Pre-Feasibility Report

Transcription

1 Pre-Feasibility Report 2.5 MTPA Coal Washery at Ghutku Village, Takhatpur Tehsil, Bilaspur District, Chhattisgarh By Paras Power & Coal Beneficiation Limited Lakshmi Tower, Vyapar Vihar, Bilaspur, Chattisagar February, 2016

2 Contents Title Sr. No. 1 EXECUTIVE SUMMARY Page no. 2 2 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION 3 3 PROJECT DESCRIPTION 4 SITE ANALYSIS 5 PLANNING BRIEF 6 PROPOSED INFRASTRUCTURE 7 REHABILITATION AND RESETTLEMENT (R & R) PLAN 8 PROJECT SCHEDULE & COST ESTIMATES ANALYSIS OF PROPOSAL (RECOMMENDATIONS) 34 Annexure I : Process Flow Sheet Annexure - II : ETP Flow Diagram Annexure - III : Plant Layout i

3 1.0 EXECUTIVE SUMMARY: S. No. Description Details 1 Name of the Project Coal Washery 2 Location of the Plant Village Ghutku, Tehsil Takhatpur, Bilaspur District, Chhattisgarh 3 Coal Washery Capacity 2.5 Million TPA [Throughput] 4 Total land requirement for the project Acres 5 Washing Technology Heavy Media Cyclone 6 Total Water requirement & Source Ground Water Process Drinking, plantation, dust suppression etc. 45 m 3 / hour 16 m 3 / hour Total 61 m 3 /hr 7 Total Power requirement & Source 1.5 MVA - Chhattishgarh State Electricity Board 8 Working hours 3 shifts per day of 8hr each [Effective 18 hrs a day] 330 days a year 9 Rehabilitation and Resettlement No R & R issue is involved. 10 Manpower [Operation] 65 persons 11 Estimated Cost of the Project Rs crores excluding EMP & railway siding costs. 2

4 2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION: 2.1 Identification of project and project proponent. Paras Power & Coal Beneficiation Ltd. [PPCBL], registered under the Companies Act, was established in the year The company deals in coal trading and transportation, provides coal consultancy and acts as linkage handling agent. PPCBL proposes to set up a 2.5 MTPA coal washery based on heavy media cyclone technology at Ghutku Village, Takhatpur Tehsil, Bilaspur District, Chhattisgarh State. Need for the project and its importance to the country and region. Coal is the most abundant fossil fuel. India is blessed with huge coal reserves. 85% of these reserves are non-coking coal, which caters to the need of power, cement and sponge iron plants. However, most of these reserves are of very low grade coal. The reserves of good quality coal are fast depleting. On one hand, the demand for coal is increasing due to higher demand from steel, power and cement sectors. On the other hand, extensive mechanization of mines is resulting in more inferior coal generation. Burning of such coal produces huge quantity of ash, disposal of which is a real problem. The Ministry of Environment, Forest & Climate Change (MoEF&CC) made it mandatory for the coal based thermal power plants located beyond 1000 km from the pit-head and also those located in urban or sensitive or critically polluted areas to use beneficiated coal with an ash content not exceeding 34% w. e. f As a result, demand for beneficiated coal has increased substantially. MoEF vide its Notification no. 02(E) dated has made certain rules further to amend the Environment (Protection) Rules, 2014 making it mandatory for the following coal based thermal power plants to use, raw or blended or beneficiated coal with ash content not exceeding 34%, on quarterly average basis, namely, (a) a stand-alone thermal power plant (of any capacity), or a captive thermal power plant of installed capacity of 100 MW or above, located beyond 1000 km from the pit-head or, in an urban area or an ecologically sensitive area or a critically polluted industrial area, irrespective of its distance from the pit-head, except a pit-head power plant, with immediate effect; (b) a stand-alone thermal power plant (of any capacity), or a captive thermal power plant of installed capacity of 100 MW or above, located between km from the pit-head, with effect from the 1st day of January, 2015; and (c) a 3

5 stand-alone thermal power plant (of any capacity), or a captive thermal power plant of installed capacity of 100 MW or above, located between km from the pithead, with effect from the 5th day of June, These new provisions are not applicable to a thermal power plant using CFBC or AFBC or PFBC or IGCC technologies or any other clean technologies as may be notified by the Central Government. As a result, demand for beneficiated coal with ash content not exceeding 34% would significantly increase. M/S Paras Power & Coal Beneficiation Limited intends to set up a 2.5 MTPA capacity coal washery based on Heavy Media Cyclone technology. The washery will produce washed coal of an average ash around 34% (GCV 4350 Kcal / kg.), middling (ash content about 58%) of GCV around 2350 Kcal per Kg useable as fuel in FBC boilers. Rejects (ash content about 86.5%) with no useful heat value (3-4% Carbon) will also be generated. The proposed project will be the State-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi roll belt press filters. 2.2 Brief description of Nature of the Project Need for the Project The coal India Limited and its subsidiaries are the major domestic producers and suppliers of coal in India. The annual requirement of non-coking coal for various industrial sectors like power, steel and cement is increasing day by day. The reserves of low ash good coal are depleting. To meet demand, huge reserves of inferior grade coal are being mined. The average ash in coal now being supplied is around 45 to 50%. PPCBL s decision to set up 2.5 MTPA washery is based on projections made by the Working Groups on Power and Coal & Lignite for XII Plan and the present market scenario. Coal washing is an important area both from economic and environment points of view. 4

6 The Working Group on Coal & Lignite for XI Plan had assessed that in the terminal year of XI th Plan, about 96% of total coal production of the country would be noncoking coal and around 2/3rd of this non-coking coal produced, would be of E to G grade (i.e. high ash content). The washed non-coking coal production for from existing and proposed washeries has been projected in the Working Group report on Coal & Lignite for XII Plan. At present [November 2011], 32 non-coking coal washeries with a total throughput capacity of Mty are in operation in the country. CIL operates 5 non - coking coal washery with a total throughput capacity of Mty and others operate 27 non-coking coal washeries with a total throughput capacity of Mty. The anticipated total capacity of beneficiation of non-coking coal in India, by the end of XII Plan, has been estimated as 199 Mty and projected low grade coal production [other than pithead linked coal] as 360 Mt, thus there will be a huge gap of 161 Mt for capacity addition requirement of washing the entire low grade coal to be produced. Coal India Ltd. (CIL) operates 17 coal washeries with a total capacity of 39.4 Mty. Of which, 5 are non-coking washeries with a total capacity of Mty and 12 coking coal washeries with Mty. Contracts have been finalized for three more washeries. Besides, action to finalize to more washeries is in the advance stage. Further, 12 more washeries have been identified by CIL to be taken up during the XII th Five Year Plan. The wide gap assessed between the projected requirement of beneficiated non-coking coal and the existing total capacity, clearly indicates that there is enough scope for building up of capacity to beneficiate non-coking coal in the private sector. Further, it may not be consistently feasible to operate washeries at their 100% capacity. Therefore, provision for another Mt capacity addition may have to be considered in subsequent phase. 5

7 As the major availability of coal during the XII Plan is expected from the Karanpura, Korba, Mand Raigarh, & Ib Valley coalfields, PPCBL proposal for 2.5 MTPA coal washery at Ghutku is justified. At PPCBL s washery, raw coal of around 46.50% ash will be washed to produce washed coal having around 34% ash. The primary discards will be subjected to secondary washing to produce middling at around 58% ash and rejects at around 86.5% ash. The use of washed coal has the following advantages: 1. Supply of consistent quality coal can be ensured thereby avoiding frequent adjustments in input to boiler and minimizing operators error 2. Higher thermal efficiency of boiler and higher steam rate 3. Less wear and tear of the coal grinding mills 4. Lower capital and operating cost for installing smaller ESP 5. Higher productivity and campaign life of DRI kiln The proposed coal washery will have the following parameters: Capacity : 500 TPH No. of operating days in a year : 330 days No. of effective operating hours in a day: 18 hours, three shifts operation Plant utilization : 85% Annual throughput : 500 X 18 X 330 X 0.85% = 25,24,500 tonnes Say 2.5 million tonnes The project will have the following outputs: Raw Coal - Ash %, Moisture 9.10 %, GCV 3000 K cal / Kg, FC 26%, VM 24%. Washed Coal - Ash - 34%, Moist 12%, FC - 36%, VM 28%, Yield 44%, GCV K cal / Kg. Middling - Ash - 58%, Moist 8.5%, FC 22%, VM 20%, Yield 47%, GCV K cal / Kg. Rejects - Ash %, Yield 9% (No useful heat value) All the yield figures indicated are tentative and are meant for estimation purposes only. 6

8 2.3 Demand-Supply Gap The demand for non-coking washed coal has significantly increased in view of the Ministry of Environment and Forests Notification on use of coal with ash content not more than 34% in power plants located beyond 1000 km from the pithead and in urban area or sensitive area or critically polluted area. The demand for use of washed coal for power generation would further increase as the distance threshold limit has been reduced to 500 km. The Government has also laid thrust on adoption of Clean Coal Technologies (CCTs) to mitigate adverse impact of coal usage on the environment. Total established non-coking coal washing capacity [November 2011] of CIL & others is MTY. The coal requirement for power generation in has been estimated by CEA as 842 MT. The requirement of washed coal will be 361 MTPA. This does not include demand from the other sectors like sponge iron and cement. By the end of XII Plan, low grade coal production, other than pithead linked coal, has been estimated as 360 MT and total capacity of beneficiation of non-coking coal as 199 MTY. Thus there is a huge gap of 161 MT for washery capacity addition in the XII Plan. 2.4 Imports vs Indigenous production Raw coal will be obtained from the SECL mines on behalf of the clients. Cost-wise indigenous production is much cheaper than the imported equivalent quality coal. 2.5 Export Possibility No coal will be exported. 2.6 Domestic / export Markets Presently, coal washeries established in India are not able to meet the beneficiated coal requirement. 7

9 2.7 Employment Generation (Direct &Indirect) due to the Project The local areas will be benefited by way of generation of employment opportunities, increased demand for local products and services. There will be an overall improvement in the income level of the local people. The project creates employment to about 65 persons once the plant comes to the operational stage and for 200 persons during construction stage. Preference will be given to the local persons for semi-skilled and unskilled jobs as per the policy of the company. About 250 persons will get indirect employment. There will be generally positive and beneficial impacts by way of economic improvements, transportation, aesthetic environment and business generation in the region. This improve the socio-economic status of people in the area. The plant management will be responsible for overall performance of the unit. The management will be supported by a team of highly skilled persons having varied expertise and experience, which will function individually as well as collectively for overall performance of the plant. The following set up is recommended to look after the various activities in the washery: Sr. No. Position Number 1 Manager Production 1 2 Engineer (Mech. & Process, Electrical & Instrumentation) 4 3 Foreman cum control room operator 7 4 Fitter cum Operator 9 5 Helper 9 6 Electrician 7 7 Helper for Electrician 7 8 Instrument mechanic 4 9 Chemist 4 10 Helper for chemist 4 11 Office and Weighbridge staff 5 8

10 12 Horticulturist 1 13 Watchman 3 TOTAL 65 Besides, unskilled workforce (10 heads per shift), mostly from the nearby villages, required for cleaning & other day to day jobs like magnetite charging etc. will be hired through contractor. 3.0 PROJECT DESCRIPTION 3.1 Type of project including interlinked and interdependent projects: Type of Project: It is envisaged to set up 2.5 Million TPA capacity beneficiation plant to wash coal using Heavy Media Cyclone technology. There is no interlinked project. (i) Location The proposed location is at Ghutku Village, Tehsil Takhatpur, Distt. Bilaspur, Chhattisgarh. The project area is acres. The project span between Latitude: N to N North and Longitude: E to E. The entire project area falls in Survey of India Toposheet No. 64 J/4. The index map of the project site is shown in Figure-1 and a map showing area 10 km around the project site is shown in Figure-2. 9

11 FIGURE-1 INDEX MAP SHOWING THE PROJECT SITE Plant Site 10

12 FIGURE-2 STUDY AREA MAP 11

13 3.3 Details of alternate sites considered: The three sites were examined. Important features of these sites are given below: Parameters Site I (Ghutku) Site - II (Pendridih) Site - III (Lokhandi) Latitude N N N Longitude E E E Village in the Vicinity Ghanapara (0.84 km NNW) Khamardih (1.2 km, N) Uslapur (2.4 km, SSE) Distance from nearest city/ town Elevation of the site, above MSL Sakri (4.2 km, E) Chakarbhata (2.8 km, NE) Sakri (2.1 km, SW) Land pattern Barren and agriculture land Agriculture land Agriculture land Land availability (in acres) Private / Government Agriculture land within 1km Barren Single crop Double crop Forest land Private Private Private Yes Yes Yes Barren as well as single crop land 20% Single Crop & 80% Double Crop House holds No Households No Households Adjacent to housing colony Water body / Transmission line Road connectivity NH 11 (3.4 km, E) Rail connectivity Religious, Archeological Monuments Single crop No Households Arpa River (2.5 km, NE) Manyari River (7 km, SW) Arpa River (2.2 km, E) SH-8 (4.6 km, W) Nearest rail head at Ghutku (1.3 km, NNW) Uslapur Railway Good Shed about (6 km, SE) NH 11 (1 km, WNW) Bilha (3.3 km, S) Nil Nil Nil Forests within 15 km None None None Overhead Transmission line crosses the land NH 11 (3.3 km, ENE) SH -7 (2.9 km, SW) Uslapur (3.0 km, SE) National parks & Wildlife sanctuaries None within 15 km None within 15 km None within 15 km 12

14 The Site 2 and Site 3 were not preferred for setting up the proposed washery because - The site-2 is adjacent to a housing colony. Adequate land is not available. Would require additional road transportation as compared to the other two sites considered as the railway siding is about 12 km. Its agriculture land with 80% double crop; and at site-3 adequate land is not available. An overhead transmission line cross the site. The site-1 at Ghutku has been preferred over the other two sites because adequate land is available. The existing railway siding at Uslapur is about 6 km. The proposed railway siding will be 300 m away from this location. The land is fairly flat and about 75% is under possession of the company. Felling / cutting of trees is not required. The site does not require any approach road construction. No water body / nallah or public road passes through or close to the washery site. Adequate and effective environmental protection measures including plantation will be taken to ensure compliance with the environmental regulations. 3.4 Size or magnitude of operation. 2.5 Million Tons/ Year (Throughput) capacity 3.5 Project description with process details The raw coal for beneficiation will be brought from the SECL mines, located within approx. 70 km, like Gevra, Deepka, Kusmunda by road and rail. There will be one module of 2.5 MTPA to beneficiate 500 TPH coal using Heavy Media Cyclone technology. Washed coal, middling and rejects will be transported as per MOU with the clients preferably by rail. Railway goods shed at Uslapur, 6km from the project, will be used till own siding is established and made operational. Clients not connected to rail network or nearby clients will be supplied coal by road. RAW COAL CHARACTERISTICS & SELECTION OF PROCESS Coal Characteristics Selection of process is based on the study of the available washability test results of coal from SECL mines in the region. It was found that in average raw coal, ash content varies from %. 13

15 Technology & Process Description Scope of the Project The project will beneficiate 2.5 MTPA coal as per the requirement of the clients. Coal Washing Processes There are several processes for coal washing which may be categorized under two broad headings as follows: Dry Process Pneumatic tables or Jig Rotary Breaker Wet Process Natural media barrel Natural media cyclone Jig Chance cone separator Heavy media Bath Heavy media drum Heavy media cyclone Larcodem Triflow separators Dyna Whirlpool separator Vorsyl Separator Froth floatation Column floatation Spirals 14

16 Brief Description of Some of the Processes Principles and techniques of different coal cleaning methods are outlined below: Jigging The separation of coal from shale is accomplished in a form of fluidized bed created by a pulsing column of water which produces a stratifying effect on the raw coal. This is quite different in its effect from dense-medium separation. This stratifying effect results in a definite order of deposition of all fragments contained in the bed. The main purpose of the rising and falling column is to create what is known as dilation or opening up of the bed, and it is the extent to which this dilation may be controlled which governs the effectiveness of the separation. During the pulsion, or rising part of the cycle, the bed is elevated en masse. But as the velocity decreases towards the end of the pulsion stroke, the bed begins to dilate, with the bottom ceasing motion first and the lowermost fragments commencing their descent. This produces an element of freedom of movement for all fragments signalling the commencement of the various principal effects leading to stratification. The most influential effects occurring during jigging are, in order of occurrence: o Dilation; o Differential acceleration; o Hindered settling; and o Consolidated tracking. The Jig is divided into two compartments lengthwise, one completely sealed from the atmosphere - called the air chamber - and one open section, which receives the material to be separated and accommodates it during the stratification process. The water valve allows admission of back water at a level below that of the bed plate. The longitudinal section is further divided into several sections or compartments along the direction of flow. The purpose of this is to provide control over the separation as 15

17 the material moves along the box; hence each of these sections has its own individual air and water controls. Two-elevator arrangement is the most common. In the first, moving along the direction of flow, the heavier shale are separated. In the second, lighter stones and any middling are extracted. The plate which supports the coal and shale bed, usually referred to as the bed plate or screen plate, allows the water current to rise and fall and is usually perforated. Fine material inevitably percolates through the perforations to the hutch compartment and this is removed by screen conveyor which delivers it to the bucket elevators. Efficient collection of the product is of paramount importance. Clean coal overflows the end of the box together with the majority of the flowing water. Merits Water is used in this process instead of magnetite. This process gives fairly good efficiency if the coal is easy to wash (low NGM like European coal) at cut point gravity above 1.7 (deshaling application). Large size coal up to ( - ) 100 mm can be fed to Jigs. Demerits Not a suitable process for washing Indian Coal which is Exceedingly Difficult to wash due to high Near Gravity Material (NGM). Mediocar efficiency. Sensitive to variations in feed rate and / or characteristics. Electronic adjustment system is complex and requires optimizing. Efficiency becomes extremely low for gravities below The process misplacement is very high. High EP (Ecart Probable) around Difficulties in maintaining good product quality. 16

18 Heavy Media Coarse Coal Bath Static dense-medium bath behave in a similar way to laboratory float-sink apparatus. Two categories of dense-medium baths, deep baths and shallow bath, have many common features. Float products are removed from the top of the baths, usually by paddles or by the natural flow of the medium. Discard removal varies from one type to another. Dense medium baths usually treat coal in the 100 mm X 6 mm size range. Merits The process has good efficiency of separation for coal above 10/13 mm size. Insensitive to variations in feed rate and / or characteristics. Easy to adjust the separating gravity. Wide range of separating gravity ( ). Fairly good EP of around 0.06 can be achieved. Demerits Coal below 10/13 mm size shall have to be separately washed in H.M. Cyclone or small Coal Jig which have lower efficiency. If lower size coal is fed, the efficiency will fall drastically and also create other problems in the bath. Efficiency lower than HM cyclone process treating sized coal. Heavy Media Cyclone Cleaning Where only gravitational forces are involved in providing the downward or high density separating force, the type of dense-medium separators employed treat only relatively coarse solids i.e., + 6 mm. They cannot separate out particles smaller than 6 mm effectively, as for such small particles, gravity is overridden by viscosity forces. What is required is a separating force surpassing gravity. As a cyclone utilizes the centrifugal force (e.g., 100 X gravity) for the separation of fractions, it became possible also to treat fine-grained coal (sized, e.g. 0.5 mm to 6 mm). Because the force 17

19 potential of cyclone separator is great, it is possible to treat relatively large quantities of raw coal in a unit of small physical size when compared to dense-medium baths. The corresponding relationship to this form of separation is: Settling Velocity, S = [S 2 /r X v(d D) R] Where, v is the volume of coal sphere, d is the density of coal, D is the relative density of the fluid, R is the resistance factor and r is the radius of the path of the grain. The feed comprising raw coal and medium is introduced at a precise pressure into the tangential inlet. The ensuing flow is rapid and spiralling towards the apex of the unit, and in the core of the cyclone a very fast flow-rate creates centrifugal classification causing shale to move outwards towards the inner wall of the conical shell. As a result shale is discharged from the spigot or nozzle and coal is carried by the rising internal spiral towards the vortex finder to be discharged from the overflow. Merits Due to higher efficiency of separation more yield of cleans. The process can handle wide variation in capacity. Specific gravity of separation can be adjusted very easily, if coal characteristics change. Quantity of water handled much less compared to Jig Process. Operation and maintenance is very easy. Most suitable for coal having difficult washability characteristics. Insensitive to variations in feed rate and / or characteristics. Wide range of separating gravity ( ). Low EP (0.025 to 0.035). Demerits As finely ground magnetite will be used there will be higher erosion in the pipe lines. Basalt lining or extra thick pipe will reduce the problem. 18

20 In case of power failure there will be a chance of jamming. The contents of slurry lines are drained out to overcome this problem. The drained material is pumped back to the system after the plant restarted. Selection of Suitable Process Selection of coal washing process depends mainly upon the following criterion: Washability characteristic of input coal. Size and quality (ash & moisture) requirement of products. Indian coal is of drift origin (unlike European, Australian or American coal which are of In situ origin), hence, have very high Near Gravity Material (NGM). Presence of high NGM (more than 20 units) in ROM coal makes the washing of coal very difficult. Hence, selection of suitable washing process is of paramount importance for Indian coal. Bird s classification of NGM Vis-à-Vis suitable washing process is indicated below: NGM Type of Coal Process 0 7 Simple Coal Jig 7 10 Moderately difficult Baths, tables, spirals Difficult to wash Very difficult HM Cyclone Exceedingly difficult > 25 Formidable From the above table, it is clear that the HM Cyclone process is the only suitable process for treating high NGM Indian coal. Moreover, from process efficiency point also the HM Cyclone process is most suitable process which gives lowest EP (Ecart Probable means Error Probable) i.e. lowest misplacement. A comparison of EP achievable in various processes is given below: 19

21 1) HM Cyclone : to ) Jig : 0.10 to ) Barrel : 0.09 to 0.10 Considering all the above mentioned factors, Heavy Media Cyclone process is recommended for both primary & secondary separation. This will contribute to higher yield by HM cyclone process, which is about 10 to 15% more than Jig or Bath. Process Know How Plant and Machineries for the washing plant will be procured from various reputed manufacturers in India and abroad as per the specifications laid down. Detail engineering, design and drawings for civil, structural, mechanical, electrical, control system and instrumentation will also be procured reputed consultants / organisations. Civil works and site construction and erection jobs will be executed through reputed parties in the field. Brief Description of the Process Pre-treatment section Coal [ROM] from SECL mines will be transported to the washing plant by rail and road. Own proposed railway siding is 300m away from the project site. Trucks will either dump coal into the ground hopper or on to the nearby ground dump from where the same will be fed in the ground hopper. From the ground hopper the raw coal will be subjected to two stage close circuit crushing and screening and finally sized to minus 50 mm. The sized coal will be taken to a series of storage bunker. 20

22 Washing Section Sized raw coal, (-) 50 mm, from bunker will be transported to the washing plant building through covered belt conveyors where the same will be fed into coal wetting launder where water will be added with coal. Coal water slurry then will flow through launder to a set of Desliming Sieve Bend and Screen to remove (-) 1 mm coal fines from the slurry. Coal slurry collected from Desliming Sieve Bend and Screen under pan will gravitate through pipes to a Fine Coal Sump. De-slimed coal coarser fraction of (+) 1 mm will go from screen discharge chute to the launder. Magnetite media of required specific gravity will be added at the back of the launder to get mixed with the coal and simultaneously to push the mixture of magnetite & coal slurry into the central column provided in the centre of the Primary HM Cyclone tank. Coal & magnetite mixture from the centre column will be pumped by Primary Cyclone Feed Pump to feed to Primary Heavy Media Cyclones. Cyclones are lined with high alumna ceramic tiles. Cyclone will have overflow and underflow. Clean coal along with magnetite media will be received as over flow from the cyclone and be fed to a set of Clean Coal Sieve Bend and Clean Coal Draining & Rinsing Screen. Magnetite media will be drained through Sieve Bend and first part of the Screen and be collected in the screen s dense catch pan. The same will be re-circulated back to the primary washing system. The carried away magnetite with the coal particles will be removed by water spraying in the discharge part of the screen. Magnetite removed from coal by water spraying will be collected in the dilute catch pan of screen as dilute media, and be taken to dilute media tank Underflow of primary cyclone treated as primary discard will be fed to a set of double sieve bend. Magnetite media drained through sieve bend will be re-circulated back to the primary system. 21

23 Primary discard collected from discharge end of double sieve bend will be fed to the central column of secondary heavy media tank along with magnetite media of required specific gravity. Coal and magnetite mixture from the central column will be pumped by secondary cyclones feed pump to feed secondary heavy media cyclones. Middling along with magnetite media will be received as overflow from the cyclone and will be fed to a set of sieve bend and draining & rinsing screen. Underflows of cyclone along with magnetite are also fed to a sieve bend & screen. Magnetite media will be drained through sieve bend and first part of the screen and be collected in the screen s dense catch pan. The same will be re-circulated back to the secondary system. Carried away magnetite with the coal particles will be removed by water spraying and be collected in the dilute catch pan of the screen and the same will be taken to dilute media tank. Clean coal collected from discharge end of clean coal screen will be dried in centrifuge and transported to clean coal storage shed through belt conveyor / or directly to clean coal storage bunker. Middling collected from overflow of the screen will be dried in a centrifuge. Dried middling along with dewatered fine coal will either be transported directly to FBC Power Plant through belt conveyor or to middling storage bunker. Reject collected will be transported to a reject bunker and from there to reject disposal area. Fine coal slurry collected in the fine coal tank will be pumped into a set of classifying cyclone. The underflow of classifying cyclone will be dewatered in Hi Frequency screen while the overflow from cyclone will be fed to a Hi-rate Thickener. Thickened slurry from thickener will be dewatered in a Multi Roll Belt Press filter. Anionic and Cationic Flocculants will be used in thickener and Belt Press to facilitate settling and dewatering 22

24 process. The discharge from Hi Frequency screen and belt press will be mixed with middling for dispatch to the end users. Media Preparation & Regeneration Circuit Dilute media as collected in the Dilute Media Tank will be pumped by a Dilute Media Pump to a Magnetic Separator Feed box. From there, the dilute media will be feed to a Wet Drum Magnetic Separator. The Separators will separate out magnetite from water and the dense media gets dislodged from the magnetic drum to the dense media launders and from there to the Primary Heavy Media Tank and Secondary Heavy Media tank. Effluent from the magnetic separator goes to fine coal tank through wetting launder. During the process of operation, some amount of magnetite gets lost which will be made up by adding fresh magnetite to the system. For this purpose, a magnetite addition RCC sump will be provided where ground magnetite will be charged and diluted with water. The dilute magnetite media then will be pumped through a vertical sump pump to the Dilute Media Tank. Process Control Philosophy There will be a control room with a centralized PLC based control system to enable operator(s) to start-up, monitor, control and shut down all main equipment and process functions like feed input to the plant, product transfer to conveyors etc. A hot standby back-up will be provided to take care of power tripping and fluctuations. All major items of equipment will be interlocked in an automatic stopping sequence within the PLC in such a manner that both material and liquid flows will always be fail safe. Stop push buttons will be located adjacent to each drive and will be operable at all times. 23

25 An emergency stop button will be located either in the control room or in the operating computer to enable the whole plant to be stopped. The density of the magnetite media will be controlled to ensure the required quality of the washed products. The specific gravity control will be achieved automatically by respective modulating splitter actuators. The density measurement will be done by a nucleonic density gauge. Indication and recording of the density levels will be done in the control room computer. 3.6 Raw material requirement, Transport etc.: Raw Material Requirement and its sources: Main raw material is ROM coal. Annual requirement will be 25,00,000 T. ROM coal will be sourced from the SECL mines like Gevra, Deepka, Kusmunda Mode of Transport for Raw materials and finished products: Railway siding is envisaged for the proposed project. Till such time the railway siding is constructed, required quantum of ROM coal from the SECL mines will be transported through covered trucks. Washed coal, middling and rejects will be transported either rail or road depending upon the MoU with clients. The existing railway siding is at Uslapur about 6 km from the project site. Clients not connected by rail will receive washed coal, middling and rejects by road. Avenue plantation will be taken up along the road to prevent the fugitive emissions. Hence there will not be any significant by fugitive dust generation during transportation of raw materials & product. The existing road is capable of absorbing this additional truck movement. Hence there will not be any adverse impact on vehicular traffic due to the proposed project. 3.7 Resource optimization / recycling and reuse envisaged in the project, if any, should be given Plant will have close circuit water circulation system so that no effluent is discharged in the open outside the plant boundary. All the process effluent will be collected in the 24

26 thickener. Settled slurry of the thickener will be dewatered in a multi roll belt press filter. The dewatered filter cake will be mixed with the middling. The clarified water from the thickener overflow will be re-circulated in the washing circuit as process water. Only make-up water requirement will be added in the clarified water tank. A set of cascading type emergency settling ponds will be constructed within the plant boundary to take care of any unforeseen situation like pipe line jamming or break down of thickener. The clarified water from these emergency settling ponds will also be pumped back to the plant for use as process water. These emergency settling ponds will also be used for harvesting rain water, which can be used as process water. Equipment like centrifuge, belt press filter, high frequency screen as well as thickener will be installed to ensure close circuit water system; minimize loss of water through products; and evaporation losses. 3.8 Market of Final Products: The washed coal will be utilized as fuel in power plant and reducing agents in sponge Iron manufacturing units; hence market prospects is quite good. 3.9 Availability of water its source, Energy/ power requirement and source: Water Requirement and its sources: Water supply arrangement for the project will basically cover the industrial and potable water demand. Washery will operate on closed water circuit, therefore, only make-up water is required. Requirement of water for pollution control measures will be 12 m 3 /hr for dust suppression, floor washing and plantation. In accordance with the technology adopted, process and other features, the process water [make-up] requirement of the washing circuit will be 45 m³/hr. A RCC water reservoir of around 5000 m 3 storage capacity will be constructed. Domestic water requirement (4 m 3 /hr) will be met from ground water source. 25

27 There will be no industrial waste water discharge as the plant will be designed on zero effluent discharge principle. Septic tanks and soak pits will be provided for sewage treatment and disposal. Particulars Water Quantity m 3 / hour Remarks Requirement Consumption / loss Waste water generation Process Close Circuit [Make-up] System Domestic & others Septic tank & soak pit Dust suppression & plantation Total Zero Effluent Sources of Energy/ Power and its sources: The total connected load for the coal washing plant including crushing & screening will be around 1.5 MVA and will be sourced from CSPDCL Grid. Two DG sets of 1250 KVA each will be provided. 3.9 Generation and disposal of Wastes [Waste Water and Solid Wastes]: Waste Water Generation: Closed circuit water system envisaged in coal washery. The entire process waste water will be recycled in the washing circuit. There will not be any wastewater discharge out the plant premises. Sanitary wastewater will be treated through septic tanks followed soak pits Solid Waste Generation and its disposal: The washery will generate reject to the tune of 38TPH [2.25 Lakh Tonnes/year]. The rejects will be sold to nearby Power Generating units / interested clients. 26

28 4.0 SITE ANALYSIS 4.1 Infrastructure For establishment and successful operation of coal washing plant, it is imperative to ensure availability of the following infrastructure: o Availability of raw coal [500 TPH] and its proximity to the plant to reduce cost of transportation o Road / Rail head connection so that raw materials and products can be easily and economically transported o Availability of water o Permanent and reliable source of power o Adequate land for the plant, storage of raw coal and products and disposal of waste material Coal from SECL mines, namely, Gevra, Deepka & Kusmunda located within about 70 km, will be transported by road and rail. Uslapur railway siding is 6 km from the project site. The nearest Railway station is Ghutku about 1.3 km from the project site. Land identified for proposed plant is adequate. About 75% of the land is already under possession of the project proponent. 4.2 Connectivity District Headquarter Bilaspur, nearest township Uslapur and rail head at Ghutku are about 8 km, 6 km and 1.3 km respectively from the project site. The nearest Airport is at Raipur, 114 km by road from the project site. The National Highway 11 is 3.4 km from the project site. 4.3 Land details Adequate land is available for the proposed washery to meet the functional needs, green belt development, etc. 27

29 Sr. No. Particulars Area (in Acres) 1. Washery Plant Raw Coal Stockyard Clean coal, middling & Rejects Other facilities Office building, Internal roads, Weigh bridge, Water reservoir, Canteen, Labourer room, Maintenance shed, Stores etc Plantation Vacant land 1.85 Total Topography and drainage The topography of the site is fairly flat and requires minimum filling. No filling material from outside is envisaged for the plant construction. 4.5 Existing land use pattern, shortest distances from the periphery of the project to periphery of the forests, water bodies One coal crusher of 8 Lakh tonnes per annum capacity has been set up at the project site with prior approval of the Chhattisgarh Environment Conservation Board. The plant is yet to be made operational. The land use of the project site is industrial. The identified project site does not have water body. There are a few patches of single crop with the project site. Information on forests and water bodies falling within 10 km from the project site is given below: 4.6 Water Bodies The Arpa and Ghongha rivers are 2.5 km and 7.5 km respectively from the project site. 28

30 4.7 Forests No forest land involved in the study area There is no notified Sanctuary, National Park, Tiger reserve or Biosphere reserve within 15 km around the project site. 4.8 Infrastructure facility The plant site is well connected by road to the State and National highways. The nearest railway station is at Ghutku about 1.3 km of the project site. The railway good shed exists at Uslapur about 6 km. 4.9 Soil classification The soils in the area are generally of clayey loam types with sandy loam soil in some areas. The soils have been classified as Ustocherpts/ Ustorthents/ Rhodustalfs/ Haplustalfs/ Haplusterts, as per pedological taxonomy Climatic data from secondary sources. The climatic condition of this area is semi arid. The maximum temperature goes upto 48ºC during summer in the month of May and the minimum temperature goes down to 4.0ºC during winter in the month of January-February. The winds in the area are light to moderate during summer and winter. The rainfall of the district is mm to mm. Generally light to moderate winds prevails throughout the year. Winds were light and moderate particularly during the morning hours. While during the afternoon hours the winds were stronger. A review of the wind rose diagram shows that predominant winds are mostly from S, SW, NW, WNW, W, NE and N directions followed by NW direction. 5.0 PLANNING BRIEF 5.1 Planning Concept (type of industries, facilities transportation etc). Town and country planning/development authority classification: It is proposed to install a heavy media cyclone technology based coal washery at Village Ghutku, Takhatpur Tehsil, Bilaspur District, Chhattisgarh annual production capacity of 2.5 Million Tonnes. The plant site is well connected through the State and 29

31 National highways. The nearest railway station is at Ghutku about 1.3 km from the project site. 5.2 Population Projection: There are no major human settlements in the close vicinity of the project site. The manpower requirement will be sourced from the local areas to the extent possible; hence not much of settlement of outside people in the area. However population concentration may increase around the project site due to increase in ancillary activities. 5.3 Land use planning: It is proposed to establish coal beneficiation plant in an area of acres at Village Ghutku, Takhatpur Tehsil, Bilaspur District, Chhattisgarh. 30% of the project land will be used for plantation that is 7.31 acres. The tentative land use of the project area is given as below: Sr. No. Particulars Area (in Acres) 1. Washery Plant Raw Coal Stockyard Clean coal, middling & Rejects Other facilities Office building, Internal roads, Weigh bridge, Water reservoir, Canteen, Labourer room, 2.00 Maintenance shed, Stores etc. 5. Plantation Vacant land 1.85 Total Assessment of infrastructure demand (physical & social) Amenities / Facilities Routine maintenance of all equipment. Incidental minor repair / replacement of sub-assemblies and components of CHP equipment, coal washery equipment and accessories, water pumps and pumping installations. Day-to-day repair and maintenance of plant and machinery. 30

32 Inspection and scheduling of major repairs from outside agencies. Service Buildings Office building, sub-station, other buildings areas such as first aid centre, rest shelter, canteen etc. of appropriate size will be provided at the project site. Residential Buildings No residential accommodation is envisaged. Roads No new approach road is required. 6.0 PROPOSED INFRASTRUCTURE (i) Industrial area (processing area) acres of project land. The main plant area comprises coal handling area, storage area, crushing / sizing area, washing plant, internal roads, water reservoir etc. contributes approx. 70% of the total project area. (ii) Residential Area No accommodation / staff quarters envisaged at the project site. (iii) Green belt 7.31 acres of the project area earmarked for plantation development. (iv) Social infrastructure Facilities like canteen, rest room, first aid facility, recreation / indoor games will be provided. Social infrastructure will be developed in nearby villages in consultation with the Local Administration under the CSR activities. 31

33 (v) Connectivity The proposed site is well connected by road. State highway-8 (4.8, W) and National highway 11 (3.4 km E). There are two railway stations, namely, Ghutku at 1.3 Km NNW and Uslapur at 6 km from the project site. Raipur airport is 114 km. vi) Drinking Water Management (Source & Supply of water) The requirement of 4 m 3 / hour water for domestic purpose will be met from ground water source. (vii) Sewerage System Domestic sewage will be treated and disposed of through Septic Tanks & Soak Pits. (vii) Industrial Waste Management. a) Washery effluent Process waste water will be collected in slime ponds and circulated back in the washing circuit. Zero effluent discharge will be practiced. b) Domestic effluent Septic Tanks & Soak Pits will be provided. Sludge after digestion is used as manure. (viii) Solid Waste Management a. Rejects 38 TPH rejects generated will be supplied to the interested client(s). b. Municipal Waste 600 kg per month municipal waste will be generated, which after composting will be used as manure. 32

34 (ix) Power Requirement & Supply/Source Power requirement of 1.5 MVA will be met from the CSPGCL grid. Two standby DG sets of 1250 KVA will be provided. 7. REHABILITATION AND RESETTLEMENT (R & R) PLAN There is no R & R issue as there is no habitation in the project site. 8.0 PROJECT SCHEDULE & COST ESTIMATES The plant will be implemented in 18 months after receipt of environmental clearance and Consent from the Chhattisgarh Environment Conservation Board. Total project cost has been estimated as Rs. 24 Crores. Broad break-up of investment is given below: 1) Land : Rs. 200 Lakhs 2) Land Development : Rs lakhs Sr. No. Total : Rs. 250 Lakhs COST ESTIMATE - COAL WASHING PLANT Item Description Make Quantity Amount (Rs. in Lakhs) Total A. Know How A.1 Design Engineering & Commissioning L.S B. Building & Structural Civil Work including Structural Steel work Sub Total B C. Plant & Machinery Unbalance Motor Feeder, Over Band Magnetic Separator & Metal Detector, Rotary Breaker, Crusher, Dry Screen, Wet Screens, Desliming D&R Screen, Sieve Bend, Pumps (Slurry), H M Cyclone, Classifying Cyclone, Hi Rate Thickener, Horizontal Basket Centrifuge, Wet Drum Magnetic Separator, High Frequency Screen, Multi Roll Belt Press Filter, Air Compressor with drier, Dust Suppression system, Belt Conveyors, Travelling Tripper, EOT Crane with grab bucket, Rock Breaker. Miscellaneous Items like gate etc. including erection & commissioning. Sub Total C D. Misc. Fixed Assets

35 Sr. No. Item Description Make Quantity Amount (Rs. in Lakhs) Pipes & Pipe fitting, Valves, Tiles & tiling work, Electricals, Instrument & cable, Plant Lighting etc., Public Address system, Laboratory Eqpt. Sub Total D E. Substation and KVA DG Set F. Total A+B+C+D+E G. Contingency 5% Grand Total ** ** Excludes cost of land and land development 9. ANALYSIS OF PROPOSAL [RECOMMENDATIONS] POLLUTION CONTROL Design of washing plant will include measures to ensure effective compliance with environmental regulations. The following measures are proposed: Dust extraction / dry fog type dust suppression system to control dust from the material transfer points. Regular Water Sprinkling on roads Plant with close circuit water circulation system so that no effluent is discharged in the open outside the plant boundary. All the process effluent will be collected in the thickener. Settled slurry of the thickener will be dewatered in a multi roll belt press filter. The dewatered filter cake will be mixed with the middling. The clarified water from thickener overflow will be re-circulated to the plant for use as process water. Only make-up water requirement will be added in the clarified water tank. Since the plant will be designed with close circuit water system, no treatment of the process waste water will be needed. Emergency settling ponds, cascading type, will be constructed to take care of any unforeseen situation like pipe line jamming or break down of thickener. The clarified water from these ponds will be recycled as process water. These ponds will also be used for harvesting rain water, which will eventually reduce ground water abstraction. 34

36 Equipment like centrifuge, belt press filter, high frequency screen as well as thickener will be installed to maximize water recovery from the washing circuit. This will ensure water conservation. Plantation in 30% of the project area is envisaged. Financial and Social Benefits The project will improve the socio-economic status of the society in the region by generating direct and indirect employment opportunities. The project will contribute additional revenue to the State & Central exchequers in the form of taxes, cess, etc. The anticipated impacts of the project are explained below: Human settlement is expected to increase after this project gets operational. In the long term, the project will have impact on the population growth due to migration of people from outside area. Indirect employment opportunities will also add to this. The literacy level of the project area is likely to increase as there will be influx of many educated people taking up jobs in the project, which is likely to result in establishment of better educational facilities. The impact of the project on the civic amenities will be minimal. Various initiatives to be planned in the project area will result in improvement / up-gradation of civil amenities. Health & Sanitation 1. Health camps offering free-check-up & medicines 2. Construction of toilet Drinking water Supply of tanker drinking water in nearby villages when scarcity arise 35