Pre Feasibility Report for Tiwarta Coal Washery Plant of M/sTiwarta Coal Beneficiation Ltd.

Transcription

1 1. PRE-FEASIBLITY REPORT Project : Tiwarta Coal Washery Plant Name of Company / Mine Owner : Tiwarta Coal Beneficiation. Ltd 1. Project : Coal Washery Project 2. Plant Capacity : 0.96 MTA 3. Plant Site Location : Village-Limha, Post-Beltara Tehsil-Bilaspur Distt.-Bilaspur, State-Chhattisgarh Pin Location (Sy Nos) : 74, 76, 38/1, 78, 47/1, 47/2, 49/1, 50, 52, 53, 54, 55, 56/1, 56/2, 56/3 K, 56/3 KHA, 56/4, 56/5, 57, 58, 59, 60, 61/3, 63, 62, 65, 66/1, 66/2, 67, 68, 69, 70/2, 71, 72, 77, 87, 37/2, 38/2, 42/1, 42/2, 44/1, 49/3, 73/1, 73/2, 75, 79, 51, 37/4, 37/8 Latitude : Between N to Longitude N : Between E to E 5. Correspondence Address : Shri Ashok Dhulyani Director M/s Tiwarta Coal Beneficiation. Ltd. Bus Stand, Pali Road, Village & Post Tiwarta Tehsil Katghora Distt. Korba (C.G.) ID : tiwartacoal@gmail.com 6. Approach to site (Air distance) a) Nearest Town b) Nearest Railway Station c) Nearest Airport d) Nearest Seaport : : : : Bilaspur Bilaspur (29.18 km) Raipur Airport (135 km) Viashakhapatnam 515 Kms. 7. Seismic zone : Zone II 8. Land Area for Plant : acres 9. Source of Water : Boreholes in the plant area 10. Coal Storage : One month stock at plant site 1

2 Say about 80,000 Tonnes. Raw Coal 40,000 Tonnes Washed Coal 32,000 Tonnes Reject coal 8,000 Tonnes 11. Mode of Coal Transportation : Raw Coal by Road From coal mines to plant Washed Coal by Road/Rail 12. Topography & Soil conditions : 309 Meters above seal level. CI soil bearing capacity 13. Water bodies : Sagri nala, 1.4 km NE Goknal nala, 8.4 km NE Ganjar nala, 5.9 km N Tati nala, 7.6 km NNW Kurung nadi, 7.9 km W Kurung tank, 4.5 km W Kurung left bank canal, 7.3 km W Kurung right bank canal, 8.6 km W Khalari reservoir, 13.3 km E 14. Forests : Bitkuli RF, 1.5km SE Chhinpani PF, 1.7 km NE Donganala PF, 2.6 km N Bhijwatkhar PF, 7.6 km NE Burbur PF, 6.1 km N Pali PF, 8.1 km NNE Kartala PF, 8.6 km NE Dhaurabhata PF, 11.6 km NE Shivpur PF, 10.8 km NW RF near Nangrahipara village, 3.1 km S 15. Total present day project cost : Crores 16. Project Commissioning Schedule : 12 months from getting permission for establishment 2

3 2) Introduction of the Project / Background Information (i) Identification of Project and Project Proponent M/s Tiwarta Coal is well known company in Korba Coalfields of SECL in the field of trading and transport of coal since last 20 years. Realizing the need for washed coal company now has decided to enter in the field of coal washing through Coal Washeries Name of the Project & Need for the Project Tiwata Coal Washery Project with a throughput capacity of 0.96 million tonnes / annum. The quality of available coal in our country is deteriorating day by day and to fulfill the stipulations of Government, there is no other option left but to go for coal washing project. To meet the consumer s requirement M/s Tiwarta Coal Beneficiation. Ltd. has decided to establish a Coal Washery Plant. (ii) Brief Description of the Nature of the Project. The proposed Coal Washery will incorporate the latest design and equipment s and will be based on Heavy Media Cyclone System 3

4 (iii) Employment Generation (Direct and Indirect) Due to Project. 1 Manager Production 1 No. 2 Engineer (Mech.& Process, Electrical & Instrumentation) 3 Nos. 3 Forman cum control room operator 4 Nos. 4 Fitter cum operator 4 Nos. 5 Helper 5 Nos. 6 Electrician 4 Nos. 7 Helper & Electrician 5 Nos. 8 Instrument mechanic 2 Nos. 9 Chemist 3 Nos. 10 Helper for Chemist 3 Nos. 11 Unskilled workers 36 Nos. Total 70 Nos. Unskilled workforce required for cleaning & other day to day jobs like magnetite charging etc. may be hired from contractor or engaged form nearby villages (12 heads per shift) 3) Project Description (i) Type of Project (including interlinked and interdependent project, if any) This is an independent coal washery project with no interlinked projects involved. (ii) Location (map showing general location, specific location and project boundary & project site specific layout) with coordinates. The washing plant is proposed is to be established at village Limha, Post Beltara, Tehsil Bilaspur, Distt. Bilaspur (C.G.) which is situated at about km air 4

5 distance from Bilaspur Railway Station on Mumbai Hawrah Line of SECR (air distance km). The site is located between N to N (Latitude) and between E to E (Longitude). Khasra No. / Plot No. / Block Range /Survey No/Gut No Survey No/Gut No : 74, 76, 38/1, 78, 47/1, 47/2, 49/1, 50, 52, 53, 54, 55, 56/1, 56/2, 56/3 K, 56/3 KHA, 56/4, 56/5, 57, 58, 59, 60, 61/3, 63, 62, 65, 66/1, 66/2, 67, 68, 69, 70/2, 71, 72, 77, 87, 37/2, 38/2, 42/1, 42/2, 44/1, 49/3, 73/1, 73/2, 75, 79, 51, 37/4, 37/8 Location Map of the Mine Lease Area is enclosed as Figure 1 (iii) Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. The coal from different mines of Area of SECL will be transported to washery by road. Adequate road infrastructures are available to cater this requirement of coal. About one month stock of raw coal; say 80,000 tonnes will be maintained over an area of 3.00 acres. The washed coal from this project will be transported to consumers by road. Some coal may be dispatched to Dadhapara Private Railway Siding for further dispatch by rail to the consumers. Sufficient infrastructures for dispatching of washed coal are available there. Company is envisaging possibility of construction of a own private Railway Siding near Kargi road or Kalmitad Railway Station in Bilaspur Katni Section of SECR Railway. When materialized the washed coal will be transported to consumers of Rajsthan & Punjab by Rail. (iv) Size or Magnitude of operation. The maximum rated capacity of the project will be 0.96 million TPA 5

6 (v)project Description with Process details (a schematic diagram/ Flow chart showing the project layout, components of the project etc. should be given. Selection Of Technology Factors effecting the selection of technology The washability characteristics and fractional analysis of crushed coal determines the quality of end product. Typical Screen analysis & washing investigations of some coal samples of Dipka Open Cost Mine of SECL are shown in Appendix-2/a,b,c,d, which is helped as guidelines for deciding washing technology. Quality required by the customers: The requirement from the customers forms the basis of technology selection. The quality requirement of coal by Power Houses is: 32% ash and for cement and sponge iron is about 28%. Therefore, the design of the washery incorporates flexibility so that the end product meets the requirement of the customers. The washability characteristics and fractional analysis of coal determine the quality of coal. Selection of Technology Some of the most commonly known technologies / Systems/ Practices for coal washing are as under- Heavy Media Cyclone System Heavy Media Bath System Barrel System Wet Jig System Dry Jig System 6

7 Considering the screen analysis, washing characteristics of available coal and customer requirement, the company has decided to go for adopting most modern and efficient washing technology with Heavy Media Cyclone System. Process Details The proposed Coal Washery will incorporate the latest design and equipments and will be based on Heavy Media Cyclone System The process will be as given below:- 1. ROM Coal (0-400mm) will be received on Grizzly having 300x300mm aperture on Ground Hopper-I through trippers. 2. The stone of +300mm size will be picked manually from over the Grizzly and thrown away. 3. The coal lumps of +300mm size, if any, will be broken manually to pass through Grizzly. 4. This ROM Coal will be delivered to Ground Hopper through the said grizzly and delivered further to a Belt Conveyor through a Vibrating Feeder below the Hopper. 5. Stone prices will be picked out manually at picking station situated on the sides of the Belt Conveyor to the extent possible. 6. This ROM Coal will be further delivered to Rotary Breaker of 200 TPH through transfer point which will yield -50mm size coal. 7. Rotary Breaker rejects will be received by a Conveyor and carried to Rotary Breaker Reject Dumps. 7

8 8. 0 to -50mm size coal will be carried to Screen House through Belt Conveyor. 9. This coal may be delivered to 10 mm Screen to -10mm size Coal Fines will be carried to Coal Fine Dumps through a Belt Conveyor mm to -50mm size coal will be carried through a Belt Conveyor to Surge Bunker. 12. Coal from Surge Bunker will be carried to Sieve Bend and disclaiming Screen at washery Building where dust (fines) coal particles will be washed by spray of water received from Magnetic Separator and fresh water reservoir. 13. This coal without fine coal dust will be delivered to Heavy Media Tank having Heavy Media of required specific gravity (mixture of Magnetite and water). 14. The Fine Coal Slurry from the Sieve Bend and disclaiming Screen will be carried to a Fine Coal Slurry Tank. 15. A mixture of Heavy Media & Coal will be pumped from Heavy Media Tank to Heavy Media Cyclone. 16. The overflow of Heavy Media Cyclone (clean coal) will be delivered to a set-of Sieve Bend and D&R Screen and further delivered to the Clean Coal Conveyor. This product is carried to a clean coal loadout bin which has Clamshell gate at the discharge for loading coal onto trucks directly. 8

9 17. The underflow of Heavy Media Cyclone (reject coal) will be delivered to another set-of Sieve Bend and D&R Screen and further delivered to reject coal conveyor. This product is carried to loadout bin which has Clamshell gate at the discharge for loading this reject coal into trucks directly for disposal. 18. In the first section of both the D&R Screens (drain sections) the water and magnetite slurry is drained partially. This drained Magnetic Slurry flows back to the heavy media sump. 19. In the second section of the D&R screens (rinse sections) water jets are used to wash the magnetite sticking to the body of clean/reject coal. The rinse water being of a lower specific gravity has to be processed through a Wet Drum Magnetic Separator (5000LPM of Magnetic Slurry) where magnetite from the rinse water is concentrated and sent back to the Heavy Media Sump (25CU.M) for make-up. 20. The trailing (mostly water with fine coal dust) from Wet Magnetic Separator is directed to mix with fresh water supply and is spread over from feed coal received from surge bunker over sieve bend dislimming screen. 21. After removing fine coal dust from body of (+10-50) mm coal the fine coal slurry (affluent) is collected in fine coal slurry tank. 22. The fine coal slurry from fine coal slurry tank is pumped to Hydro Classifying cyclone. 23. The underflow of Hydro Classifying cyclone containing fine solid particles of coal dust are directed to High Frequency Screen. 9

10 24. The solid fine coal from top of High Frequency Screen is directed to clean coal belt to get mixed with clean coal. 25. The rinse water of High Frequency Screen is directed to fine coal slurry tank. 26. The overflow of Hydro Classifying cyclone having very fine coal dust is directed to affluent treatment plant. 27. The effluent treatment plant consists of one Hi-Rate Thickener and its associated with Flocculent Dosing System, underflow sludge carrying pump and a Multiroll Belt Press or settling tank (optional) 28. The effluent from the plant which reports to the hi-rate thickener is collected in the thickener tank. This tank is dosed with suitable amounts of flocculent which aids faster suspension of solids and helps to give a clearer overflow. 29. The settled solids are collected at the bottom cone of the thickener tank by rotating rake arms the height of which can be adjusted if the amount of solids in the effluents varies. The solids which are collected in the bottom of the thickener flows to the settling pond/settling tank for reclamation of water. The dewatered solid are blended with the reject coal. 30. The overflow of the thickener which is clear water is pumped back for recirculation to the plant. 31. The proposed plant is a zero effluent plant and the process selected ensures minimum generation of dust. The washing process flow sheet is shown as Figure 5 10

11 Equipment Details S.NO DESCRIPTION CAP. MAKE QTY UNIT 1 Structural Steel 530 MT 2 Rotary Breaker 200 TPH ESFCPL 1 SET 3 Electro Mechanical Vibrating Feeder 400 TPH ELECTRO MAG 2 SET 4 Vibrating Screen 400 TPH METSO 1 SET 5 Gear Box s --- ELECON 11 SET 6 Motor s --- KIRLOSKER 1 LOT 7 Conveyor Belt --- EURECA/HINDUSTAN 1,000 MTR 8 Conveying EquipmentS --- BAJRANG/SIML 1 LOT 9 Electrical Panel & PLC --- SS ELECTR. 1 SET 10 Electrical Cables --- V' GUARD /POLY CAB 1 SET 11 Electrical Instrument & Lighting --- CG / BAJAJ 1 SET 12 Electrical Accessories --- LOCAL NETWORK 1 LOT 13 Transformer 1000 KVA BILASPUR TRANS. 1 SET 14 Foundation Bolts --- ESFCPL 1 LOT Miscellaneous Item ( Like, Nut, Bolt, Packing, Gasket, Paint, Grease, Oil, Etc. ) LOCAL NETWORK 1 LOT 16 Colour Coated Sheet --- TATA/JINDAL 1 LOT 17 Coupling, Bearing, Plummer Block --- SKF/ELECON/SKI 1 LOT 18 Bag Filter 20,000M3 SOIL INVIRO 1 SET 19 Lab Equipments --- LOCAL NETWORK 1 LOT 20 Floor Sump Pump --- METSO 2 Nos 21 Disliming Screen 200 TPH HUMBOLDT/IC 1 No. 22 Heavy Media Pump ( SIZE-10"X8" ) 500 M3 WARMAN / METSO 1 No. 23 FIXED SEAVE Nos. 24 High Frequency Screen 8 TPH HUMBOLDT/IC 1 No. 25 Thickner ( SIZE - Ø 14 Mtr.) --- IMT 1 No. 26 Thickner Under Flow Pump ( WARMAN / METSO --- SIZE-4"X3" ) 2 No. 27 Floculent Dosing System ( SIZE- METSO "X2") 1 No. 28 Hydro Classifying Cyclone ( SIZE- Ø ) 3 Nos. 11

12 S.NO DESCRIPTION CAP. MAKE QTY UNIT 29 Fine Coal Pump ( SIZE - 8"X6") --- WARMAN / METSO 1 Nos. 30 Weight Drum Magnetic Separator --- ELECTRO MAG 1 Nos. 31 Dilute Media Pump ( SIZE-8"X6") --- WARMAN / METSO 1 Nos. 32 Thickner Over Flow Pump ( SIZE- WARMAN / METSO --- 8"X6") 1 Nos. 33 Screw Air Compressor 108 CFM ATLAS COPCO 1 Nos. 34 Heavy Media Cyclone 200 TPH MULTOTEC/MURGAPPA 1 Nos. 35 Clean Coal De-Watering Screen 160 TPH HUMBOLDT/IC 1 Nos. 36 Reject Coal De-Watering Screen 80 TPH HUMBOLDT/IC 1 Nos. 37 Fresh Water Pump ( SIZE- 2.5"X2") --- WARMAN / KIRLOSKER 1 Nos. 38 High Pressure Pump ( SIZE- WARMAN / KIRLOSKER 7kg/cm2 1.25"X2") 1 Nos. 39 Setteling Pond Return pump ( SIZE WARMAN /METSO "X3") 1 Nos. 40 Pipe Line & Accessories ( Schedule- MAHARASHTRA S LTD ) 1 LOT 41 Manual & Automatic Valves --- KIRLOSKER / BDK 1 LOT 42 Water Sprinkling System LOT 43 Heavy Media Sump 25 KL ESFCPL 1 No. 44 Dilute Media Sump 15 KL ESFCPL 1 No. 45 Fine Coal Sump 15 KL ESFCPL 1 No. (vi) Availability of water, its source, Water Requirement Considering 300 working days in a year, for a capacity of 0.96 million tones/annum, about 3200 tonnes of raw coal per day will be utilised, out of which about 40% (5% eradication through manual picking and rotary breaker and 35% as 10 mm coal fines) i.e tones will be directly disposed off. Remaining 60% i.e tones/day of coal will be washed. Considering requirement water of 0.15 Cum/tones water for washing total requirement of water will be (1920 x 0.15) KLPD = 288 KLPD. About 60 KLPD water will be required for spraying and domestic use so total requirement of water will be KLPD i.e. say 350 KLD 12

13 Thickened slurry shall pass through Belt Press to produce cakes, which shall be dispatched as clean coal. Processed water shall be clarified through thickener and cyclones. Clarified processed water will be recycled & reused. The whole project is being planned for Zero Discharge System. It means that the Coal Washery Plant water will be supplied from the underground boreholes with submersible pumps and waste water will be clarified, recycled and reused. No waste water will be discharged out side. Infrastructure Requirement 0.96 MTPA Coal Washery is proposed to be constructed at Village Limha, Distt. Bilaspur (C.G.) where acres of land is already in possession for the purpose. The proposed layout of the washery is shown in Figure 2 (viii) Quantity of wastes to be generated (liquid and solid) and scheme for their management / disposal. Waste Water Management The plant will be designed to have process with No effluent discharge. Effective system of water management would be made operative with use of modern equipment like Thickeners, Cyclone, High Frequency screen and belt press filters. These will ensure total separation of coal fines from water and the same water can be recycled for re-use. Domestic waste water from office toilets etc. shall be disposed in soak pits through septic tank Solid Waste Management The reject coal of the washery would be disposed off in the market to interested consumers. 13

14 4) Site Analysis (i) Connectivity Nearest Railway Station Nearest Airport Bilaspur (29.18 km) Raipur Airport (135 km) (ii) Land Form, Land use and Land Ownership Land Form & ownership: The proposed plant area is private waste land Land Utilization Pattern Total requirement of land for the project is about acres including green belt development and provision for essential staff accommodation. 31% of the project area is for raising, plantation including peripheral green belt development and internal road side plantation using native plant species in consultation with the local Forest Officials. A tentative breakup of land is given below: Area in Acres S.No. Particulars Area (in acres) % 1. Washery Plant Raw Coal Stock Yard 3. Clean Coal, Middling & Rejects Other Facilities (Internal Roads, WTP, Staff Quarters etc.) Plantation Area Vacant Land Total % 14

15 (iii) Topography along with maps Topography of Mine Lease Area The applied area is waste land. The terrain is sloping towards south. No human settlement within the applied area. The elevation of the project area is 309m AMSL with CI Soil bearing Capacity The drainage pattern of the buffer zone is dendritic to sub dendritic in nature. No perennial nallahs or streams are seen within the proposed project area. The area is covered by local shrubs, and bushes. The area experience humid tropical climate and receives an average rainfall of 877 mm with maximum rainfall of 1429mm The study area map, google map are provided as Figure 3 & 4 (iv)existing infrastructure Roads: The project area is approachable by road from Bilaspur Railway: Bilaspur Railway Station. 29 km Airport: Raipur Airport 135 km Seaport: Visakhapatnam 515 km (v) Social Activities Employment to about 70 person s directly Transportation and Communication facilities Education facilities Medical facilities and Health check-up camps for the public at least once in six months Recreation facilities Business establishments Community facilities 15

16 Maintenance of the village roads Drinking water facility through bore wells 5) Proposed Plantation & Infrastructure Development (i) Afforestation Program 34% of the Total Plant area will be covered under plantation program (ii) Social Infrastructure Road facility Loading facilities Staff accommodation Automobile workshop Increase in mining equipment s Addition of new staff (iii) Solid Waste Management The reject coal of the washery would be disposed off in the market to interested consumers. Topsoil Management There is no topsoil generation. However, if any topsoil is generated during Construction phase the same will be utilized for green belt program. 6) Rehabilitation and Resettlement (R & R) Plan There is no resettlement or rehabilitation involved in this project. 16

17 7) Plant Operations & Maintenance The plant would be operated 16 hours a day and 8 hours would be used for maintenance. Adequate inventory of spares would be maintained to cut down on the down time of equipment 8) Project Cost Estimates: Rs lakhs : S.NO DESCRIPTION QTY AMOUNT (in Lacs) 1 Land L.S Plant & Machineries L.S Foundation & Civil works L.S Fabrication & Erection work L.S Pollution Control & Safety L.S Vehicles L.S Misc & Contingencies L.S Total TRAINING While the plant is under construction a nucleus team of operative and maintenance person would be given On-the-job in the neighboring plants of the company. Assistance would also be taken from various equipment manufacturers to impart specific equipment training at site. 10. QUALITY ASPECT DURING CONSTRUCTION A special team would be in position to ensure that all civil and structural works are carried out as per approved ISO codes of practice for different activities. 17

18 11. COMPLETE SCHEDULE The various activities with their start and completion schedules would be rigorously monitored to ensure final completion of the project within the timeframe of six months. 18