to
22058’24.41”N and Longitude 83021’02.3” to 83021’56.58”E. Latitude and Longitude of
all boundary Pillars are given in Table No.2.2.
8
Figure No 2.1: Toposheet showing 10km radius from the proposed Plant
9
Figure No 2.2: Location & Accessibility of the proposed Plant
10
Table No: 2.4 GPS survey reading of all boundary pillars
BOUNDARYPI LATITUDE LONGITUDE

LLAR
1 22°58'24.39"N 83°21'55.74"E
2 22°58'23.72"N 83°21'56.04"E
3 22°58'23.77"N 83°21'57.26"E
4 22°58'21.06"N 83°21'57.56"E
5 22°58'16.22"N 83°21'56.51"E
6 22°58'15.87"N 83°21'54.48"E
7 22°58'15.69"N 83°21'50.69"E
8 22°58'16.43"N 83°21'50.65"E
9 22°58'15.93"N 83°21'45.78"E
10 22°58'16.09"N 83°21'42.82"E
11 22°58'13.06"N 83°21'42.40"E
12 22°58'12.80"N 83°21'38.94"E
13 22°58'9.77"N 83°21'38.78"E
14 22°58'9.74"N 83°21'40.07"E
15 22°58'7.87"N 83°21'40.31"E
16 22°58'8.13"N 83°21'42.73"E
17 22°58'9.77"N 83°21'43.84"E
18 22°58'9.79"N 83°21'44.68"E
19 22°58'9.58"N 83°21'46.72"E
20 22°58'9.95"N 83°21'46.82"E
21 22°58'10.20"N 83°21'50.45"E
22 22°58'11.68"N 83°21'50.49"E
23 22°58'11.81"N 83°21'51.47"E
24 22°58'13.43"N 83°21'51.36"E
25 22°58'13.24"N 83°21'53.35"E
26 22°58'11.46"N 83°21'53.47"E
27 22°58'11.33"N 83°21'52.09"E
11
28 22°58'8.40"N 83°21'52.14"E
29 22°58'8.76"N 83°21'54.82"E
30 22°58'6.68"N 83°21'55.23"E
31 22°58'6.65"N 83°21'53.15"E
32 22°58'5.98"N 83°21'52.90"E
33 22°58'4.68"N 83°21'51.79"E
34 22°58'3.04"N 83°21'52.92"E
35 22°58'2.97"N 83°21'53.52"E
36 22°58'3.98"N 83°21'54.74"E
37 22°58'1.49"N 83°21'54.56"E
38 22°58'1.43"N 83°21'51.83"E
39 22°58'0.04"N 83°21'51.72"E
40 22°57'59.95"N 83°21'52.96"E
41 22°57'58.33"N 83°21'52.76"E
42 22°57'58.16"N 83°21'51.81"E
43 22°57'57.33"N 83°21'51.72"E
44 22°57'58.84"N 83°21'47.66"E
45 22°57'56.97"N 83°21'46.46"E
46 22°57'55.76"N 83°21'49.14"E
47 22°57'54.35"N 83°21'47.71"E
48 22°57'55.03"N 83°21'46.41"E
49 22°57'54.39"N 83°21'45.47"E
50 22°57'53.60"N 83°21'45.62"E
51 22°57'52.55"N 83°21'44.30"E
52 22°57'50.76"N 83°21'44.71"E
53 22°57'51.32"N 83°21'45.67"E
54 22°57'50.95"N 83°21'48.70"E
55 22°57'53.53"N 83°21'46.77"E
56 22°57'53.10"N 83°21'53.13"E
12
57 22°57'53.63"N 83°21'53.20"E
58 22°57'54.00"N 83°21'51.37"E
59 22°57'57.24"N 83°21'51.94"E
60 22°57'57.21"N 83°21'55.92"E
61 22°57'55.16"N 83°21'57.36"E
62 22°57'55.10"N 83°22'0.76"E
63 22°57'53.78"N 83°22'0.87"E
64 22°57'52.30"N 83°22'0.13"E
65 22°57'49.70"N 83°22'0.28"E
66 22°57'49.20"N 83°22'1.29"E
67 22°57'47.25"N 83°22'1.11"E
68 22°57'47.87"N 83°22'2.90"E
69 22°57'41.28"N 83°22'3.31"E
70 22°57'41.56"N 83°22'0.77"E
71 22°57'40.41"N 83°22'0.77"E
72 22°57'40.72"N 83°21'54.96"E
73 22°57'40.11"N 83°21'54.81"E
74 22°57'40.00"N 83°21'54.21"E
75 22°57'38.40"N 83°21'54.33"E
76 22°57'38.40"N 83°21'56.87"E
77 22°57'38.87"N 83°21'58.27"E
78 22°57'39.52"N 83°21'58.26"E
79 22°57'39.51"N 83°21'58.88"E
80 22°57'37.54"N 83°21'59.29"E
81 22°57'37.70"N 83°22'1.88"E
82 22°57'36.55"N 83°21'58.40"E
83 22°57'35.39"N 83°21'52.35"E
84 22°57'34.67"N 83°21'51.14"E
85 22°57'32.38"N 83°21'42.93"E
13
86 22°57'31.73"N 83°21'41.97"E
87 22°57'33.35"N 83°21'40.84"E
88 22°57'34.22"N 83°21'42.02"E
89 22°57'33.37"N 83°21'43.01"E
90 22°57'36.20"N 83°21'45.54"E
91 22°57'36.09"N 83°21'46.54"E
92 22°57'36.97"N 83°21'45.99"E
93 22°57'37.66"N 83°21'46.93"E
94 22°57'38.06"N 83°21'46.61"E
95 22°57'37.88"N 83°21'45.95"E
96 22°57'37.86"N 83°21'45.30"E
97 22°57'37.76"N 83°21'44.35"E
98 22°57'38.43"N 83°21'43.02"E
99 22°57'34.54"N 83°21'38.07"E
100 22°57'34.69"N 83°21'36.09"
101 22°57'35.78"N 83°21'35.94"E
102 22°57'35.78"N 83°21'34.97"E
103 22°57'43.30"N 83°21'34.65"E
104 22°57'45.37"N 83°21'34.85"E
105 22°57'45.47"N 83°21'37.16"E
106 22°57'47.98"N 83°21'37.06"E
107 22°57'47.99"N 83°21'36.02"E
108 22°57'46.86"N 83°21'35.81"E
109 22°57'46.79"N 83°21'32.30"E
110 22°57'48.79"N 83°21'27.94"E
111 22°57'48.08"N 83°21'23.88"E
112 22°57'50.13"N 83°21'23.79"E
113 22°57'50.35"N 83°21'21.89"E
114 22°57'51.89"N 83°21'22.19"E
14
115 22°57'52.63"N 83°21'25.53"E

116 22°57'53.33"N 83°21'25.43"E
117 22°57'52.74"N 83°21'23.83"E
118 22°57'52.52"N 83°21'21.51"E
119 22°57'53.64"N 83°21'20.32"E
120 22°57'56.42"N 83°21'20.09"E
121 22°57'56.82"N 83°21'21.21"E
122 22°57'57.78"N 83°21'21.32"E
123 22°58'2.83"N 83°21'24.29"E
124 22°58'3.59"N 83°21'20.36"E
125 22°58'2.51"N 83°21'19.89"E
126 22°58'1.70"N 83°21'20.72"E
127 22°58'0.95"N 83°21'19.08"E
128 22°58'0.27"N 83°21'16.61"E
129 22°58'3.83"N 83°21'18.28"E
130 22°58'5.90"N 83°21'20.76"E
131 22°58'12.14"N 83°21'20.49"E
132 22°58'12.31"N 83°21'28.80"E
133 22°58'17.49"N 83°21'37.53"E
134 22°58'17.55"N 83°21'42.80"E
135 22°58'19.87"N 83°21'46.04"E
15
Figure No 2.3: Surface plan of the Proposed Plant
16
Figure No 2.4: GIS based buffer of 500m & 300mradius over the google earth image
17
2.4 Need and justification for the Project
Bauxite is the basic raw material to produce alumina hydrate from which pure
aluminium is produced.Aluminium Industry is the second most important metallurgical
industry in India.Bulk of the Aluminium usage is in overhead conductors and power
cables used in generation, transmission and distribution of electricity. Aluminium is used
in switchboards, coil windings, capacitors, and many other applications as well.So it is
very necessary to extract initially alumina hydrate from bauxite ore to produce
aluminium. This project is also the Mineral Beneficiation Project of extracting alumina
hydrate from bauxite.
The metal industry is a crucial sector in the Indian economy as it meets the requirements
of a wide range of industries including engineering, electrical and electronics,
infrastructure, automobile and automobile components, packaging etc. The metal
industry comprises of two major segments: ferrous metals and non-ferrous metals.
Ferrous metals primarily consist of iron and different varieties of steel. Non-ferrous
metals, which include aluminium, copper, zinc, lead, nickel and tin, are used to make
alloys, castings, forgings, extrusions, wires, cables and pipes.
India has nearly 10% of the world’s bauxite reserves and a growing aluminium sector
that leverages this. Demand in the domestic market is expected to rise by 8-10%.
Aluminum is the second most used metal in the world after steel with an annual
consumption of approximately 88 million tonnes (including scrap). So there is a great
demand in worldwide also.
Even though some leading companies in India producing million tonnes of aluminium
per year there is still in demand of aluminium in India and other countries. So the
company MAA KUDARGARHI ALUMINA & REFINERY PVT LTD planned to propose
a new Bauxite Beneficiation Plant to extract Alumina Hydrate in Chiranga Village,
Batauli Block, Surguja District, and Chhattisgarh in order to overcome the demand
ofaluminium by producing alumina.
The employment problem in India rises day by day due to many reasons. The important
reason is highest population rate in India. The proposed Bauxite Beneficiation Plant
generates direct employment to 203 skilled persons and outsourced employment of
nearly 194 members. Depending on the proposed project so many small businesses
such as mechanic shops, welding shops, hotels, tea stalls, etc., will be developed around
the industry which increases the survival of the people in the nearby villages.
18
Chapter 3 - Project Description
3.1 Type of the Project
The Company,MAA KUDARGARHI ALUMINA & REFINERY PVT LTDproposes a

Bauxite Beneficiation Plant located at Chiranga village, Batauli Block,Surguja District of
Chattisgarh State. This is a mineral beneficiary project of extracting Alumina Hydrate
from Bauxite oreby Bayer’s Process Technology with Double Digestion Technique. The
proposed project receives a raw material from five bauxite mine sites located in three
villages such as Barima, Pathari, Narmadapur, of Mainpat, Sitapur Taluk and Surguja
district.
3.2 Details of Alternative Site Required
The land for the proposed alumina factory is moderately elevated hilly terrain with
elevation ranges from 635m – 745m above MSL, nearest to mine site and away from the
habitations. So the proposed project does not disturb the surrounding villages in any
ways. Moreover the proposed land is not an agricultural land. This land requires minimal
earthworks as major plant area is located on gentle ground on western side of the land.
Examining most of the site, this is favored site for the newly started alumina hydrate
plant as close as Bauxite mines.
3.3 Location of the Project
The proposed Bauxite Beneficiation Plant is located in S.F No.57/1, 70/1 &
70/77,Chiranga Village, Batauli Taluk, Surguja Distric of Chhattisgarh State. Figures
map….
3.4 Size or Magnitude of operation
The proposed Bauxite Beneficiation Plant for production of aluminahydrate from bauxite
oreis given in Table-3.1
Table No. 3.1 Project details for Bauxite Beneficiation Plant
S.No Description Details

1 Alumina Production Capacity 200,000 TPA of alumina hydrate from
bauxite ore of 376,000 MT per annum
@53% recovery and 47% tailings
19
2 Land Requirement 91.942 Ha

3 Water Consumption 173 KLPH
4 Steam Requirement 50t/h
4 Power Requirement 7.9 MW, 9.5 MW on Peak Load
5 Bauxite Requirement Per day 1100TPD
6 Man Power requirement 203 Skilled
3.5 BASIS OF PROCESS DESIGN
The Bayer Process is the most economic means of obtaining alumina from bauxite.
The process stages are:
3.5.1. Crushing and Milling
The bauxite is washed and crushed, reducing the particle size and increasing the
available surface area for the digestion stage. Lime and "spent liquor" (caustic soda
returned from the precipitation stage) are added at the mills to make a pumpable slurry.
Feed quantity shall be 1100 TPD or 3,76,000 MT per annum with composition of
Bauxite feed to plant containing 33% of alumina (gibbsite), 8% mono hydrate alumina
(boehmite) 3% silica and 5% moisture.
The bauxite is received from five mines located in three villages brought by trucks is
stacked as piles in the factory stocking yard.
The bauxite feed which is generally are at a size of 100mm is crushed down to a size of
90% passing through20mm. The area has two crushers, one working and one spare with
closed circuit vibratory screen.
Table 3.2 : Parameters for Bauxite Crushing
Item Units Value

Feed bauxite Particle Size Distribution
F100 mm 150
F80 mm 100
Crushed Bauxite Particle size Distribution
P100 mm <30
P80 mm 20
20
The area mainly does the function of reducing the size of the bauxite to 20mm so that
feed to ball mill is suitable for grinding, as a larger feed size would consume a lot more
power for the grinding.The crushed bauxite is thereafter taken to the grinding mill
through a set of belt conveyors. A control room near Secondary Crusher House controls
and monitors the operation of Bauxite Handling Plant manned by operators.
Bauxite feed to the ball mill –20mm. Product size of the ball mill — 300 microns.
Milling :The bauxite grinding areas primary function is to reduce the particle size of
bauxite to an appropriate level required for leaching of alumina hydrate, silica
dissolution and slurry suspension in subsequent process areas. The digestion holding
time, downstream equipment abrasion, settling and consolidation issues are considered
when selecting the mill product-sizing target.
The main objectives of bauxite close circuit grinding are:
Output Size : 200 microns and 812 microns as to produce bauxite solids concentration
of 750 g/l.The unit consists of two 50 t/h ball mills.
It is wet grinded in the mills as it is mixed with digestion liquor to minimize the power
consumption before passing into De-silication step.
3.5.2. Desilication
Bauxites that have high levels of silica (SiO2) go through a process to remove this
impurity. Silica can cause problems with scale formation and quality of the final product.
Desilication is that reaction whereby the silica concentration of Bayer liquor falls. The
reactive silica present in the bauxite reacts with the caustic to form a precipitated
product mainly insoluble sodium aluminum silicate, commonly known as ―
Sodalite‖.
This sodalite formed acts as a seed to attract other reactive silica, thereby reducing the
presence of silica to a great extent.
Desilication is important in Bayer process mainly for two reasons:
1. Precipitation of silica as sodalite, removing it from the bauxite.
2. If desilication is incomplete before other processes, the dissolved silica, which remains
in aluminate liquor, is likely to precipitate with hydrate to cause contamination of the
21
final product alumina. It could also lead to sodalite scaling in regions of relatively higher
temperature like heat exchanger, flash vessels etc.
Sodalite is not a single compound but a member of a family of compounds having the
general chemical formula: (Na2O.Al2O3.SiO2.2H2O). Na2X where X stands for radicals
like CO3, SO4, 2Cl, 2OH, etc., depending on the type of impurities present in the Bayer
liquor. Thus, we have carbonate sodalite, sulphate sodalite, chloride sodalite and so on.
The sodalite formed from an aluminate solution with interstitial ions is called the Bayer
sodalite. Bayer sodalite on prolonged heating or on heating at high temperature forms a
cancrinite type mineral whereby the carbonate gets attached to the sodalite.
When Bayer sodalite is formed in process by the desilication reaction there are losses of
process materials like caustic soda and alumina. Two cases may be considered here to
illustrate this:
1. Reaction of kaolinite (Al2O3.2SiO2.2H2O) with sodium aluminate liquor containing

sodium carbonate to yield Bayer sodalite:
3(Na2O.2SiO2.2H2O). (0.3-0.6) Na2O.Al2O3. (0.7-0.9) Na2CO3.
For these 6 moles of silica take about 3.3 to 3.6 moles of caustic, which is unrecoverable.
2. Reaction of kaolinitic silica (SiO2) with sodium aluminate liquor containing sodium
carbonate to form Bayer sodalite. Alumina loss in this case works out to 0.98 kg per kg
of silica.
ProcessDescription:
The predesilication area conditions the Bauxite slurry prior to digestion by removing
most of the silica contents of the Bauxite and it also acts as storage for Bauxite slurry as
it keeps the process in action even when there is any interruption in the grinding area.
There are two types of silica, reactive and non-reactive. The reactive silica
(Al2O3.2SiO2.2H20) and (Al2O3.2SiO2.2H20) i.e. Kaolinite and Halloysite reacts with
Caustic (NaOH + Nasal (OH)4) to form silicates, which is insoluble and separates it out.
This is known as D.S.P.=desilication product.
22
Reaction:
(NaOH + Nasal (OH) 4) + Bauxite 3(Na2O.2SiO2.2H2O). (0.3-0.6) Na2O.Al2O3 .(0.7-0.9)Na2CO3
Caustic +Oxalate (Na2C2O4)
System Description:
This desilicated product acts as a seed during the digestion process i.e. it initiates the
agglomeration process and helps in precipitating the additional silica found in digestion.
The solid has sulphate, carbonate and chloride in addition to silica.
The unit consists of four tanks in series with heat exchanger system. The tanks have
agitators to speed up the reaction kinetics. The Bauxite slurry received from the area is
preheated by a shell and tube heat exchanger, and then by contact heater to raise the
Bauxite slurry temperature to suit the predesilication temperature.
The heat is provided to the slurry heater through the flash vapor from the digestion unit.
The slurry moves from one tank to another by aid of two underflow pumps and the
slurry from last tank is sent to digestion train by the two centrifugal pumps.
Table 3.3 – Parameters for Pre-desilication
Item Units Value

o
Temperature C 95
Holding Time @ Temperature Hours 16
% solids % 50
Direct through contact
Heating Methods
heaters/Vapor
SiO2 % 85
3.5.3. Digestion
The fraction of caustic soluble alumina present in boehmite (MHA) is expected to be

more than 8% as alumina and hence a high temperature digestion process operating at
~240oC has been chosen, a method suitable for efficiently extracting gibbsitic and
boehamite or “available”, TA, alumina.
23
A hot caustic soda (NaOH) solution is used to dissolve the aluminium-bearing minerals
in the bauxite (gibbsite, böehmite and diaspore) to form a sodium aluminate
supersaturated solution or “pregnant liquor”.
Gibbsite:
Al(OH)3 + Na+ + OH- → Al(OH)4- + Na+
Böehmiteand Diaspore:
AlO(OH) + Na+ + OH- + H2O → Al(OH)4- + Na+
Conditions within the digester (caustic concentration, temperature and pressure) are set
according to the properties of the bauxite ore. Ores with a high gibbsite content can be
processed at 140°C, while böhmitic bauxites require temperatures between 200 and
280°C. The pressure is not important for the process as such, but is defined by the steam
saturation pressure of the process. At 240°C the pressure is approximately 3.5 MPa.
The slurry is then cooled in a series of flash tanks to around 106°C at atmospheric
pressure and by flashing off steam. This steam is used to preheat spent liquor. In some
high temperature digestion refineries, higher quality bauxite (trihydrate) is injected into
the flash train to boost production. This "sweetening " process also reduces the energy
usage per tonne of production.
Although higher temperatures are often theoretically advantageous, there are several
potential disadvantages, including the possibility of oxides other than alumina
dissolving into the caustic liquor.
Table 3.4– Parameters for Digestion
Item Units Value

Digester Type Single
Caustic Concentration, Test Tank Liquor to g/L 290
Digestion
o
Digestion Temperature C 245(250 max)
Holding Time @temperature Minutes 45
Number of flash stages per line 8
Target Digestion discharge Rp ratio 0.69
Rp ratio – Margin below gibbsitic solubility 0.030
Energy Resource
Steam Pressure Kg/cm2 45.0
Gibbsite Extraction % 98
24
Returned to Power House

Live steam condensate as boiler feed water( unless
contaminated)
Regenerative Condensate used S/cm <100
Mud filters, if excess
Regenerative Condensate uses
cooling tower makeup
3.5.4. Clarification/Settling/Mud washing
The first stage of clarification is to separate the solids (bauxite residue) from the
pregnant liquor (sodium aluminate remains in solution) via sedimentation. Chemical
additives (flocculants) are added to assist the sedimentation process. The bauxite
residue sinks to the bottom of the settling tanks, then is transferred to the washing
tanks, where it undergoes a series of washing stages to recover the caustic soda (which
is reused in the digestion process).
The blow –off slurry, which flows out of the digestion, contains sodium aluminate and
other impurities like iron oxide, silicon, titanium and other impurities, which remain
insoluble in the sodium hydroxide. These are needed to be separated from the slurry for
the recovery of sodium aluminate solution. Therefore, the slurry is separated into liquid
aluminate solution and solid iron oxide impurities in settling tanks, which follows gravity
settling principle to separate solid and liquid.
This process of separating solid and liquid is also known as sedimentation or

clarification or thickening in broad scientific terminology.
The mud settling process separates the suspended solid particles from the slurry by
gravity settling units by using deep cone thickener technology. The process separates
sodium aluminate in the form of clear overflow having 0.1 g/l of fine suspended solids
which is further sent to the security filtration area to get a clear pregnant liquor
containing sodium aluminate after removal of the fine particles.
The under flow from the thickeners comes out in the form of red mud which is further
sent to the washers for recovery of caustic by countercurrent washing with wash water.
The recovered amount is sent to settler overflow tank, which sends it to the filtration for
removing any finely suspended solid particles.
25
The current trend in the industry is to use a settling unit which produces settled mud of
maximum consistency in the minimum time. Therefore, we employ hi rate thickening
system instead of conventional thickening technology.
The hi rate thickening system takes advantage of efficient use of flocculants polymers
for the settling purpose to provide acceptable overflow and underflow slurry in
extremely short time. As it is also a flocculant which combines with the suspended solids
increases the adhesive force to attract other solids and help in agglomeration and
formation of compact solid particle finally settling it down and thus enhancing the
possibility of a clear clarified liquor which is send for filtration.
Table 3.5 Parameters for Clarification
Item Units Value

Decanter overflow clarity Ppm <150
Underflow density Settlers % w/w solids 40
Settling rate m/h 6-8
Auto Precipitation Ratio drop
between DBO and
LTP
MUD WASHING
The recovery of caustic is essential for the cost minimization of the alumina plant, since
85% of the caustic is used up in reaction with gibbsite to form sodium aluminate and
this cannot be recovered here. The rest 15 %, which contains caustic, is recoverable and
Mud Washing is one of the processes to recover the caustic from mud by counter
current washing of the underflow from the mud settler.
The mud washing area receives thickened mud from the settlers, the washers is mainly
single train comprising of 5 washers (4 working and 1 stand by) which is configured as a
counter current decantation process that is receiving mud from one side and wash water
from the other side.
The settling and thickening of the mud is achieved through the addition of synthetic
flocculants namely NALCO 85050 (liquid) and Cytec HX 50 (powder). The flocculants
combine with the mud to remove the solid suspension and thus settle the solids and
recover the caustic in form of washer overflow.
26
Generally, in the washers the overflow from the 1st washer contains the caustic soda
with the minimum residue. The thickened mud slurry from the last washer is disposed to
the red mud area for improving the caustic recovery. The washer area also receives
other streams from caustisizer, causticized oxalate slurry and other streams from security
filtration area.
Last washer consists of screen boxes with 8 mm screens, which traps tramp materials,
which may block the mud disposal pumps.
Washer overflow recycle is also used as secondary flocculant dilution to improve

flocculants mixing and reduce flocculant consumption.
It is important to achieve a high mud density in the last washer underflow to reduce
soda losses and assist mud disposal operations. The thickened mud slurry is also
pumped to the last washer having 760 g/l of solids, which is also disposed to red mud
pond.
Table3.6 Parameters for Mud Washing
Item Units Value

No.of washers in CCD Mode 5
st
Underflow Density settlers % w/w solids 43 1 stage
45 2nd stage
47 3rd stage
48 4th stage
50 Last stage
Scandrett Washing Efficiency % 90
Settling rate m/h 5-6
Mud solid density t/m3 3.3
3.5.5 SECURITY FILTRATION
The security filtration plays a vital role in filtering the pregnant liquor overflow from the
last settler of impurities before feeding to precipitation (via Heat interchange). These
impurities consisting of suspended particles like iron, calcium, TiO2 & Silica, if not
removed contaminate the hydrate produced in precipitation area resulting in
contaminated product in calcinations. The security filtration area comprises of Diastar
filters.
27
The main feed for diastar filters comes from the settler overflow tank through the settler
overflow pumps. Generally the settler overflow is mixed with a filter aid TCA (Tricalcium
aluminate) and pumped to the diastar filters where filtration takes place. Apart from the
diastar filters being supplied by Gaudfrin (France), the security filtration area will contain
cake discharge tank, filter turn back tanks, filtered aluminate tanks and also TCA reactor
area & caustic cleaning batch tanks.
Concepts of Filtration:
Filtration usually results in the formation of a layer of solid particles on the surface of
porous body, frequently a textile fabric that forms the filtering medium. Once this layer
has formed, its surface acts as the filter medium, solids being deposited and adding to
the thickness of the cake while the clear liquor passes through.
The cake is composed of a bulky mass of particles of irregular shapes, among which run
small channels, which are streamline in nature.
Obstruction to filtration:
1. Resistance of medium to filtrate.

2. High viscosity of filtrate.
3. Rapid blinding of filter medium.
4. Low temperature.
Filters may be intermittent (batch) or continuous and batch filters may be operated with
constant pressure driving force at constant rate or in cycles that are variable with respect
to both pressure and rate.
Table 3.7 Parameters for Security Filtration
Item Units Value

Filtration Rate m3/m2/h 1.5
Filtrate solids mg/L <15
Number of filters (in Operation) 2 and 1 spare
Area per filter m2 60
Cake solids Wt% 10-12
Filter aid g/L filter feed 2.0
Dump to decanter feed
Residue
well
28
3.5.6 RED MUD FILTRATION
The mud filtration design, in lieu of any laboratory test work is based on analysis of
bauxite samples provided by SMHL from its captive bauxite mines. The mud filters are
designed to produce mud cake with sufficient consistency to be handled by belt
conveyor for mud disposal.
Further, the slurry surge volumes required for the stabilization of the plant flow have
been designed into the mud filter feed tank and filter capacity. The design objectives for
the mud filtration are as follows:
Transform the red mud slurry received from Mud Washing into a filter cake which
can be handled and transported by trucks to red mud storage areas.
Recover the alumina, caustic and water in the form of the filtrate and return it to
the washer train in Mud Washing.
Process Description
The mud filtration area is fed with underflow mud slurry from the last online mud
washer mixed with gross wash water.
The purpose of the mud filtration area is to produce a mud cake that can be transported
by trucks for disposal and recover the associated soluble caustic and alumina in the
filtrate to be returned to Mud Wash circuit.
This facility provides pressure filtration of red mud slurry after 4 stages CCD to render a
filter cake of ~73% solids containing soluble soda of 10 g/L as Na2O. The limit in
reduction of liquor content is a function of the pressure applied to the filter press and
porosity of solids (red mud). The residue is discharged from the plant at controlled
soluble soda content such that cost of production is not exceeded and, on the other
hand, impurities are not allowed to build in the plant liquor.
Three, two operating and one spare pressure filters (Plate and Frame type) will be
installed to handle mud slurry containing ~35% solids. The wash water from wash water
tank (6m diameter and 8m height), equipped with pumps is mixed in the suction of last
online mud washer underflow pump and transferred to filter feed tanks with a closed
top to provide a surge of ~2 hours. Each filter is fed with a dedicated pump connected
to a common suction manifold receiving slurry from the filter feed tank. Filter feed tank
is equipped with a stack and a mist eliminator on top to allow air removal during the
29
core blowing of the filter presses, and an agitator to maintain the suspension
homogeneous.
Due to the thixotropic nature (shear thinning) of the mud, the agitator will assist in shear
thinning the mud prior to entering the pump suction.
The feed line to each filter splits into two lines which enter the filter plate pack. During
blow back to clear the feed line of slurry within the filter, one feed line is isolated by a
valve just after the split, and high pressure air is injected just after the isolation valve,
thus blowing the slurry in the internal feed line through the plate pack and back to the
feed tank. Feed recycle is normally injected into the feed tank tangentially close to the
feed pump suction. The backup to this arrangement is return to the top of the feed tank.
The filter feed tanks and their associated pumps are contained in a dedicated bunded
area.
Two (1+1) closed top, agitated filtrate tank of be installed to collect the filtrate from the
filter presses. This tank also collects the wash water of the filter cloths and the discharge
of the sumps located in this facility area. The filtrate tank and two, one operating and
one spare filtrate pumps are contained in a dedicated bunded area.
Main Equipment: Filter Press, Filter Cake Discharge Conveyor, Air Squeezing Units, Hp
Cloth Washing Units, Wash Water Feed Tank, Wash Water Feed Tank, and Flushing
Water Feed Pumps
Figure No 3.1: Filter Press
30
Table 3.8 Parameters for Mud Filtration
Item Units Value

No. of filters in operation 2 and one spare
Filter feeds solid Wt% ~30
Filtration rate Kg(dry)/m2/h 50
Filtration Area m2 90
Wash water rate t/t mud 1.5
Cake solids Wt % ~73
Soda in mud to disposal g/l in liquid ~15
3.5.7 HEAT INTERCHANGE
The precipitation needs to operate at lower temperature in order to get the required
super saturation in the circuit. Hence the pregnant liquor coming out of the security
filtration area needs to be cooled before being fed into the first agglomeration tank.
The heat interchange area cools the pregnant liquor from security filtration area as it
transfers the heat to the spent liquor coming from 1st interstage cooler. This improves
the thermal efficiency of the circuit as the spent liquor is preheated before entering
evaporation area and hence requires less heat for heating to the required temperature.
As heat is exchanged between both spent liquor and pregnant liquor to attain their
respective set temperature in the same plate heat exchanger, this area is called heat
interchange area.
Basically, heat interchange area consists of two-plate heat exchanger out of this 1 will be
working and one will be standby.
31
Figure No 3.2: Plate Heat Exchanger
Process Description
Hot pregnant liquor from the filtrate tanks in security filtration is supplied to the Plate
heat exchanger area. A part of the pregnant liquor stream is sent around the PHE
directly to the first agglomeration tank for temperature control at the first
agglomeration tank. A control valve varies this stream flow in order to achieve the
required temperature.
Relatively cold spent liquor from the first inter stage cooler situated between 3rd and
4th growth tanks of precipitation is fed to the heat exchanger. This spent liquor is used
to cool the hot pregnant liquor there by, acquiring the heat itself.
The flow of spent liquor is counter current to that of the pregnant liquor and here spent
liquor acts as the coolant. The heat gained by the spent liquor through the heat
interchange is an energy efficient way to preheat the spent liquor before it is sent to
evaporation area.
32
Pregnant liquor temperature is an important process parameter as the precipitation

reaction kinetic depends upon it. Hence the hot pregnant liquor by pass flow is
controlled to get the exact required temperature at the agglomeration tank inlet.
The capacity of the spent liquor pump in the outlet of the seed thickener is sufficient to
carry the spent liquor through the inter-stage slurry cooler to the heat interchange and
ultimately to the evaporation feed tanks.
Table 3.9 Parameters for Heat Inter change
Item Units Value

o
Spent Liquor to HID temp C 55 typ , 50 min
o
Target Pregnant Liquor to HID C ~103
o
Target Fill temperature C 60 to 70
o
Target SPL temperature ex HID C 84
o
Exchanger type C plate
3.5.8 Evaporation
The main objective of this is to concentrate a solution containing a non-volatile solute

and a volatile solvent.
Basic heat transfer equation is Q=UAdT.
Q=heat U=heat transfer coefficient A=area dT=temperature difference.
Evaporation of a Bayer solution results in increasing the concentration of a solution

constituents in a medium in which these become less soluble due to increase in caustic
solution. Depending on the type of evaporation process the temperature may decrease
with increasing amount of solution concentration. Thereby, it further decreasing the
solubility of solution constituent.
Eventually the degree of super saturation is which where the solution constituent begins
to precipitate, the impurities which precipitates and the formation various components
as precipitates are:
1) Na2CO3 as Na2CO3
2) Na2SO4 as double salt (Na2CO3.2Na2SO4)
3) Oxalates
4) NaF.2Na2VO4.19H2O.
33
The extent to which different solution constituents precipitate will increase depending
on increase in caustic concentration and decrease in temperature of evaporation of the
product.
The basic components of this process consist of heat exchangers, vacuum system,
vapors separators and condensers.
Generally the unit is employed, in an alumina refinery to remove water that has entered
the liquor circuit from bauxite moisture, mud washing, hydrate washing, and
miscellaneous dilution streams. This is located in the spent liquor side to avoid high
alumina concentration in the precipitation and to maximize feeding of strong caustic
liquor to digestion.
The main components of evaporation units are calendria type falling film evaporators
where low-pressure steam is supplied from the power plant to heat up the incoming
feed and subsequently vaporize the excess amount of water from the spent liquor.
Therefore,
Steam economy is of prior importance in the plant for which Multi Effect Evaporators are
generally used where vapors from one effect is used in another as heating medium.
Thus there is an increase in the steam economy by reusing the vaporized solvent.
Table 3.10 Parameters for Evaporation
Item Units Value

Duty t/h 50(Design for60 t/H)
Feed flow rate M3/hr 211
Energy Source Steam, Boiler house
Evaporator Type Multi stage flash
O
Feed temperature C 84
Product Liq. Caustic concentration ( Na2O) g/L Nominally 184, Max 190
Evaporator Economy t/t 3.8
O
Barometric Condenser CW Temperature C 35
Feed caustic concentration g/L 240
34
3.5.9 PRECIPITATION
In this stage, the alumina is recovered by crystallisation from the pregnant liquor, which
is supersaturated in sodium aluminate.
The crystalisation process is driven by progressive cooling of the pregnant liquor,

resulting in the formation of small crystals of aluminiumtrihydroxite (Al(OH) 3, commonly
known as ―hydrate‖), which then grow and agglomerate to form larger crystals. The
precipitation reaction is the reverse of the gibbsite dissolution reaction in the digestion
stage:
Al(OH)4- + Na+ → Al(OH)3 + Na+ + OH-
The main processes taking place within precipitation are:
i. Agglomeration
ii. Crystal Growth
iii. Crystal Breakage
Inputs to the area are:
i. Hot and Cold Pregnant Liquor from Heat Interchange area

ii. Fine washed and unwashed seed from Fine Seed Filtration
iii. Coarse seed from Hydrate Classification.
iv. Spent Liquor from Hydrate Seed Thickeners
v. Plant Air from Air Compressors
vi. Cooling Water from Alkaline Cooling Tower
vii. Low Pressure steam from Co-generative Power Station
Outputs from the area are:
i. Precipitated Slurry to Hydrate Classification

ii. Hot Spent Liquor to Heat Interchange department
iii. Heated cooling water to Alkaline Cooling Towers
iv. Condensate to Condensate storage
Heat
Al (OH) 3 + NaOH -------------- Al (OH) 4- + Na
Cool
35
Figure No 3.3: Precipitation Flow Diagram
Table 3.11 Parameters for Precipitation
Item Units Value

Filling Liquor Chemistry
Total Caustic g/L 240
Rp 0.66
C/S 0.900
Number of Trains 1
Seed to 1st tank g/L 400-500
Precipitation tank solids g/L 450-550
Final tank temp 55 typ, 50 min
Draw-off ratio target 0.345
Precipitation yield net g/L 0.345
36
3.5.9. HYDRATE CLASSIFICATION BY HYDROCLONES
The purpose of Hydrate Classification is to separate Coarse, Intermediate and Fine

fraction of hydrate to allow control of Precipitation particle size. Slurry from the last
online Precipitation stage is separated into Coarse product hydrate, an Intermediate
coarse seed fraction, a Fine seed fraction.
The product hydrate is sent to Product Filtration for De-liquoring and washing. The
coarse seed is charged to Lead Growth Precipitator Tank. The fine seed is sent to Fine
Seed Washing Area before being charged to the first online Agglomeration Precipitator
Tank.
COARSE SEED SLURRY

TO PRECIPITATION
HYDRATE SLURRY
FROM PRODUCT SLURRY TO
PRECIPITATION PRODUCT FILTRATION
HYDRATE
FINE SEED SLURRY TO
CLASSIFICATION HYDRATE SEED THICKENER
1ST STAGE FILTRATE

FROM COLD PREGNANT
LIQUOR
FINE SEED WASH AREA
FROM HID
Figure No 3.4: Hydrate Classification
Hydrocyclones
The hydro cyclones use centrifugal forces to separate coarse from the fine particles
contained in the feed slurry. The heavier coarse particle spiral to the outside of the
hydro cyclone while the lighter fine particles move into the center portion of the unit
and exit as cyclone overflow. All cyclones have the same basic design component but
with varying dimension that dictate the quality/quantity of size split between the coarse
and fine particle streams.
37
All cyclones are individually connected and valved to the cluster feed distribution vessel.
This allows any cyclone to be taken off line/ placed in service as required. Approximately
20 % of the valves are fitted with remotely controlled actuators. The remaining 80%
have manual isolation valves. This arrangement allows cyclone bodies to be repaired or
replaced with the cluster on line and for changes in flow to be managed by varying the
number of cyclones online.
The following table outlines the parameters that are considered critical to successfully
operation.
TABLE: 3.12 OPERATING PARAMETERS
Parameter Unit Sample Frequency

point
Inlet pressure in Primary Kg/c PIT reading at the inlet Continuous via
cyclones m2 of Splitter Box DCS
Inlet pressure in Secondary Kg/c PIT reading at the inlet Continuous via
cyclones m2 of Splitter Box DCS
Level in Primary Cyclone M LIT reading Continuous via
Overflow Tanks DCS
Level in Primary Cyclone M LIT reading Continuous via
Underflow Tanks DCS
Level in Coarse Seed Tanks M LIT reading Continuous via
DCS
Level in Fine Seed tanks M LIT reading Continuous via
DCS
Density of product Slurry Kg/c DIT reading at the Continuous via
to Disc Filters m3 discharge of DCS
Product Deliquoring
FilterFeed pump
Coarse Seed Density to Kg/c DIT reading at the Continuous via
Lead Growth Tank in m3 discharge of DCS
precipitation CoarseSeed
TransferPump
38
Figure No 3.5: Process Description of Alumina Hydrate Plant
39
The process adopted for the production of Alumina hydrate is Bayer’s Process
technology. Additionally, double digestion system is introduced in this project which is
most economical for 200 KTPA project as compared to full-fledged High Pressure – High
Temperature digestion system.
The product from Hydro cyclone is made into cakes of Alumina Hydrate.
3.6 Raw Material Requirement

Major raw materials required for the alumina hydrate plant is Bauxite. Other material will
be caustic soda, coal, lime, filter cloth and synthetic flocculent. Bauxite will be sourced
from a raw material from five bauxite mine site located in three villages such as Barima,
Pathari, Narmadapur, of Mainpat, Sitapur Taluk and Surguja district.
The details of raw material requirement of project are represented in Table.
Table No. 3.13 Details of Raw material requirement
S.No Raw materials Unit Consumption Factor, Per t of

Hydrate
1 Bauxite(moist) t/t 1.82
2 Soda loss (as NaOH Kg/t 65.5
3 Coal (dry for standard) t/t 0.6
4 Lime Kg/t 30.0
2
5 Filter cloth m /t 0.15
6 Synthetic flocculent g/t 300
7 Steam t/t 2
8 Power Consumption including kWh/t 250
utilities
9 Steam for Drying t/t 0.15
10 Power for drying kWh/t 50
3.6.1 Quality of Raw Material
a) Bauxite
It is assumed that the bauxite will be crushed at the mines to 80% passing minus
100mm, and then delivered to the refinery by truck.
40
The mass and energy balance described by the BFD is based on the assumed bauxite
quality as described below. The bauxite consumption will be ~1.88 t/t of hydrate as
alumina hydrate product. Annual consumption will be ~376000 tonnes.
Table No 3.14 – Bauxite Quality
1 Moisture 5%
2 Gibbsitic alumina 33.%
3 Boehmitic Alumina <8.0%
4 Reactive silica 3.0%
b) Coal
Coal will be used for steam generation using single steam pressure discharge. Typical
quality parameters are indicated below.
Table No 3.15– Coal Quality
Property Units Value

Net Calorific value Kcal/kg 5000
Fly ash content & 10
c) Caustic
Liquid caustic will be used to make up for the caustic loss in the plant. It is assumed to
be delivered to site as a 50% NaOH solution in trucks. On site storage of 30 days is
expected, for a total of 1350 tonnes (900 cubic meters). Typical quality parameters are
indicated in the table below.
Table No.3.16– Caustic Soda
Item Units Value
NaOH % w/w 50
Nacl % w/w <1.2
SG @ 25 degree C 1.50 -1.53
41
d) Lime
Lime is required as a filter aid and to react with the soluble phosphorous entering with
the bauxite. It is assumed to be delivered (as “pebble” quicklime) by trucks and
transferred to the slaking-slurrying section as required. The quicklime’s typical quality is
described below.
Table No.3.17 – Lime
Item Units Value

Composition
CaO %w/w >75
CO2 %w/w <2
Al2O3+SiO2+Fe2O3 %w/w <2.5
MgO %w/w <2
Particle size distribution Mm D70: 0 to 40 (max 100)

Bulk density t/m3 1-1.2
Angle of repose % 45-50
e) Flocculent
Various types of synthetic flocculants will be used to thicken red mud residues in
settling and mud washing. As per lab study, CYTEC HX 600 and NALCO Chemicals RRL
grade of flocculent are suitable for this bauxite settling. Synthetic polymers are delivered
to site in liquid concentrate or powder form by bulk containers.
f) Sulphuric Acid
Sulphuric acid is used for cleaning heat exchangers. It is assumed that the acid will be
delivered to site as 98% H2S04 in bulk trucks.
3.7 Water requirement
The total quantity of water required for the proposed project is estimated as 173 tph. In
that 50 tph of water will be used as raw and 114 tph of water will be used as processing
water.
42
3.8Steam and Power Balance
Steam Generation Capacity

Coal fired Boiler #1 Tph 40.0
Total steam generation Tph 120.0
Steam requirement
Evaporator steam (4 Bar) Tph 15.0
PDS injection (4Bar) Tph 3.0
Mud washing (4 Bar) Tph 3.0
Caustic cleaning (4 Bar) Tph 5.0
Hydrate washing (4 Bar) Tph 3.0
De-aeration (4 Bar) Tph 1.0
Digestion Steam (8 Bar)
Digestion Steam (45 Bar) Tph 20.0
Total Tph 50.0
Power and Steam Balance
Power generation capability from TG
TG #1 MW 5.00
TG#2 MW 5.00
TG#3 MW 5.00
Total from TG MW 15.00
Power generation capability from DG

DG #1 MW 0.8
DG#2 MW 0.8
Total from DG MW 1.6
3.9 Utilities
3.9.1 Cooling Tower
Cooling waters will be sourced from separate non-alkaline and alkaline cooling towers.
The non-alkaline cooling towers will be used to supply all non-contact cooling duties
within the plant. Alkaline cooling tower water will be used in evaporation barometric
condensers vacuum pumps as well where chance of contamination/carry over exits
43
The routing of blow-down from the cooling systems, and the streams used for make-up
to the cooling towers, are shown by the BFD and PFDs. The information below will be
used for design purposes.
Table No 3.18 Non Alkaline cooling tower
Item Units Value

Process condensate and fresh
Make-up water source
water supply
o
Supply temperature, max C 35
o
Return temperature, max C 50
TDS ppm <2000
Total Hardness ppm ,250
Langelier index 0<x<1.5
pH 7-10
Suspended solids Mg/L 1000
Table No 3.19 Alkaline cooling tower
Item Units Value

o
Supply temperature, max C 35
o
Return temperature, max C 50
TDS ppm <2000
Total Hardness ppm <250
Langelier index 0<x<1.5
pH 7-12
Soda g/L <5
Caustic g/L <5
Alumina g/L <2
Suspended Solids mg/L <2000
3.9.2 Effluent water
The refinery design is based on zero emission of any aqueous streams which do not
meet the specified quality standard. Various measures are used to prevent
contamination of the environment with caustic contaminated water, including:
Process spillages (from tanks etc.) will be kept within the curbed process areas
and recovered to process by floor sump pumps.
44
Rainfall in the process areas normally will pass to the area sumps and pumped
into the process.
Rainfall in non-process areas will be collected in ditches and routed to the Dirty
Water Pond. The storm water pond will discharge to storm water ditch outside
the plant boundary with provisions for contaminant monitoring and rerouting to
process pond if necessary.
Rainfall run-off from the bulk storage bauxite and coal stockpiles will be routed
to adjacent collection basins, where any solids will settle before the clean water is
either used for dust control or released to the environment.
Run-off water from the mud residue storage site will be collected in an effluent
holding pond and returned as make-up for the dirty cooling water system.
3.9.3 Compressed Air
Compressed air will be used to operate process airlifts (dip tubes), process control valves
and supply tools. It is assumed that the compressors will be located in the power house
and that the battery limit conditions are as indicated below.
Table No 3.20 Compressed air
Item Units Value

Plant air
Pressure Kg/cm2 8.25
o
Dew point C 5
Oil Mg/m3 <1
Instrument air
Pressure Kg/cm2 8.25
o
Dew point C -40
Oil Mg/m3 <1
3.9.4 Steam and power
Considerable quantities of steam from the power house are required in the digestion
and evaporation areas. Smaller amounts are required in several other sections for
heating the cleaning caustic or other purposes. Normally, the plant steam will come
from installed coal fired package boilers on site. Digestion will be supplied at 8.16
kg/cm2.a and the all other process areas will be supplied by 4.6 kg/cm2.a steam.
45
Table No 3.21process steam and power house
Item Units Value

Steam at battery limit
Pressure Kg/cm2.a 8.16
o
Sat. Temperature C 170.5
Pressure Kg/cm2.a 45
o
Sat.Temperature C 290
Pressure Kg/cm2.a 4.6

o
Sat.Temperature C 147.9
3.10 Solid Waste
Red mud will be produced in the settling process. After the Washing and filtration of the
red mud, the red mud will be transported to the red mud pond. Red mud pond is
located in the eastern side of the plant.
3.11 Employment Generation
The proposed project generates direct employment to nearly 203 skilled people,
outsourced employment of nearly 194 members and so much of unskilled persons like
sweeper, security, etc. During the execution and after the completion of the project,
number of small business will be developed around the project area like welding shop,
mechanic shop, tea stall hotels etc. This step provides the indirect employment to too
many people in the nearby villages.
3.12 Environmental Pollution Control Measure
For controlling dust pollution, mechanized handling systems for bauxite, coal and
alumina have been proposed. Dust collections systems shall be installed for bauxite,
coal, alumina and lime. The proposed boilers are to be by state of art AFBC type boilers
which shall be have ESP and sufficient stack height for controlling dust and gaseous
pollution.
It is recommended to undertake detailed study (during DFR stage) of the red-mud

disposal system and the available stacking area with a view to achieve longer stacking
life. Presently ash is disposed off by trucking using dry disposal method.
Presently the plant is being designed at “zero liquid effluent discharge”.
46
CHAPTER 4 SITE ANALYSIS
4.1Connectivity
The nearest village road (Manja) is 190m away from the proposed alumina hydrate
project site in the north direction. The national highways – 78, Pathalgaon to Ambikapur
is 4.6 km away from the project site in the East direction. The nearest railway station is
Ambikapur railway station which is 28 km away from the project site in northwest
direction.
4.2 land Form, Land Use and land ownership
Total land required for the proposed Alumina hydrate project is 91.942 Ha. The land is a
fairly flat terrain. The ownership of the land is CG government.
4.3 Topography
The land for alumina hydrate plant is fairly flat terrain with 635-745m MSL. There is no
stream found in the land.
4.4 Existing land use pattern
The existing land is not an agricultural land. The land is flat terrain which is very
favorable for the proposed Bauxite Beneficiation Plant.
4.5 Environmental Setting of the site
The environmental setting of the existing and proposed expansion project site is given
inTable 4.1.
Table No 4.1 Environmental setting of the site
S.No Particulars Details

1 22 57’34.54’’N to 22o58’24.39’’N
o
Latitude & Longitude
83o21’38.07’’E to 83o21’55.74’’E
2 General elevation above MSL 635-745m
3 Present land use at the site Empty land
4 Nearest highway NH 78 Pathalgaon – Ambikapur- 4.6 km E
5 Nearest railway station Ambikapur railway station – 28 km NW
6 Nearest airport Darima Airport in Ambikapur -16 km - W
7 Nearest town/city Balauli – 4.7 km - NE
8 Hills/valley
47
9 Topography Flat terrain

Badalkhol Wildlife Sanctuary , Jashpur 57 km
10 National parks/Wildlife Santuary –East
Tiger Point ( Mainpat) – 15 km - South
11 Reserved forest/Protected Forest
12 Seismicity Seismic Zone-II as per IS 1893 (Part I): 2002
13 Defence Installation Nil
Water Bodies Ghunghutta reservoir Dam – 10 km – NW
14
River Boundary – 690 m – SW
Coastal Zone 420 km from project side in Southeast
15
direction
16 Interstate Boundary 80 Km- E
17 Police Station Lakhanpur 32 Km - W
18 NTPC Fire Station Korba – 94 km -SW
4.6 Climate data from the secondary sources
The maximum, minimum and average temperature for the past ten years of Surguja
district is shown in fig A. Fig B shows the average rainfall (mm) in Surguja district for the
past 10 years.
48
4.7 Population in villages around project site
Village Name Population Direction Distance
Chiranga 2308 East 0.970 km

Laigu 492 West 410 m
Manja 955 North 71 m
Kalipur 976 Northwest 369 m
4.7 Infrastructure Facility
The proposed alumina hydrate project provides the enough facility to run the plant
efficiently. Separate infrastructure is allocated for various works in this project. The
infrastructure like workshop, Admin building, Canteen, first aid clinic, Laboratory, central
control room car parking are well planned in this proposed project.
49
Figure No 4.1: Location of Alumina Hydrate Plant
50
Figure No 4.1: GIS based buffer of 1km,5km & 10kmk radius of Alumina Hydrate Plant
51
Chapter 5 Planning Brief
5.1 LAND DETAILS
Details of the proposed area for Bauxite BeneficiationFactory are given in Table No. 6.1.
Table No: 5.1. Location details

S.F.No. 57/1, 70/1&70/77
Area granted for Proposed Factory (Ha) 1.40.5 Ha
Village Chiranga
Taluk Batauli
District Surguja
State Chattisgarh
Owner of the Land CG Govt
5.2 Brief description of Main Process and Equipment required for the Various
Process
Step -1 Bauxite Reception, Storage and Reclamation
Bauxite is normally mined from mining pits. The mined bauxite will be scheduled to be
delivered to the plant, to the extent possible, evenly from these pits daily. Mined bauxite
will be delivered to the hydrate plant in rear dump trucks of 20 - 30 tonne capacity. The
bauxite will be stockpiled at the refinery using mobile equipment, such as bull dozers
and front-end loaders.
Daily bauxite requirement is for about 1100 t. It is recommended that a 60-day live
storage, ~ 66000 t. be maintained at the plant site. Preferably, 2 stockpiles be built, one
operating and one being built. It is recommended that the bauxite stockpile area be
designed to accommodate future doubling of the hydrate plant production capacity.
Bauxite will be reclaimed from the operating stockpile with front end loaders and fed to
a bauxite crusher feed hopper. The crushing plant will operate for 2 shifts a day.
Step -2 Bauxite Crushing andscreening
Front end loaders will deliver bauxite to a crusher feed hopper and crusher feed
conveyor, rated for 80 t/h will feed a dedicated single bauxite roll crusher or hammer
mill with vibratory screen. The crushed bauxite will be conveyed to bauxite grinding mill
feed bin
52
Step - 3 Bauxite Grinding
One ball mill will be used to wet grind the bauxite. The mill will operate in close circuit
with classifying screen such that 100% <1 mm (typical a P80 of 300 microns) passes to
the product slurry tank and the oversize slurry returns to the mill feed chute. The
product slurry is then pumped by dedicated pump to the pre-desilication section. Hot
test lank liquor at ~85oC will be used for grinding.
Step – 4 Pre-desilication
Bauxite slurry from grinding product slurry tank will be pumped to 3 desilicators in
series for desilication at~95 oC with a total desilication time of 14 - 16 hours. When a
tank is off line for cleaning (typically every 12 months) the desilication time will reduce
to 18 hours. It is important to ensure that a desilicator and a digester vessel are not off
line for cleaning at the same time.
Step - 5 Digestion with indirect slurry heater
Double digestion process comprises of extracting first the gibbsite from bauxite at
145°C in the Bayer liquor, separate the residue in specially designed equipment
Decanter and then treat the thickened residue at 245°C to extract the boehmite. The
digestion process thus operated results in higher precipitator liquor productivity and
lower bauxite, caustic and energy consumption as compared to a single high
temperature digestion plant. For an alumina refinery that is being operated as a low
temperature digestion unit but needs to process higher boehmitic bauxite, it is less
capital intensive to introduce the double digestion process as it utilizes the combination
of low temperature digestion equipment and the High Temperature Digestion (HTD).
Step – 6Settling(Clarification)
High rate mud thickening technology will be used for separating solids and pregnant
liquor in digester blow off slurry and recovering caustic and alumina values from red
mud residues in the CCD area. 1st washer will serve as a decanter while the decanter is
being cleaned.
Step – 7 Mud Washing
High rate mud thickening technology consisting of 5 stages CCD will be used. First
washer overflow will be used to dilute the digester blow-off stream while controlling the
53
feed caustic to the decanter at ~145 g/L caustic.
Step -8 Red Mud Filtration
Pressure filters will be used to filter the last mud washer underflow to ~73% solids to
allow hauling and stacking of red mud residue. Washing on the pressure filter is not
expected.
Step – 9 Polishing Filtration
Pressure leaf filtration technology will be used for this duty; the filtration rate assumes
the use of the high rate filters similar to Gaudfrin Filters used in the Bayer alumina
plants.
Step -10 Heat Interchange Department
Pregnant liquor is cooled by a pair of plate heat exchangers in series; one against spent
liquor and one against water from non-alkaline cooling tower. A complete pair of heat
exchangers will be on standby.
Step -11 Precipitation
The precipitation section will use an updated version of the well proven 2 stage
precipitation process. It will allow 36 hours residence time in a growth and 6-8 hours in
agglomeration chain of flat-bottom tanks with mechanical agitation.
Step 12 Seed Filtration
The slurry from the last precipitator will be filtered two of three-disc filters, and the
product stream will be cut from the moist cake, and subject to further washing/drying.
Around 80% of the moist cake will be conveyed to the first precipitator and dispersed in
the slurry in that tank.
Step 13 Evaporation
Multistage flash spent liquor evaporators will be used to maintain the plant water
balance. The evaporation capacity of this facility has been determined by considering
normal water additions to the process and the various “parasitic” dilution inputs around
the refinery, as follows:
Pump gland water, 4 m3/h; Instrument purge water 1 m3/h;
54
A design margin on evaporator of 20% capacity.

Process Line Sizing Guidelines
Liquor Process Lines: 1.5 to 2.5 m/sec

Slurry Process Lines: 1.5 to 2.0 m/sec. Except for lime slurry lines 2 m/sec
minimum
Vapor lines: 25 to 30 m/sec
5.3 Solid Waste
5.4 Employment Generation
The proposed project generates direct employment to nearly 203 skilled people,
outsourced employment of nearly 194 members and so much of unskilled persons like
sweeper, security, etc. During the execution and after the completion of the project,
number of small business will be developed around the project area like welding shop,
mechanic shop, tea stall hotels etc. This step provides the indirect employment to too
many people in the nearby villages.
5.5 Environmental Pollution Control Measure
For controlling dust pollution, mechanized handling systems for bauxite, coal and
alumina have been proposed. Dust collections systems shall be installed for bauxite,
coal, alumina and lime. The proposed boilers are to be by state of art AFBC type boilers
which shall be have ESP and sufficient stack height for controlling dust and gaseous
pollution.
It is recommended to undertake detailed study (during DFR stage) of the red-mud

disposal system and the available stacking area with a view to achieve longer stacking
life. Presently ash is disposed off by trucking using dry disposal method.
Presently the plant is being designed at “zero liquid effluent discharge”.
55
Table No 5.2: List of Equipments used for the proposed project.
1 Bauxite Handling Unit

1.1 Crusher 1
1.2 Screen 1
1.3 Conveyor 6
1.4 Magnetic Separator 1
2 Bauxite Grinding
Ball Mill 2
Main drive 2
Inching Device 2
2.1
Main reducer 2
Girth Gear & Pinion Spray System 2
Bearing Lubrication System 2
2.2 Mill feed Bin 2
2.3 Apron Feeder 2
2.4 Weigh Scale Belt conveyor 2
2.5 Vibratory Banana Screen 2
2.6 Mill Discharge Slurry Pump 4
2.7 Product Transfer slurry pump 4
2.8 Sump tank with agitator 1
2.9 Sump Pump 1
3 Predesilication
3.1 Predesilication Tank 3
3.2 Predesilication Tank Agitator
3.3 Slurry Contact Heater
3.4 Bauxite Slurry Transfer Pump 2
3.5 Digestion Slurry Feed Pump 2
3.6 Bauxite Slurry Recirculation Pump 2
4 Low Temperature digestion
4.1 Live Steam Heaters &Flash Heaters 8
4.2 Digestor Pressure Vessel 3
4.3 Flush Vessel 3
4.4 Blow off-Tank 1
4.5 Process Condensate Receivers 1
4.6 Steam Condensate Receivers 1
4.7 Pressure Relief Tank 1
56
4.8 Process Relief Valve 1

4.9 Process condensate Pumps 2
4.10 Live Steam Condensate Pumps 2
4.11 Booster Pumps 2
4.12 Sump Pit with agitators 1
4.13 Sump Pump 1
5 High temperature Digestion
5.1 Live Steam Heaters And Flash Heaters 16
5.2 Digestor Pressure Vessel 3
5.3 Flush Vessel 7
5.4 Special Decanter 1
5.5 Process Condensate Receivers 1
5.6 Steam Condensate Receivers 1
5.7 Pressure Relief Tank 1
5.8 Process Relief Valve 1
5.9 Process condensate Pumps 2
5.10 Live Steam Condensate Pumps 2
5.11 Booster Pumps 2
5.12 Sump Pit with agitators 1
5.13 Sump Pump 1
6 Mud Settling & Washing Unit
6.1 Decanter
Decanter Tank
Decanter Rake Drive
2
Decanter Underflow Pumps
Decanter Overflow Pumps
6.2 Mud washer
Tank
Rake Drive
5
Underflow Pumps
Overflow Tanks
Overflow Pumps
6.3 TCA
TCA Preparation Tank
2
Tank Agitators
Transfer Pump
57
Dosing Pump
Host Water Tank 2
Host Water Pump 2
Mud wash water tank 1
Wash water pump 2
Flushing water pump 2
Static Mixer 6
Flocculant Dosing Systems 2
Sump Pit with Agitators 2
Sump Pump 2
7 Red Mud Filtration Unit
7.1 Filter Press 3
7.2 Red Mud Filter Feed Tank 1
7.3 Filter Tank 1
7.4 Squeezed Water Tank 1
7.5 Cloth wash water tank 1
7.6 Cake Wash Water Tank 1
7.7 Air Receiver 1
7.8 Feed Tank Agitator 1
7.9 Filter Feed Pump 2
7.10 Mud Filtrate Pumps 2
7.11 Squeezed Water Pumps 2
7.12 Cloth Washing Pumps 2
7.13 Cake Wash Pump 2
7.14 Conveyor 6
7.15 Sump Pit with Agitators 1
7.16 Sump Pumps 1
8 Polishing Filtration
8.1 Vertical Press Filter 4
8.2 Turbid Liquor Tank 1
8.3 Condensate Tank 1
8.4 Caustic Cleaning Tank 1
8.5 Liquor Filter Tank 1
8.6 Turbid Liquor Tank Agitator 1
8.7 Cloudy Filtrate recycle Pump 2
8.8 Process Condensate Pump 2
58
8.9 Caustic Cleaning Liquor Pump 2

8.10 Liquor Filtrate Pump 2
8.12 Sump Pumps 1
9 Heat Interchange Unit
9.1 Plate Heat Exchangers 2
10 Precipitation
10.1 Precipitation Tanks 12
10.2 Precipitation Tank Agitators 5
10.3 Interstage Cooler 2
10.4 Precipitation Draw Off Pump 2
10.5 Precipitation Transfer Pump 2
10.8 Sump Pumps 2
11 Seed Filtration
11.1 Hydrate Seed Filters 2
11.2 Product De-liquoring Filters 2
11.3 Spent Liquor Tank (Conical Bottom) 2
11.4 Condensate Tank 1
11.5 Filtrate Seal Tank 2
11.6 Conveyors 4
11.7 Static Mixer 2
11.8 Filtrate Receiver 5
11.9 Blow Back air vessel 2
11.10 Spent Liquor Pump 2
11.14 Sump Pump 2
12 Hydro-Cyclone
12.1 Set of Hydro-Cyclone
13 Product Filtration
13.1 Horizontal Pan Filter 2
13.2 Pan Filter Feed Tank 2
13.3 Deliquoring Tank 2
59
13.4 Strong Wash Filter Tank 2

13.5 Weak Wash Filter Tank 2
13.6 Pan Filter Feed Tank Agitator 2
13.7 Conveyor 4
13.8 Mother Liquor Receivers 1
13.9 Strong Liquor Receivers 1
13.10 Weak Liquor Receivers 1
13.11 Control Lubrication System 2
13.12 Inline Heaters 2
13.13 Pan Filter Feed Pump 2
13.14 Wash Water Recirculation Pump 2
13.15 Pan Filter Deliquoring Filtrate Pump 2
13.16 Wash Filtrate Pump 2
13.17 Vaccum Pump ( For seed Filters) 2
13.18 Vaccum Pump ( For product Filters) 2
13.19 Blower ( For Seed Filters) 2
13.20 Blower ( For Pan Filters) 2
13.22 Sump Pumps 2
14 Tank Firm
14.1 Evaporation Condensate Tank 2
14.2 Digestor Condensate Tank 1
14.3 Evaporation Feed Tank 2
14.4 Evaporator Product Liquor Tank 2
14.5 Mix Liquor Tank 1
14.6 Flush Vessel 6
14.7 Evaporator Condensate Pumps 2
14.8 Instrument Process Water Pumps 2
14.9 Gland Water Pumps 2
14.11 Evaporation feed Pumps 2
14.12 Strong Liquor Pumps 2
14.13 Mix Liquor Pumps 2
14.14 Mix Liquor to Bauxite Grinding units 2
14.16 Sump Pumps 2
60
15 Evaporation Units
15.1 Evaporators
15.2 Feed Flush Vessel
15.3 Product Flush Vessel
15.4 Condensate Pots
15.5 Hot well tank
15.6 Evaporator Recirculation Pumps
15.7 Evaporator Feed Pumps 1
15.8 Evaporator Transfer Pumps
Evaporator Concentrated Liquor
15.9 Pumps
15.10 Hot Well Pump
15.11 Sump Pit with Agitators
15.12 Sump Pumps
16 Utilities
Caustic Storage and Caustic Cleaning Liquor
PreparationUnit
16.1 Spent Caustic Cleaning Liquor Tank 2
16.2 Fresh Caustic Tank 2
16.3 Process Slurry Heaters 2
16.5 Spent Liquor CCL Pump 2
16.6 Fresh caustic Unloading Pump 2
Clean Cooling Tower
16.7 Clean Cooling Tower 1 1
16.8 Clean Cooling Tower 2 1
16.9 Fan for Clean Cooling Tower 1 3
16.10 Fan for Clean Cooling Tower 2 2
16.11 Precipitation & HID Cooling WaterPump 2
16.12 Compressor Cooling Water Pump 2
Dirty Cooling Tower
16.13 Dirty Cooling Tower 1 1
16.14 Fan for Cooling Tower 1 3
16.15 Evaporator Cooling Water Pump 2
Raw Water Treatment Plant
16.16 Raw Water Tank 2
16.17 RO Water Tank 2
61
16.18 RO Package 1
16.19 Drinking Water Pump 2
Sulphuric Acid Tank
16.20 Strong Sulphuric Acid Tank 1
16.21 Dilute Sulphuric Acid Tank 1
16.22 Strong Sulphuric Acid Pump 1
16.23 Dilute Sulphuric Acid Pump 2
Compressor Unit
16.24 Compressor 3
16.25 Dryer 2
16.26 Compressor Lubrication Systems 3
Raw Water Storage
16.27 Raw Water Storage Tank 1
16.28 FRW Pumps 2
16.29 Main Fire Pump 2
16.30 Raw Water Transfer Pump 2
Clean Water Pond Unit
16.31 Neutralization Pit 1
16.32 Pumps 2
Dirty Water Pond Unit
16.33 Dirty Water Pond 1
16.34 Pumps 2
16.35 Red Mud Pond including process pond 1
Steam and Power Units
16.36 Boiler 3
16.37 Turbines 3
16.38 DM Water Units 1
16.39 Coal Handling Units 1
16.40 Cooling Towers 1
16.41 Dump Condensor 1
62
CHAPTER 6 PROPOSED INFRASTRUCTURES
6.1 Industrial Area.
The total land area proposed for the newly started Bauxite Beneficiation Plant is 91.942
ha. The topography of the land is fairly flat terrain which is 635 -745m above the MSL.
6.2Greenbelt
The area for the green belt of the proposed project is allocated as more than 30 ha in
the southern side of the plant.
Figure No 6.1: GIS based buffer of 500m& 300m radius of the proposed plant
63
6.4 Connectivity
The nearest village road (Manja) is 190m away from the proposed alumina hydrate
project site in the north direction. The national highways – 78, Pathalgaon to Ambikapur
is 4.6 km away from the project site in the East direction. The nearest railway station is
Ambikapur railway station which is 28 km away from the project site in northwest
direction.
6.5 Drinking Water Management (Source & Supply of Water)
Water is sourced from Ghunghutta River. The raw water is treated in clarifier and filter
beds. Total quantity of water required for the drinking purpose is 19tph but the design
is 25tph
Figure No 6.2: Water Management
64
6.6 Solid Waste Management
6.7 Plant Areas byDetail
The approximate dimensions of each Bauxite Beneficiation Plant area are estimated and
same are projected here
Table No 6.1: Details of Plant Area
Dimensions of Layout areas

Area Dimension (m)
Stockpile 250*500
Crusher 40*50
Box Grinder 70*50
Pre-desilication Plant (PDS) 60*30
Digester 150*75
Settling 100*70
Filtration 50*40
Red Mud Filtration 70*50
Red Mud Pond 500*500
Overflow Collection Pond 150*100
Heat Interchange Department (HID) 40*25
Precipitation 150*50
Seed Filtration 60*40
Evaporation 100*60
Tank Farm 50*50
Product Storage 70*50
Finished Product Storage 100*100
Control/ Sub Station 60*40
Milk of lime 30*40
Compression House 25*25
Cooling Tower 30*30
Caustic Storage Tank 25*25
Power Plant (Coal Generator) 200*200
Workshop 50*60
Admin Building 40*50
65
Canteen 30*30
First Aid/ Clinic 20*20
Laboratory 30*50
Central Control Room (CCR) 40*40
Ash Pond 200*200
Car park 30*30
Water Reservoir 40*40
Chapter 7 Rehabilitation and Resettlement (R&R) Plan
The land proposed for the newly started Alumina hydrate plant is empty land with few
shrubs. There is no single habitation in the land. So the rehabilitation and resettlement
plan is not needed for the proposed project site.
After the complete execution of proposed project there is a lot of chances of

resettlement of people around the project site from various villages and towns because
the proposed project generate direct employment to nearly 203 persons, outsourced
employment of nearly 194 members and indirect employment to more than 500
Persons.
66
CHAPTER 8: PROJECT SCHEDULE AND COST ESTIMATION
8.1 General
Company has proposed a Greenfield 200,000 TPA Alumina Trihydrate plant at Chiranga
Village, Batauli Taluk, Surguja District. The preliminary capital cost estimates for this
project is shown in Table 1. The above cost is as on March 2019 level and does not
include any future escalation and foreign exchange rate variation, working capital cost
including financial charges and required external infrastructure developments, etc. It is
also important to note that the no future closure plan is incorporated in the present
capital cost, which can be further considered on later stage depending on local
regulatory requirements. The battery limit of this cost estimate is planned alumina
refinery at given site and does not include jetty and port facilities and all external
infrastructure.
8.2 Basis of Cost Estimation
The estimate methodology has been based on the philosophy of execution of the site
related works only i.e. civil and structural works, erection/installation of equipment/bulk
materials and actual equipment cost. Cost head wise details of the methodology and
basis adopted in this regard are as follows:
1. Land and Site Development
Since the plant is to be setup within the land to be acquired by Company, a cost
provision has been made in the estimate for the acquisition of the land. About 1.5
million USD has been considered in the estimate for land acquisition activities within the
area.
2. Plant and Machinery
Equipment: The cost estimate for equipment has been prepared using the in-house data
available for similar projects after giving due consideration for technical parameters,
time factors, and exchange rate variation. This also includes steam generation (3 X 40
tonnes per hour) and power plant (3 X 5.0 MGW) capacity. The detail equipment cost in
Indian Rupees (INR) and US$ for this ATH plant is provided.
67
Table No 8.1: Cost details of Plant and Machenieries
Detailed Cost of Plant & Machinery for Bauxite Beneficiation Plant
S.No Description INR Remarks

(inCrore)
A Major Equipment
1 Bauxite Handling 15.15 LSTKVendor: F.L. Smith
2 Bauxite Grinding 32.47 LSTKVendor: F.L. Smith
sed on the in-house data
PDS Tanks & all miscellaneous
3 30.31 Approximate tonnage: 2500
tanks
metric tonnes
4 Digestor Pressure vessels 21.65 Vendor: Chem Process
5 Heat Exchangers 21.65 Vendor: Chem Process
6 Evaporators 43.29 Vendor: Meso& Alfa Lavals
7 Settling and Washing 43.29 Vendor: F.L. Smith
8 Red Mud Filtration Unit 15.15 Vendor: Jinzhing
9 Polishing Filtration Unit 19.48 Vendor: Gaudfrin
Hydrate Classification
Cyclones, Product Filters, Seed Vendor: AKW Cyclones &
10 30.31
Filters & Hydrate Washing Filters: Gaudfrin
Filters
11 Agitators 10.81
Vendor: Metso Minerals
12 Pumps 25.98
&Weirman International
13 Valves 21.65 Vendor: SmartPower China
Milk of lime, floc, unit water
14 38.96 Vendor: Westech
treatment and miscellaneous
Sub Total (A) 370.16
B Bulk Material (including erection)
6000 tons structural
1 Structural Materials 43.29
quantity
2 Piping(including piping rack) 21.65 Based on in-house data
Electrical package including
3 substation, transformer, 32.47 Vendor: Seimens&Alstorm
motor,DG etc
4 Instrumentation 21.65 Vendor: Forbe& Marshall
5 DCS 17.32 Vendor: Honeywell
68
Sub Total (B) 136.38

C SPARES(2% of A+B) 10.13
Building & Civil Works for the
plant including red mud pond
D 86.11
and ash pond etc
(18% OF(A+B))
Insulation & Painting
E 5.07
(1% OF (A+B))
Sub Total (A+B+C+D+E) 607.85
F. Contingency
1 Ocean Freight
2 Duties &Taxes
Port Handling & Inland
3 Freight
4 Transit Insurance
5 Works Contract
Total Cost 620.00
Piping, electrical, instrumentation, DCS: Cost estimate for piping, electrical and
instrumentation is derived from the execution of similar projects.
Spares: Cost provision towards spare for 2 years normal operation has been
made 2% of equipment and bulk materials excluding piping and structural.
Erection: The cost estimates for erection of equipment, piping, electrical and
instruments is based on in-house cost data for similar project.
Building and civil works: Cost estimate for building and civil works like equipment
foundation, technological structure, etc. is derived from the execution of similar
projects.
3. Exchange Rate :One unit of USD = Rs.72
69
4. Engineering Costs
i) Process Know-How: Cost Provision has been made in the capital cost estimate on
factor basis towards basic engineering technical knowhow and expenditure for
expatriates.
ii) Project management, engineering, procurement and construction supervision:
cost provision has been made in the capital cost estimate on factor basis towards
project management, engineering, procurement and construction supervision to
be provided by consulting engineering organization.
5. Other costs
i) Owner’s Construction Period Expenses: Cost provision under this subhead in the
capital cost estimate has been made towards establishment of owner’s team for
project execution at home office and site office. A team of approximate 10
people at home office for 36 months and a team of 10 people for 24 months at
site have been considered. Provision for transportation and communication has
also been provided.
ii) Pre-project activity: Cost provision under this subhead in the capital cost estimate
has been made for EIA/EMP study and preparation for DFR.
iii) Start-up and Commissioning: Cost provision in the capital cost estimate has not
been made for the same.
6. Contingency
Contingency provision at the rate of 5% on global costs has been considered in the
capital cost estimate.
7. Working capital Margin and Financial Charges
No cost provision in the capital cost estimate has been made for the same.
Exclusion
a) Working Capital & Financial Charges

b) Future escalation and exchange rate variation.
c) Start up and commissioning cost
70
Based on all the above assumptions, a capital cost for setting up this alumina hydrate
plant is worked out and summary is given here.
Table No 8.2: Capital cost summary
Summary of Capital Cost of Bauxite Beneficiation Plant

S.No Description INR
EQUIPMENT PURCHASE
A MAJOR EQUIPMENT
1 Plant & Machinery (Detailed break-up Provided) 620.00
B POWER PLANT
1 Steam Generation and Power Plant

a. Boiler 60.00
b. Turbine 40.00
C LAB EQUIPMENT 50.00
SUB TOTAL (A+B+C) 770.00
D INFRASTRUCTURE 33.93
E ENGINEERING COST
1
Basic and detail engineering (3%) 85.70
2 Project management including procurement 14.30
F. Land And Site Development related cost 115.34

G Basic Infrastructure Cost 61.54
H Interest Capitalization cost 10.34
I Other Costs & Contingency (5%) 55.56
SUB TOTAL (D+E+F+G+H+I) 376.71
TOTAL 1146.71
71
8.3 Operating Cost Estimate
8.3.1 Operating Cost
The Bauxite Beneficiation Plant is presently designed at 200,000 TPA capacities by

adopting high temperature digestion. The estimated consumption and prices of major
raw materials including steam and power are given below:
Table No 8.3: Raw Material Consumption
Item Consumption factor, Per t of Hydrate

Bauxite, t/t 1.82
Caustic (as NaOH), kg/t 65.5(dry basis)
Steam, t/t 2.0
Make-up Water, t/t 1.3
Lime, kg/t 30
Synthetic flocculent, kg/t 0.3
Power Consumption including 250
utilities,kWh/t
Table No 8.4: Raw Material Price
Item Unit Landed Price

Bauxite $/T 22
Caustic (as NaOH) $/T 440
Steam $/T 16
Make-up Water $/T 0.5
Lime $/T 80
Power Cost $/KwH 0.065
FIXED COST
The fixed cost has 3 major components (excluding depreciation, financial charges, etc.)
has been assumed based on experience on similar projects:
i) Salary and Wages: $11/T

ii) Repair and maintenance including services: $12/T
72
iii) Supply and other costs (Flocculents, filter cloth, consumables, etc..): $6/T
Based on all the above assumption and estimation, operating cost model for 400,000
TPA alumina refineries is worked out and the model is presented her.
Table No 8.5: Operating Cost Model
Table : Operating Cost Model

Bauxite Quality:
TA(THA 33and MHA8) % 41.0%
SiO2 % 3.%
Moisture % 5.0%
Overall Recovery % 92.0%
COP:
Bauxite $/T 40.0
Caustic $/T 29.0
Lime $/T 2.0
Steam $/T 32
Energy $/T 16
Water $/T 0.6
Fixed exp $/T 29
Gross COP $/T 149
COP (As Al2O3.3H2O) $/T 149
Specific Consumptions:
Bauxite T/T 1.82
Caustic Kg/T 65.5
Lime Kg/T 30
Steam T/T 2.0
Energy Kwh/T 250
Water T/T 1.30
Raw Material Rates:
Bauxite $/T 22
Caustic $/T 440
Lime $/T 80
Steam $/T 16
Energy $/Kwh 0.065
73
Water $/T 0.5

Fixed Exp $/T 30
Exchange Rate Rs/$ 72
Thus, the cost of production (COP) of 1 ton of standard wet hydrate will be in the range
ofUS$.149.
Chapter 9 Analysis of Proposal
The Proposed Bauxite BeneficiationFactory in this area will benefit to the local people
both directly and indirectly. The direct beneficiaries will be those who get employed in
the factory as skilled and un-skilled workers.
Depending on the proposed project so many small businesses such as mechanic shop,
welding shop, hotels, tea stall, etc. will be developed around the industry which
increases the survival of the people in the nearby villages.
It greatly increases the Indian Economy which increases the status of our country across
the world.The Proposed project will satisfy the demand of Alumina in India and also in
other Countries.
As part of the Corporate Social Responsibility (CSR),MAA Kudargarhi Alumina &

Refinery Private Limited is to take steps indeveloping education, health, infrastructure
development, women empowerment,sports and vocational training facilities etc.
MAA Kudargarhi Alumina & Refinery Private Limited
(Project Proponent)
Mr.S.Suriyakumar)
M.Sc., M.Phil, F.C.C. (Min) PGDBA, PGDIPC
EIA Co-ordinator (Mineral Beneficiation – A cat.)
74

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PRE-FEASIBILITY REPORT

AADHI BOOMI MINING AND ENVIRO TECH (P) LTD.

S.No Description Page No.

CHAPTER: 1. EXECUTIVE SUMMARY

1.2 Project at a Glance

The proposed new project at a glance is given in Table-1.

Type of Project Bauxite Beneficiation and extracting Alumina Hydrate

Brief description of Process Flow

i) Crushing and Milling

INTRODUCTION OF THE PROJECT/ BACK GROUND INFORMATION

2.1 LAND DETAILS

Table No: 2.1. Location details

2.2Identification of Project Proponent and Project

Maa Kudargarhi Alumina&Refinery Private Limited is a Private incorporated on

Directors of Maa Kudargarhi Alumina & Refinery Private Limited isMrSunil

Table No: 2.2. Name of Directors

Maa Kudargarhi Alumina &Refinary Private Limited having Corporate Identification

2.3 Brief Description of Nature of the Project

High Temperature Digestion System - Extract Boehmitic Alumina from bauxite by

1 Barima Block – Mainpat 69 54.268 SinghalBusines 115290

2 Barima Block – Sitapur 7 4.764 SinghalBusines 29980

3 Barima Block – Mainpat 2 80.414 SinghalBusines 80161

4 Pathari Block – Sitapur 12 99.35 MKSPL 198875

2.4 Geographical Location

22058’24.41”N and Longitude 83021’02.3” to 83021’56.58”E. Latitude and Longitude of

all boundary Pillars are given in Table No.2.2.

Figure No 2.2: Location & Accessibility of the proposed Plant

Table No: 2.4 GPS survey reading of all boundary pillars

BOUNDARYPI LATITUDE LONGITUDE

115 22°57'52.63"N 83°21'25.53"E

Figure No 2.3: Surface plan of the Proposed Plant

2.4 Need and justification for the Project

Chapter 3 - Project Description

3.1 Type of the Project

The Company,MAA KUDARGARHI ALUMINA & REFINERY PVT LTDproposes a

3.2 Details of Alternative Site Required

3.3 Location of the Project

3.4 Size or Magnitude of operation

Table No. 3.1 Project details for Bauxite Beneficiation Plant

S.No Description Details

2 Land Requirement 91.942 Ha

3.5 BASIS OF PROCESS DESIGN

The process stages are:

3.5.1. Crushing and Milling

Table 3.2 : Parameters for Bauxite Crushing

Item Units Value

The main objectives of bauxite close circuit grinding are:

Desilication is important in Bayer process mainly for two reasons:

1. Precipitation of silica as sodalite, removing it from the bauxite.

1. Reaction of kaolinite (Al2O3.2SiO2.2H2O) with sodium aluminate liquor containing

3(Na2O.2SiO2.2H2O). (0.3-0.6) Na2O.Al2O3. (0.7-0.9) Na2CO3.

(NaOH + Nasal (OH) 4) + Bauxite 3(Na2O.2SiO2.2H2O). (0.3-0.6) Na2O.Al2O3 .(0.7-0.9)Na2CO3

Caustic +Oxalate (Na2C2O4)

Table 3.3 – Parameters for Pre-desilication

Item Units Value

The fraction of caustic soluble alumina present in boehmite (MHA) is expected to be

Table 3.4– Parameters for Digestion

Item Units Value

Returned to Power House

3.5.4. Clarification/Settling/Mud washing

This process of separating solid and liquid is also known as sedimentation or

Table 3.5 Parameters for Clarification

Item Units Value