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[1]
PRE-FEASIBILITY REPORT
COAL WASHERY PROJECT
AT
BHENGARI VILLAGE,
TEHSIL GHARGHORA, DISTRICT RAIGARD,
CHHATTISHGARH
MAHAVIR COAL WASHERIES PVT. LTD.
MARCH – 2015
[2]
CONTENTS
Sr.No. Title Page no.
1 EXECUTIVE SUMMARY
3
2 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION
4
3 PROJECT DESCRIPTION
10
4 SITE ANALYSIS
27
5 PLANNING BRIEF
36
6 PROPOSED INFRASTRUCTURE
38
7 REHABILITATION AND RESETTLEMENT (R & R) PLAN
41
8 PROJECT SCHEDULE & COST ESTIMATES
41
9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
44
Annexure – I : Process Flow Sheet
Annexure - II : Water Balance
Annexure – III : Typical ETP flow Diagram
Annexure-IV : Plant Layout
Annexure – V : TOR Dated 09.02.2012 Annexure-VI : TOR Dated 27.04.2012 Annexure-VII : TOR Dated 16.12.2013
[3]
1. EXECUTIVE SUMMARY
S .No Description Details
1. Name of the Project Coal Washery 2. Location of the Plant Village Bhengari, Tehsil
Gharghora, Distt. Raigarh, Chhattisgarh
3. Coal Washery Capacity 5 Million TPA [Throughput] Two identical modules of 2.5 MTPA in two phases
4. Total land requirement for the project
43.18 Acres (17.48 ha.)
5. Washing Technology Heavy Media Cyclone 6. Total Water requirement & Source
Process Plantation, dust suppression etc. Domestic
Ground Water 44 m3 / hour 12 m3 / hour 3 m3 / hour
7. Total Power requirement & Source 5 MVA - Chhattisgarh State Electricity Board
8. Working hours 3 shifts daily of 8 hr each [Effective 18 hrs a day] 330 days a year
9. Rehabilitation and Resettlement No R & R issue is involved.
10. Manpower [Operation] 70 persons
11. Estimated Cost of the Project Rs. 56.78 crores
[4]
2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of project and project proponent
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 & Forests (MoEF)
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. 01.06.2001. As a result, demand for
beneficiated coal has increased substantially. MoEF vide its Notification no.
02(E) dated 02.01.2014 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 750 – 1000 km from the pit-head,
with effect from the 1st day of January, 2015; and (c) 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 500-749 km from
the pit-head, with effect from the 5th day of June, 2016. These new
[5]
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 further increase
significantly.
M/S. Mahavir Coal Washeries Pvt. Ltd. (MCWPL), a subsidiary company of
Mahavir Group, intends to set up a 5 MTPA coal washery based on Heavy
Media Cyclone process at Bhengari Village, Tehsil Gharghora, Distt.
Raigarh (C.G). The washery will produce washed coal of an average ash
around 34% (GCV 4500 Kcal / kg.), middling (ash content about 58%) of
GCV around 2400 Kcal / Kg useable as fuel in FBC boilers. In the washing
process, waste in the form of rejects (ash content about 86.5%) will also
be generated.
The proposed coal washery will be the State-of-the-art with close circuit
water system; classifying cyclone, high frequency screens, thickener and
multi roll belt press filters. Modular concept of designing is envisaged. Two
identical modules of 2.5 MTPA capacity will be established.
The then Ministry of Environment & Forests granted TOR for the coal
washery proposed at village Bhengari, Gharghora Tehsil, Raigarh District,
Chhattisgarh vide letter no. J-11015/117/2011-IA.(M) dated 9th
February, 2012. Subsequently, two Modifications of TOR were issued on
27/04/12 and 16/12/13 permitting coal transportation over a period not
more than 5 years or till the railway siding comes up, whichever is
earlier. MCWPL submitted a proposal in November, 2014 to the Ministry
for extension of TOR validity by one year. The Ministry has advised
MCWPL to apply for fresh TOR.
(ii) Brief description of nature of the project
Need for the Project
The coal India Limited and its subsidiaries are the major domestic
[6]
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%.
The Working Group on Coal & Lignite for XI Plan had assessed that in the
terminal year 2011-12 of XI Plan, about 96% of total coal production of
the country would be non-coking 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 2012-2017 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 95.96 Mty are in
operation in the country. CIL operates 5 non - coking coal washery with a
total throughput capacity of 17.22 Mty and others operate 27 non-coking
coal washeries with a total throughput capacity of 78.74 Mty.
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
17.22 Mty and 12 coking coal washeries with 22.18 Mty. Contracts have
been finalized for three more washeries. Further, 12 more washeries have
been identified by CIL to be taken up during the XIIth Five Year Plan.
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.
The wide gap assessed between the projected requirement of beneficiated
non-coking coal and the existing total capacity, clearly indicates that there
[7]
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 40-50 Mt capacity addition may have to be considered in
subsequent phase.
As the major availability of coal during the XII Plan is expected from the
Karanpura, Korba, Mand – Raigarh, & Ib Valley coalfields, MCWPL’s
proposal for setting up a 5 MTPA washery in Raigarh Distt. is justified. The
decision to establish a washery is based on projections made by the
Working Groups on Power and Coal & Lignite for XII Plan. Coal washing is
an important area both from economic and environment points of view.
Raw coal of around 50% ash will be washed in the proposed coal washing
plant to produce washed coal having around 34% 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 washing plant of 5.00 Million TPA of raw coal
throughput will have the following parameters:
Capacity : 1000 TPH No. of operating days in a year : 330 days No. of operating hours in a day : 18 hours three shift operation including daily short maintenance and start stop Plant utilization : 85% Annual throughput : 1000 X 18 X 330 X 0.85 = 5049000 tonnes Say 5.00 million tonnes
[8]
As already mentioned, the project will be established in two phase having
the following input & outputs.
Raw Coal - Ash - 50%, Moisture 5.5%, GCV 3000 K cal /
Kg, FC 26%, VM 24%. Washed Coal - Ash - 34%, Moist 12%, FC - 36%, VM 28%, Yield 44% GCV - 4500 K cal / Kg. Middling - Ash - 58%, Moist – 8.5%, FC 22%, VM 20%,
Yield 47% , GCV - 2400 K cal / Kg. Rejects - Ash - 86.5%, Yield 9% (No useful heat value) All the yield figures indicated are tentative and are meant for estimation
purposes only. Actual yield figures vis-à-vis product qualities can be
predicted only after full scale washability data are available.
(iii) Demand-Supply Gap
It is projected that by 2015, coal requirement for power generation alone
will be 810 MTPA. The requirement of beneficiated coal will be much more
than projected 361 MTPA as a standalone TPP (of any capacity), or a
captive TPP of installed capacity 100MW or above, located between 750
km – 1000 km from the pit head, would also require to use beneficiated
coal from 01.01.2015. Presently, established capacity in India is around
100 MTPA.
(iv) Imports vs Indigenous production
Raw coal will be obtained from SECL mines on behalf of the clients. Cost-
wise indigenous production is much cheaper than the imported equivalent
quality coal.
(iv) Export Possibility
No coal will be exported.
(v) Domestic / export Markets
[9]
Capacity of coal washeries established in India is potentially in adequate to
meet the domestic requirement of beneficiated coal at present.
(vi) Employment Generation (Direct & Indirect) due to the Project
During construction period of the project requirement of man power will be
about 200. In the operation phase, 70 persons will get direct employment
in various services. About 250 persons will get indirect employment.
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:
S. No. Position Number 1. Manager Production 1 2. Engineer (Mech. & Process, Electrical &
Instrumentation) 4
3. Foreman cum control room operator 8 4. Fitter cum Operator 10 5. Helper 10 6. Electrician 8 7. Helper for Electrician 8 8. Instrument mechanic 4 9. Chemist 4 10. Helper for chemist 4 11. Office and Weighbridge staff 5 12. Horticulturist 1 13. Watchman 3
TOTAL 70
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.
[10]
1. PROJECT DESCRIPTION
(i) Type of project including interlinked and interdependent
projects, if any.
2 x 2.5 MTPA coal washery is envisaged.
(ii) Location
The washery is proposed at village Bhengari, Gharghora Tehsil, Raigarh
District, Chhattisgarh over an area of 43.18 acres. The project will span
between Latitude 22°08’05.7” - 22°08’19.4” North and Longitude
83°14’21.2” - 83°14’49.4” East. The entire project area falls in Survey of
India (SoI) Toposheet No. 64 N/4 & N/8.
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.
(iii) Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted.
The then Ministry of Environment & Forests granted TOR for the coal
washery proposed at village Bhengari, Gharghora Tehsil, Raigarh District,
Chhattisgarh vide letter no. J-11015/117/2011-IA.(M) dated 9th February,
2012. Subsequently, two Modifications of TOR were issued on 27/04/12
and 16/12/13. All these letters are at Annexure VI, VII & VIII. MCWPL
submitted a proposal in November, 2014 to the Ministry for extension of
TOR validity by one year. The Ministry has advised MCWPL to apply for
fresh TOR.
[11]
FIGURE-1 INDEX MAP SHOWING THE PROJECT SITE
[12]
FIGURE-2
MAP OF THE AREA 10 KM AROUND THE PROJECT SITE
[13]
(iv) Size or magnitude of operation.
5 [2 X 2.5] MTPA (1000TPH Throughput) coal washery.
(v) Project description with process details
The entire raw coal for beneficiation will be brought by road in tarpaulin
covered rear dump trucks of 35 tonnes capacity from the SECL mines
located within 50 km from the project site. Coal purchased by MCWPL
through e-auction will also be subjected to beneficiation.
Modular concept of designing the washery is envisaged. Two identical
modules of 2.5 MTPA each will be installed. The project will be
implemented in two phases. Washed coal will be produced at 34% ash
level (on air dry basis) and it will be transported to the concerned clients
by road over a period of 5 years or till railway siding comes up whichever
is earlier. Washing technology selected matches with the raw coal
characteristics and care has been taken to produce least rejects.
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 Raigarh region. It was found that in
average raw coal, ash content varies from 45% to 50%.
Technology & Process
Scope of The Project
The scope of the project is to establish a coal beneficiation facility with
associated mechanical facilities for sizing of raw coal to ensure supply of
washed coal to suit the requirement of sponge iron kiln and also middling
coal to suit the requirement of FBC power plant.
[14]
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
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 fluidised
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.
[15]
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 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.
[16]
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 1.60.
The process misplacement is very high.
High EP(Ecart Probable) around 0.14.
Difficulties in maintaining good product quality.
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.
[17]
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 (1.30 – 1.90).
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 utilises 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 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:
[18]
Settling Velocity, S = ê [ S2/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 ( 1.30 – 1.90).
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.
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.
[19]
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 10 – 15 Difficult to wash 15 – 20 Very difficult HM Cyclone 20 – 25 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:
1) HM Cyclone : 0.025 to 0.035.
2) Jig : 0.10 to 0.12
3) Barrel : 0.09 to 0.10
The process misplacement which is depicted by the partition curve (Fig 8.3
attached) also shows minimum misplacement in case of HM Cyclone
process.
[20]
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
Complete process knowhow will be provided by M/s A. Mukherjee &
Associates, a company incorporated in 2003 with a totally futuristic
perception about the needs of the industry.
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 be provided
by M/s. A. Mukherjee & Associates. 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
Raw coal from mines will be transported to the washing plant by Rear Dump
Trucks. 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 / 20 mm.
The sized coal will be taken to a series of storage bunker
Washing Section
Sized raw coal, (-) 50 mm / 20 mm, from bunker will be transported to the
washing plant building through covered belt conveyors where the same will
[21]
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 slurryl. Coal slurry
collected from Desliming Sieve Bend and Screen under pan will gravitate
through pipes to a Fine Coal Sump.
Deslimed 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.
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.
[22]
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 process. The
discharge from Hi Frequency screen and belt press will be mixed with
middling for dispatch to the end users.
[23]
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.
The following drawings are attached:
1) Process Flow Diagram 2) Effluent Treatment Flow Diagram 3) Water Balance 4) A conceptual plant layout
Process Control Philosophy
Plant control will be achieved by a centralised PLC based control system
designed to enable one operator to start-up, monitor, control and shut down
all main equipment, and process functions from the feed input to the plant
through to product transfer conveyors. The PLC will have provision for hot
standby. An UPS with 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
[24]
flows will always be fail safe. Stop push buttons will be located adjacent to
each drive and will be operable at all times.
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 accurately controlled within the
wide range to maintain required quality of the washed products. The density
measurement will be done by a nucleonic density gauge. Indication and
recording of the density levels will be given in the control room computer.
The specific gravity control will be achieved automatically by respective
modulating splitter actuators.
(vi) Raw material required along with estimated quantity likely
source, marketing area of final products, mode of transport of raw
material and finished product.
On behalf of the clients, 1000 TPH coal will be brought to the proposed
washery site by road from the SECL mines. Coal will also be purchased for
beneficiation through e-auction. The washery will produce clean coal,
middling, fines and rejects. Clean coal and middling mixed with fines will be
transported to the end users by road using tarpaulin covered 35 tonnes
trucks. Rejects will be also be transported by road. The existing road network
[Chhal – Gharghora & Ambikapur – Raigard] is adequate. The nearest rail
head is Robertson, located about 16.8 km from the project site. Railway
siding is proposed for the project. The Ministry of Environment & Forests vide
TOR letter no. J-110015/117/2011-1A.II (M) dated 16.12.13 has allowed coal
transportation by road for a period not exceeding 5 years or till railway siding
comes up whichever is earlier.
(vii) Resource optimization / recycling and reuse envisaged in the project, if any, should be given.
[25]
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 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 for use as fuel for
the FBC power plant. 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 as
described above, no tailing dam will be required for treating the
process effluents / tailings. However, a set of cascading type
emergency settling pond 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 also be used as process water.
Expensive imported equipment like centrifuge, belt press filter, high
frequency screen as well as thickener will be installed to ensure close
circuit water system and also to minimise loss of water through
products, evaporation losses and conserve this precious natural
resource.
(vi) Availability of water its source, Energy / power
requirement and source should be given.
Water Supply & Sewerage
Water Supply arrangement for the proposed washery will basically cover
[26]
the industrial water demand of the washery, potable water demand for
the plant premises and water requirement for pollution control
arrangement. Washery has been planned to operate on closed water
circuit, therefore only make-up water requirement has been considered.
Requirement of water for pollution control arrangements will be primarily
for dust suppression, floor washing and plantation. In accordance with
the technology adopted, process and other features, the consumptive
water requirement of the washery for the above usage works out to be
about 59 m³ / hour. The plant will be provided with a RCC water reservoir
of around 1000 cu. m. storage capacity.
The entire water requirement of the project, both potable as well as
industrial, will be met from ground water through bore wells. Stage of
ground water development is 14.71%. The project area falls under “Safe
Category” on ground water resource considerations. Approval of CGWA is
awaited.
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 m3 / hour Remarks
Requirement Consumption / loss
Waste water generation
Process 44 44 - Close Circuit System
Domestic 3 1 2 Septic tank & soak pit
Dust suppression & plantation
12 12 -
Total 59 57 2 Zero Effluent
Power
The total connected load for the coal washing plant including crushing &
screening will be around 5 MVA. Specific power consumption for washing
including crushing & screening will be around 3.5 units per tonne of raw
[27]
coal throughput.
Power for the proposed Washery will be received through the State Grid.
The electrical equipment like Transformers, MCC distribution centers,
cables, lighting etc will be suitably selected as per requirements.
Proper earthing is envisaged as per the Indian Electrical rules and relevant
Indian standards.
Proper illumination of the plant, conveyor gantries, and transfer points
and general illumination etc is also envisaged. Proper PLC automation
system is envisaged for the automatic control of all the equipment
including instrumentation like level transmitters, flow meters, pressure
gauges, fire alarms system.
Standby DG Set of 125 KVA will be provided.
(vii) Quantity of wastes to be generated and scheme for their Management/disposal.
The washery will generate 90 TPH rejects. Possibility of using the rejects for
back filling the worked out pits in opencast mines will be explored with
SECL. Efforts will also be made to supply rejects to the brick kiln owners in
the region or any other user (s).
4. SITE ANALYSIS 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 [1000 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
[28]
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
There are many coal mines of SECL within 25 km from the proposed
project site. Adequate road network is already available between the plant
site and these mines. The nearest Rail Head is Robertson, which is about
16.8 Km from the proposed site. A new broad gauge line between Raigarh
(Mand Colliery) to Bhupdeopur railway station is being constructed
through a JV consisting of IRCON International Ltd., SECL & Govt. of
Chhattisgarh. A railway siding is proposed for the project.
Power supply can be easily met from the State grid at Gharghora.
Sufficient land for setting up of coal washing plant is available at the
proposed site.
(i) Connectivity
District Headquarter Raigarh, is located on National Highway NH# 200-
(Bilaspur to Jharsugua) and Gharghora is the nearest town at a distance
of 11.4 km on SH#1 in ESE from the project site. The nearest railhead is
Robertson about 16.8 km. from the project site. The nearest Airport is at
Raipur, 195 km south west from the proposed site. The proposed broad
gauge time between Mand Colliery and Bhupdeopur railway would improve
the connectivity further.
(ii) Land details
Land requirement of 43.18 acres for the project has been assessed
considering the functional needs, green belt development and essential
staff accommodation. The land is under physical possession of the sister
companies. Additional 10 acres will be required for the railway siding.
[29]
Initially, it is proposed to bring coal from the SECL mines to the proposed
site by road. Washed coal is also proposed to be evacuated for dispatch
by road to the concerned clients for a maximum period of 5 years or till
railway siding comes up whichever is earlier. Raw coal will also be
received by rail from the mines linked to the rail network once the
proposed railway siding comes up.
Tentative break-up of the project area is given below:
Sr. No.
Particulars Area (in Acres)
Percentage
1 Washery Plant 9.75 22.6 2 Raw Coal Stockyard 4.40 10.2 3 Clean coal, middling &
Rejects 2.00 4.6
4 Other Facilities Internal roads, WTP, Maintenance Shed, Office, Stores, Staff Quarters, etc.
7.50 17.4
5 Plantation Area 14.25 33 6 Vacant land 5.28 12.2
Total 43.18 100
(iii) Topography and drainage
The present land use of the site is mostly barren land. The topography of
the site is fairly flat and requires minimum filling. No filling material from
outside is envisaged for the plant construction.
The overall drainage pattern in the area 10 km around the project site is
dendritic. The surface drainage is controlled mainly by the southwestward
slope that ultimately discharges the sedimentary load into Kurket River.
The important rivers of the region are Mahanadi, Mand, Kelo, IB, Kanhar
and Geor.
(iv) Existing land use pattern, shortest distances from the periphery of the project to periphery of the forests, water bodies.
The entire project land is private. There is no water body in the project
[30]
area. Information on forests and water bodies falling within 10 km from
the proposed project site is given below:
Water bodies: There are three water bodies, namely, Kurket river, Mand
river and Rabo dam, falling within 10 km from the project site. The
nearest one is Kurket River, a tributary of Mand Rivers, at a distance of
about 3.6 km in ESE direction from the proposed site.
Forests:
There are around 6 major forest blocks which include Protected Forests (PF),
Reserved Forests (RF) and open mixed forest blocks within 15-km radius
from the project boundary. The forest blocks mainly consist of Salai, Tendu,
Mahua, Bija, Saja, Char Ganja, Dhauwra, Harra and Dhobin. The nearest
forest is Suhai RF about 1.3 km south of the site.
There are no sanctuaries, biosphere reserves or national parks, tiger or
elephant reserves within 10 km radius from the proposed plant boundary.
The land use pattern within 10 km radius based on IRS-P6 Geo-Coded
FCC of LISS-III [5th January, 2013] is given in Table- 1.
TABLE – 1 : LANDUSE BREAKUP BASED ON IRS-P6 DATA
Sr. No. Land Use Area (ha) Percentage (%) Built up Land
1 Settlements 655 1.91 2 Industry/Institutional Area 73 0.21
Forest 3 Degraded/Reserve/Protected Forest 11117 32.35 4 Dense/Mixed Jungle 5079 14.78
Agricultural land 5 Plantation 41 0.12 6 Agriculture Land 7342 21.37
Waste Land 8 Land with Scrub 5510 16.04 9 Land without Scrub 3390 9.86 10 Rocky/Stony Barren Land 51 0.15
Water Body 11 Stream/River/Tank/Reservoir 1102 3.21
Total 34360 100.00 Source: IRS-RS2 LISS3 data, 5th January 2013
[31]
FIGURE -3 THEMATIC MAP OF STUDY AREA (IRS-P6: : LISS3)
[32]
(v) Infrastructure facility
The proposed plant site is well connected through State Highway and
National Highway. The nearest railway is Robertson Railway station, which
is at 16.8 km.
The surroundings of the proposed site are relatively poor in infrastructure
such as post-offices, telephones, schools, public health centres etc.
The Cabinet Committee on Economic Affairs on 7th February, 2013
approved construction of a new broad gauge line between Raigarh (Mand
Colliery) to Bhupdeopur Railway Station of length of 63 km at a cost of
Rs.379.08 crore to be funded through a Joint Venture (JV) consisting of
IRCON International Ltd. (a Railway PSU) and other stakeholders - M/s.
South Eastern Coalfields Ltd.(SECL) and Government of Chhattisgarh.
IRCON will spearhead the process of formation of a Special Purpose
Vehicle (SPV) with 26 percent equity and the Government of Chhattisgarh
will transfer Government land free of cost. The Government of
Chhattisgarh will thus participate to the level of 10 percent in equity,
either through capitalization of land or through cash contribution, and
SECL will take the balance equity. The project is likely to be completed in
the next five years during the 13th Plan period.
Presently, the survey work and marking of railway corridor is under
progress. MCWPL has planned to establish railway siding for the proposed
washery linking the project site to the main railway network.
(vi) Soil classification
The soil is predominantly sandy loam followed by weathered material and
bed rock. (vii) Climatic data from secondary source
Environmental baseline data monitoring for the proposed project was
carried out by M/s Vimta Labs. Ltd. Hyderabad during December, 2011 –
February, 2012 as per TOR granted by the Ministry of Environment &
[33]
Forests vide letter no. J-11015/117/2011-IA.II (M) dated 09/02/2012
(Annexure-VI). Details are summarized below:
Meteorological Data
The average annual rainfall based on the IMD (Raigarh) data is 1572 mm.
The southwest monsoon generally sets in during the first week of June.
About 75% of the rainfall is received during the southwest monsoon. The
rainfall gradually decreases after September. The maximum number of
rainy days is observed in the month of August.
The air is generally dry in the region especially during Pre-monsoon when
the average relative humidity is observed around 20% to 41%.
Generally, light to moderate winds prevail throughout the year.
TABLE – 2 : CLIMATOLOGICAL DATA - IMD STATION RAIGARH
Month
Atmospheric Pressure (mb)
Temperature (0C)
Relative Humidity (%) Rainfall
(mm) 8:30 hr 17:30 hr Max Min 8:30 hr
17:30 hr
January 991.6 987.6 28.3 13.2 61 40 11.2 February 989.6 985.5 31.6 16.0 53 30 15.7 March 987.3 982.7 36.0 20.4 41 23 22.4 April 983.9 978.7 40.3 25.1 38 20 13.8 May 979.5 974.4 42.6 28.0 40 21 17.5 June 976.2 972.2 38.0 27.1 63 50 199.0 July 976.2 973.2 31.6 24.7 85 76 453.8 August 977.2 974.2 31.1 24.7 86 78 494.5 September 980.8 977.3 32.2 24.5 81 73 287.2
October 986.4 982.8 32.4 22.0 71 59 49.1 November 990.4 986.7 30.3 17.1 61 47 3.7
December
992.2 988.3 28.2 13.3 62 44 4.1
Total Rainfall 1572
SUMMARY OF THE METEOROLOGICAL DATA MONITORED AT SITE
Month Temperature (0C) Relative Humidity (%) Rainfall (mm) Max Min Max Min
December-2011 29.9 13.2 60.3 42.5 Nil January-2012 29.1 13.8 62.2 41.2 Nil February-2012 34.6 16.1 57.5 31.4 Nil
[34]
Ambient Air Quality
PM10, PM2.5, SO2, NOX and CO concentrations were observed in the
range of 30.8 – 69.1 g/m3, 8.8 – 18.5 g/m3, 6.6 – 12.9 g/m3, 7.4 –
14.3 g/m3 and 230 – 381 g/m3 respectively. All the parameters are
within the prescribed NAAQ standards. Summary of ambient air quality
monitored during December, 2011 – February, 2012 is below
TABLE – 3 : AMBIENT AIR QUALITY
(in g/m3) Name of Station PM10 PM2.5 SO2 NOX
Min. Max. Min. Max. Min. Max. Min. Max. Bhengari village 30.8 50.2 8.9 15.3 6.6 10.0 7.4 11.2 Dongabana village 38.4 56.1 10.2 16.2 6.8 11.4 8.3 12.4 Danganinara village 37.7 56.9 9.9 16.6 7.1 11.2 8.6 12.6 Tenda village 40.0 65.8 8.8 16.2 7.6 11.3 8.4 13.1 Katangdi village 37.9 62.1 9.6 16.9 6.8 10.4 8.2 12.8 Beharamura village 41.6 69.1 10.3 18.5 8.2 12.9 9.2 14.3 Talaipara village 35.8 59.2 10.1 17.2 6.6 10.8 8.0 12.6 Charratnagar village 37.6 52.1 9.8 16.9 6.8 10.9 7.9 11.8 Range 30.8-69.1 8.8 – 18.5 6.6 – 12.9 7.4 – 14.3 NAAQ Standards 100 60 80 80
Water Quality
Ground Water Quality
pH and conductivity of the ground waters were found in the range of 6.5 –
7.4 and 186 - 720 S/cm. The TDS were found to be well within the limits
ranging between 130 – 420 mg/l. Hardness of ground water was in the
range of 73 – 262 mg/l. Fluorides are in the range of < 0.1 mg/l.
Chlorides and Sulphates were observed in the range of 14 – 65 mg/l and
1.6 to 12 mg/l. Heavy Metal concentrations are below the limits. Water
quality conforms to the standards.
Surface Water Quality
pH and TDS were found in the range of ranges from 6.9 – 7.0 and 132 -
176 mg/l. The DO values were observed ranging from 5.9 – 6.0 mg/l.
[35]
Chlorides, Sulphates and Nitrates were observed in the range of 18 – 26
mg/l, 5.0 – 5.2mg/l and 2.8 to 3.6 mg/l. Heavy Metal concentrations are
below the limits. Water quality conforms to the standards.
Noise Levels
TABLE – 4 : AMBIENT NOISE LEVELS IN dB(A)
Location L10 L50 L90 Leq Lday Lnight Ldn
Bhengari village 49.2 45.7 41.9 46.6 47.4 43.7 50.9 Dongabana village
50.0 45.5 42.1 46.5 48.5 43.6 51.1
Danganinara village
48.5 44.6 40.9 45.6 46.4 42.8 49.9
Tenda village 49.5 45.7 41.9 46.7 47.9 44.0 51.2 Katangdi village 48.9 44.7 40.8 45.8 46.8 42.4 49.8 Kataipali village 50.4 46.6 42.8 47.6 49.2 44.9 52.2 Talaipara village 48.7 43.9 40.3 45.1 47.2 41.4 49.3 Suhai village 49.1 45.2 41.3 46.2 47.1 42.5 49.9
a) Day time Noise Levels (Lday)
The day time nose levels ranged from 46.4 – 49.2 dB (A). The minimum
value 46.4 dB (A) was recorded at Dangianinara village and maximum
value 49.2 dB (A) was recorded at Katapali village. The day time noise
levels at all the locations were observed to be well within the limits.
b) Night time Noise Levels (Lnight)
The night time noise levels ranged from 41.4 – 44.9 dB (A). The minimum
value 41.4 dB (A) was observed at Talaipara village and maximum value
44.9 dB (A) was observed at Kataipali village. The night time noise levels
at all the locations were observed to be well within the limits.
Soil Quality
pH of the soil ranged from 6.7 – 7.4 indicating that the soils are neutral
to alkaline in nature. The bulk density is in the range of 1.1 to 1.2 g/cc.
[36]
The soil in the study area is predominantly of sandy clay type. The
electrical conductivity was observed to be in the range of 68 - 220
S/cm. The nitrogen values are in the range of 48.6 – 98 kg/ha
indicating that soils are very less to less in nitrogen levels. The potassium
values range between 86 – 304 kg/ha, which indicate that the soil falls
under less to better category.
5. PLANNING BRIEF
(i) Planning concept (type of industries, facilities transportation etc). Town and country planning/development authority classification
There are only 2 operating plants within 10-km radius - one is group’s own 12 MW biomass based power plant, which is just adjacent to the proposed plant and a sponge Iron unit at about 6-km in the NE direction.
The project area falls within the region which is well connected by road and rail to the District Headquarters – Raigarh which is at about 60-km in the south.
The industrial growth and development in the surroundings is being organized by District Industrial centre under the Department of Industries, Govt. of Chhattisgarh.
(ii) Population Projection: The distribution of population in 10 km around the project site is shown in Table-5.
TABLE-5 : DISTRIBUTION OF POPULATION
Particulars Details
Schedule caste 3236 % To the total population 9.29 Schedule Tribes 19761 % To the total population 56.74 Total SC and ST population 22997 % To total population 66.04 Total population 34825
Source: District Census Statistics –2011
Population Density
The overall density of population in 10 km around the project site is 152
persons per km2 as per 2011 census data.
[37]
Literacy Levels The area experiences a very moderate literacy rate of 59.99%.
Occupational Structure
As per 2011 census records, the main workers are 32.03% of the total
population. The non-workers constitute to 49.47 %. The occupational
structure in 10 km around the project site is shown in Table-6.
TABLE-6: OCCUPATIONAL STRUCTURE
Sr. No. Particulars No. of Persons 1 Total Population 34825 2 Total workers 18080 3 Work participation rate (%) 53.41 4 Total main workers 10842 5 % of main workers to total population 32.03 6 Marginal workers 7238 7 % of marginal workers to total population 21.38 8 Non-workers 16745 9 % of non-workers to total population 49.47
Source: District Census Statistics –2011
(ii) Land use planning
Total requirement of land for the project is 43.18 acres including green
belt development and provision for essential staff accommodation. In
addition, approx. 10 acres will be needed for railway siding.
33% of the project area is for raising plantation including peripheral
green belt development using native plant species in consultation with
the local Forest officials. A tentative break-up of land is given below in
TABLE 7:
TABLE-7 : PROJECT AREA BREAK-UP
S. No. Particulars Area (in Acres) Percentage 1. Washery Plant 9.75 22.6 2. Raw Coal Stockyard 4.40 10.2 3. Clean coal, middling &
Rejects 2.00 4.6
4. Other Facilities [Internal roads, WTP,
7.50 17.4
[38]
staff quarters etc. 5. Plantation Area 14.25 33.0 6. Vacant land 5.28 12.2
Total 43.18 100
(iii) Assessment of infrastructure demand (physical & social)
Amenities/Facilities.
Facilities will be created at the project site for -
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.
Inspection and scheduling of major repairs from outside agencies.
Service Buildings
Office buildings, sub-station, statutory buildings such as first aid
centre, rest shelter, canteen etc. of appropriate size will be provided.
Residential Buildings
The Bachelor’s accommodation and staff quarters will be located in the
project area at a suitable place.
Roads
Approach road to project site will be provided.
6. PROPOSED INFRASTRUCTURE
(i) Industrial area (processing area)
43.18 acres of project area will be under industrial use. Of which
approximately 37% will be for Washing Plant, Stock Yards and Bunkers.
[39]
(ii) Residential Area
Bachelor’s accommodation and staff quarters will be located in the
project area.
(iii) Green belt
14.25 acres of the project area (33% of total land area) will be used for
plantation and greenery development.
(iv) Social infrastructure
Canteen, Rest shelter / room, Recreation Room will be provided.
(v) Connectivity
The existing road network is adequate and does not require any up-
gradation. Already coal from the Chhal and Baroud mines is being
transported via this route. Additional traffic load due the proposed
washery at Bhengari will not be much. It is envisaged establish railway
siding. Coal and beneficiated products will be transported by road
over a maximum period of 5 years or till railway siding comes up
whichever is earlier.
(vi) Drinking Water Management (Source & Supply of water)
The requirement of 15 m3 / hour water for domestic purpose, dust
suppression, plantation etc. will be met from ground water resource. The
project area on ground water resource considerations falls in “Safe Zone”
category. The stage of ground water development is 14.71%. CGWA
approval is awaited.
[40]
(vii) Sewerage System.
Domestic sewage will be treated and disposed of through Septic Tanks &
Soak Pits.
(viii) Industrial Waste Management.
a) Washery effluent:
Waste water will be collected in slime ponds and circulated back into the
process. Zero effluent discharge will be practiced.
b) Domestic effluent:
Septic Tanks & Soak Pits will be provided. Sludge after digestion will be
used as manure.
(ix) Solid Waste Management. a. Rejects 90 TPH Rejects will be generated. Efforts will be made to utilize this
waste material in backfilling of de-coaled pits in SECL opencast mines
and also in the brick kilns or any other end user(s) will be identified.
b. Municipal waste
About 1 Tonne per month municipal waste will be generated, which will
be composted and used as manure.
(x) Power Requirement & Supply / source.
Total power requirement has been assessed as 5 MVA and will be
obtained from CESB through the State grid.
A standby DG set of 125 KVA will be provided.
[41]
7. REHABILITATION AND RESETTLEMENT (R & R) PLAN There is no human settlement or structures at the project site. Thus no R
& R issue is involved.
8. PROJECT SCHEDULE & COST ESTIMATES (i) Likely date of start of construction and likely date of Completion
It is planned to award EPC contract within 2 months of issuance of
“Environmental Clearance” and ‘Consent to Establish” and complete first
phase of the project in 18 months period. Thereafter, second phase will
be executed.
(ii) Estimated project cost along with analysis in terms of economic viability of the project.
Total project cost has been estimated as Rs. 56.78 crores. This cost excludes land & its development and railway siding costs.
Broad break-up of Investment is presented below. All figures are in Rs. Lakhs
1) Land : Rs. 310.00 Lakhs 2) Land Development : Rs. 70.00 lakhs 3) Know How : Rs. 80.00 Lakhs TOTAL : Rs.460.00 Lakhs
TABLE-8 : COST ESTIMATE FOR 1000 TPH THROUGHPUT CAPACITY COAL WASHING PLANT
Sr. No.
Item Description Make Quantity Amount (Rs. in Lakhs)
Total A. Know How
A.1
Design and Engineering
L.S. 60.00
B. Building & Structural
[42]
Sr. No.
Item Description Make Quantity Amount (Rs. in Lakhs)
B.1 Civil Work (RCC work including)
3000 Cu M3 240.00
B.2 Structural Steel work
3000 MT 1550.00
Sub Total B 1790.00 C. Plant & Machinery C.1 Unbalance Motor
Feeder IC /
ELECTROMAG/TRF Lot 32.00
C.2 Over Band Magnetic Separator & Metal Detector
ELECTROMAG 2 Sets 20.00
C.3 Rotary Breaker L&T/TRF/MBE 1 No. 150.00 C.4 Crusher TRF/MBE/MECH
TECH 4 Nos. 160.00
C.5 Dry Screen MECHTECH / TRF / IC
4 Nos. 56.00
C.6 Wet Screens : Desliming D&R Screen
TRF/IC
12 Nos.
144.00
C.7 Sieve Bend MMH 16 Nos. 40.00 C.8 Pumps (Slurry) Metso/Warman / MBE Lot. 80.00 C.9 H M Cyclone
710 Carborundum 12 Nos.
48.00
C10 Classifying Cyclone
Carborundum 12 Nos.
18.00
C.11 Hi Rate Thickener
HDO/MBE/Delkor 2 Nos. 60.00
C.12 Horizontal Basket Centrifuge
Don Valley, UK
6 Nos. 300.00
C.13 Wet Drum Magnetic Separator
Eriez/Ing. Mineral 4 Nos. 60.00
C.14 High Frequency Screen
Linatex, S.A / Parnaby, UK
3 No. 60.00
C.15 Multi Roll Belt Press Filter
Parnaby 2 Nos. 220.00
C.16 Air Compressor with drier
IR/Atlas
2 Sets. 30.00
C.17 Dust Suppression system
TPS / Kaveri Lot 50.00
C.18 Belt Conveyor MMH/TRF / Masyc 900 Mtr. 220.00 C.19 Travelling Tripper MMH 2 Nos. 24.00 C.20 EOT Crane with
grab bucket WMI / Federal / Asian
/ Jaypee 3 Nos. 75.00
C.21 Rock Breaker 1 No. 25.00
[43]
Sr. No.
Item Description Make Quantity Amount (Rs. in Lakhs)
C.22 Miscellaneous Items like gate etc.
MMH Lot 25.00
C.23 Erection & Commissioning
LS 188.00
C.24 Taxes & duties 325.00 Sub Total C 2410.00
D. Misc. Fixed Assets
D1 Pipes & Pipe fitting Steel Tube / Vasuki Lot 55.00 D.2 Valves Vaas/ Audco/ Steam
& Mining / Vasuki Lot 45.00
D.3 Tiles & tiling work VS Enterprise/ CUMI Lot 65.00 D.4 Electricals Lot 210.00 D.5 Instrument &
cable Lot 120.00
D.6 Plant Lighting etc. Lot 25.00 D.7 Public Address
system Lot 25.00
D.8 Laboratory Eqpt.. Lot 60.00 Sub Total D 605.00
E. Substation and 125 KVA DG Set
105.00
F. Total A+B+C+D+E 4970.00 G. Contingency 5% 248.50
Grand Total 5218.50**
** Excludes cost of land and land development
OPERATING COST
The operating cost of the coal washery per tonne of raw coal
throughput will be Rs. 50.00, which does not include interest and
depreciation components. Its break-up is given below:
Manpower - Rs. 8.00 Magnétite - Rs. 5.00 Floculant - Rs. 10.00 Spares - Rs. 12.00 Lubricants etc. - Rs. 8.00 Electricity - Rs. 28.00 Misc. - Rs. 9.00 Total - Rs. 80.00
On the basis of capital investment envisaged for the project, this project
is economically viable.
[44]
9. ANALYSIS OF PROPOSAL (FINAL 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 for use as fuel
in the FBC power plants. 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 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
ponds will be recycled as process water. These ponds will also be
used for harvesting rain water, which will eventually reduce ground
water abstraction.
Expensive imported 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, a precious natural resource.
[45]
Plantation in 33% 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 by MCWPL in the project area will result in
improvement / up-gradation of civil amenities.
Health care facilities will be developed for the employees of the proposed
project. These medical facilities will be extended to surrounding villages.
Under the social- welfare measures and CSR initiatives MCWPL will also
take up various community health care programmes in consultation with
the local Gram Panchayats.
The project related construction activities will benefit the local populace
in a number of ways such as supply of construction labourers – skilled,
semi-skilled and un-skilled, tertiary sector employment and provision of
goods and services for daily needs including transport. The proposed
[46]
project will provide employment to the skilled as well as un-skilled
persons. The local population will be given preference depending upon
their suitability to the job requirement. Besides direct employment,
indirect employment opportunities will also open up. The project will
have positive impact in the region. Quality of life of the people will
improve, which in-turn will improve the socio-economic conditions of the
area.
[47]
ANNEXURE-I: PROCESS FLOW SHEET
HEAVY M
ED
IACYCLO
NES
DIV
ER
TER
CLE
AN
CO
AL
CO
NVEYO
R
MAG
NETIT
E
SU
MP
CH
ARG
ING
TAN
K &
PU
MP
FIN
E C
OAL
HEAVY M
ED
IATAN
K &
PU
MP
TAN
K &
PU
MP
DIL
UTE M
ED
IA
BO
X
DESLI
ME S
CREEN
SIE
VE S
CR
EEN
DIV
ER
TER
BO
XSIE
VE S
CR
EEN
CLE
AN
CO
AL
D &
R S
CREEN
with
MAG
. SEP.
FEED
BO
X
PLA
NT F
EED
BELT
MAG
NETIC
SEPAR
ATO
R
SIN
GLE
DR
UM
MID
DLI
NG
CO
NV
EYO
R
TAN
K &
PU
MP
SECO
ND
ARY W
ASH
ING
SU
MP &
PU
MP
CLE
AN
UP
TO
PU
MPP
RO
CESS
WASH
DO
WN
HI-
RATE T
HIC
KEN
ER
PUM
PU
'FLO
W
MAK
E-U
PW
ATER
O'F
LOW
PU
MP
D &
R S
CR
EEN
with
CLE
AN
CO
AL
CEN
TRIF
UG
EPR
IMARY D
ISC
AR
D
BO
XD
IVERTER
SIE
VE S
CR
EEN
WASH
ING
CYC
LON
E
BELT
PR
ESS
FIN
E C
OAL
HI-
FREQ
UEN
CY S
CR
EEN
CLA
SSIF
YIN
GC
YC
LON
ES
LEG
EN
D
REJE
CT C
ON
VEYO
R
FIN
ES D
UM
P
MID
DLI
NG
CEN
TRIF
UG
E
SIE
VE S
CR
EEN
SEC
ON
DAR
Y
[48]
ANNEXURE-II: WATER BALANCE DIAGRAM
[49]
ANNEXURE-III : EFFLUENT TREATMENT PLANT DIAGRAM
[50]
ANNEXURE-IV: PLANT LAYOUT
[51]
TOR dated 09.02.2012 ANNEXURE-V
[52]
[53]
[54]
[55]
ANNEXURE-VI
Modified TOR dated 27.04.2012
[56]
ANNEXURE-VII Modified TOR dated 16.12.2013
[57]
Recommended